Biodiesel - BIOPA - Pardubice

Technologies:

BIOPA technologies for production of MERO

        BIOPA group developed and realized three various technological procedures of MERO production. They are differenciated by the yield and quality of MERO and further by the number and quality of coproducts.

1.    The first technology allows to transfer practically 100% of energy of the rape oil into MERO so, that in MERO remain also the free fatty acids of the rape oil, which have similar fuel properties as the methylesters of these acids. But free acids can affect the corrosion of some metals (Zn, Pb, Cd) and increase the Neutralisation Number of MERO up to the value 2.5 to 4.5 , compared with the allowed standard maximum value 0.5 mg KOH/g MERO. The corrosivity can be put down by addition of small amount of a suitable additive, which, however, does not change the value of the Neutralisation Number. All remaining parameters in the norm cited there after are fulfiled with a considerable reserve. In this MERO technology two by-products arise:
   - Highly concentrated glycerol phase with ca 80 %w/w of glycerol. The rest create water, small amounts of methanol, anorganic salts and vegetable pigments. - Directly utilisable phosphorus-potassium (PK) fertilizer. This technology was originally used by all in the frame of BIOPA realized production units
   
2.     The second technology was developed for such fast and undemanding adaptation of the units with the above described procedure, which allows to produce MERO fulfilling all demands of the Czech norm ČSN 656507/Z1. However, only ca 85% of energy in the used rape oil are tranfered into MERO in this case. The same coproducts are arising as in the previous case. GP includes, however, only ca 60% w/w of glycerol, in addition the potassium soaps and unreacted catalyst (KOH). This technology was used to the adaptation of several units delivered originally with the technology 1.
   
3.    The third technology was developed to eliminate the imperfections of the technology 1. (high Neutralisation Number) and technology 2. (relative low yield of MERO). This technology was applied for the adaptation of one transesterification unit delivered originally with the technology 1. Its description is given in the next chapter.
   

New technology of production of MERO

        The cited technology is protected by the Czech patent and is registrated for patenting in the Slovakia and Hungary.

This technology is noted for:

• Simplification and thus also acceleration of the production with lower costs.

• Total transfer of catalyst KOH from the reaction mixture into the glycerol phase.

• Reduced consumption of catalyst KOH.

• Absence of technological waste water.

• Fast and quantitative separation of MERO from the glycerol phase.

• No next cleaning operations for MERO.

• High yield of MERO (94 - 97 %w/w related to the used rape oil).

• Rational use of methanol. Unreacted methanol is returned without any treatment back into the MERO production.

• Practically wasteless production process, because the sole waste is the glycerol phase, which creates the raw material for the production of pure glycerol.

• Good quality of MERO, which fulfils in all parameters the Czech norm ČSN 656507/Z1 (e.g. average conversion >98.5 %w/w, Neutralisation Number 0.15 mg KOH/g MERO, Conradson Carbonisation Index (100%) < 0.05 %w/w).

• Composition of the glycerol phase: glycerol ca 60 %, water ca 15 %, methanol ca 2 %, potassium soaps ca 20 %, all w/w.

• Specification of the main raw material - Rape seed oil with the Neutralisation Number up to 2.0 mg KOH/g and with the content of phosphorus up to 15 ppm.

• Next technical characteristics of the process

• Specific consumption of raw materials and helping components for the production of 1000 kg of MERO:
          - Rape seed oil          1075 kg
          - Methanol                  127 kg
          - KOH 100%                 8 kg
          - Helping components (Helping components do not increase practically the MERO production costs. Their list and amounts are the part of know-how of the production process and cannot be revealed to the interested persons before the conclusion of the taciturnity agreement).
• Production of ca 200 kg of the glycerol phase by the production of 1000 kg of MERO.
• Specific consumption of energies fot the production of 1000 kg of MERO:
          - Electric energy                                           76 kW
          - Air dried, 8 bar                                         12 Nm3
          - heat energy (gas, steam, water 90°C)      312 MJ
          - cooling (water 17-20°C)                            80 kWh

Checking of the new technology

        The new technologic process is suitable both for building of new transesterification units as also for arrangement of the existing units with the technology using KOH as the catalyst. To verify the new technology, the arrangement was carried out in the existing transesterification unit ABC Bransouze, CZ with the production capacity ca 700 tons of MERO for year, delivered by the firm KOROPECKÝ Pardubice® in the year 1996 and producing so called "acid biodiesel" according to the first technology. After the arrangement the production capacity increased up to ca 1600 tons MERO for year and it is probable that after the detailed tuning of the apparatus, the performance of the unit will be still higher. At the same time, the number of vessels decreased and some unpleasant operations (e.g. filtration) must not be used.

Reserving of the delivery

        The firm KOROPECKÝ Pardubice^® can ensure in the collaboration with cooperating organisations:

1. Complete delivery of the full automatized transesterification unit for practically arbitrary production capacity, and that from the documentation for the building license up to the realisation and taking into operation.
2. Arrangement of the existing transesterification unit, provided it is using KOH as the catalyst.