1. French Fry Fuel Sponsored by J.R. Simplot, Co.
Conditioning used frying oil for conversion to biodiesel
Shane Bird, Marie Stark, Kate Burlingame,
Chuck Weatherspoon, John Neal

2. Design Review Outline Background Accomplishments Problem Definition
Remove Particulate Matter
Reduction of Water Content from Oil
Reduction of FFA Content from Oil
Integrated Solution Concepts
Project Challenges
Budget/Timeline
Discussion Questions

3. Background
The J.R. Simplot Company generates 2 million pounds of waste oil each year.
Simplot would like to condition the oil and convert it to biodiesel, which would then be returned to Simplot to offset the diesel used in the transportation fleet.

4. Accomplishments
The waste oil generated in production lines forms two waste streams.
Team French Fry Fuel has performed numerous tests on the mainstream oil. We determined that it is suitable for conversion to biodiesel.

5. Problem Statement
The secondary waste stream generated, DAF (Dissolved Air Floatation) oil, is an economic drain on Simplot.
Our goal is to pretreat both elements of DAF oil, MOP (oil from plant clean-up) and WESP (wet electrostatic precipitator), before sending them to a biodiesel manufacturer.
In order to condition the oil, the team will design a system to remove free fatty acids, water, particulates, and other carbon impurities from the used oil to a specification defined by the biodiesel manufacturer.
<4% FFA
<.1% Water by weight
< micron particulate size

6. Integrated Solution Test FFA Level Test FFA Level & Water Content Heat
Biodiesel Conversion for FFA < 4%
Water Removal
Filter
Esterification for
FFA > 4%
Falling Film
Evaporator
Flash
Evaporator
Self Cleaning Paper Filters
Bag Filter
BD20 Beads
Sulfuric Acid

7. Particulate Removal: Bag Filter
Advantages:
Easy to clean.
Filters large amounts of particulates.
Low start-up cost.
Disadvantages:
Large particulate may push through filter bags.
Manual maintenance.
Easy Access Filter-Bag Housings Stainless Steel
Felt Filter Bags

8. Particulate Removal: Self-Cleaning Paper Filter
Advantages:
Self cleaning.
Filters large amounts of particulates.
Low maintenance.
Disadvantage:
High Start-up cost.
Continuous Paper Filter

9. FFA Reduction: Acid Esterification Using Sulfuric Acid
Sulfuric acid (catalyst) is dissolved in methanol, then added to the oil
While the reaction takes place continuous dewatering must also occur
Advantages:
Can be batch or continuous
Higher removal of FFA
Make more fuel out of high FFA feedstock
Disadvantages:
Must remove water continuously for high yields
Potential hazardous chemical, methanol utilized
Increased chemical cost

10. FFA Reduction: BD20
This emerging technology uses the same principles as acid esterification.
Advantages:
Treats oils with FFA ranging from 0.5 to 100%
Fast reaction time
High conversion efficiency
Can treat oils with low levels of water
Fewer toxic chemicals
Disadvantages
Availability issues
Unknown cost

11. Water Reduction: Falling Film Evaporator
Falling film evaporators work by allowing a film of the liquid to flow down the tubes of the heat exchanger.
Advantages:
Will remove high water content from fluids
Works with low temperature differences.
Disadvantages:
Complicated design
Requires higher heat
A: Product B: Vapor C: Concentrate D: Heating Steam E: Condensate
1: Head 2: Calandria 3: Calandria, Lower part 4: Mixing Channel
5: Vapor Separator

12. Flash Evaporation (Water Removal)
Flash evaporation is the vaporization of a saturated liquid (in this case oil) as it undergoes a pressure reduction through a small orifice or throttling device.
The oil is heated and then sent via a pump to the feed inlet where it goes through a reduction in pressure. The applied heat and reduced pressure converts the water in the oil to a vapor.
Note: If the oil has greater than 5% water in it then multiple evaporators may be needed to remove that water to an acceptable level.
                                 

13. Recommended Treatment Process
Water
Heated
Agitated
Tank Q
(1)
DAF Oil
To Blue Sky
(2)
Water Q P
Evaporator
Filter System
(3) P P P
Particles
Esterification P
Sample taken for Water content and FFA testing
Send to Blue Sky if FFA ≤ 4% FFA
Test for Water and FFA content
Methanol
Recovery

14. Cost for Full Scale Design
Process
Unit
Cost/Unit
Est. Cost
Sulfuric Acid
5 190mL Bottles
$32.00
BD-20
Bag Filter
Ea.
$1200
$1500
Self Cleaning
$100,000
Flash Evaporator
$50,000
Falling Film
$60,000

15. Design Challenges
Further lab analysis of the WESP and MOP oils will allow us to determine a treatment plan.
Hazardous chemicals near food processing plant.
Effective cost analysis.
Bench-top model.

16. Timeline Snapshot Day ……………….Nov. 30 2007
Semester End Report Due…Dec
Winter Break…………………Dec
Spring Semester Begins…….Jan
2nd Design Review………….Feb. ?? 2008
Final Report Due…………….May ?? 2008
Engineering Expo……………April

17. Ideas, Comments, or Suggestions
Questions?
Ideas, Comments, or Suggestions