Abstract:
The instant invention describes a method and system for producing biodiesel which increases energy efficiency by reducing the overall amount of energy associated with producing the biodiesel. Unlike most systems which use a batch procedure, the instant method and system utilize a continuous flow sonification procedure which provides for reactions to take place in tubes as the biodiesel moves along through the process. The continuous flow sonification procedure is performed in two main stages, utilizing the steps of acid esterification, transesterification, and a waterless washing.

Description:
CROSS REFERENCE TO RELATED APPLICATIONS 
       [0001]    The present invention claims priority under 35 U.S.C. §119(e) to U.S. Provisional Patent Application No. 61/509,815, filed on Jul. 20, 2011, the contents of which are herein incorporated by reference in its entirety. 
     
    
     FIELD OF THE INVENTION 
       [0002]    The instant invention relates to methods and systems for manufacturing and producing fuels; and more particularly, to methods and systems for manufacturing and producing biodiesel fuels in a manner which reduces the amount of energy needed to produce such fuels. 
       BACKGROUND OF THE INVENTION 
       [0003]    Over the last decade, petroleum-based fuel prices in the United States have steadily risen. It is estimated that the price for petroleum-based fuel will continue to rise, with the average price in the range of 5 to 6 dollars per gallon as the norm. Several reasons have been cited for the increasingly high prices seen at the gas pump. The United States continues to be one of the world&#39;s largest users of petroleum-based fuel. It is estimated the U.S. uses 18-20 million barrels of crude oil a day. As other countries, such as China and India, become more industrialized, they compete with the United States. Competition for such limited resources results in increasing prices. Despite international competition for petroleum-based fuel increases, the U.S. has steadily decreased its domestic production, creating a dependency on foreign oil sources. About half of the petroleum-based fuel purchased by the United States now comes from foreign sources. Such dependence on foreign oil provides ample opportunity for fluctuations in price. Moreover, given the fact that some of the foreign oil originates from the Middle East where governments may not be stable or friendly to the United States, social occurrences and influence over oil cartels are beyond the control of the Unties States, thereby presenting opportunity for increasing energy costs. 
         [0004]    Exploring and drilling for new sources of domestic oil may be a mechanism to reduce the country&#39;s dependence on foreign oil sources. However, recent environmental disasters, such as the 2010 oil spill in the Gulf of Mexico, may prevent, or at lest reduce, the likelihood of exploring for and drilling new oil wells. In addition to rising gas prices, environmental concerns regarding the use of fossil fuels, i.e. increased levels of carbon dioxide emissions believed to contribute to the global warming phenomenon, have contributed to increased efforts for the development of alternative petroleum-based fuel sources. As environmental groups pressure Congress to eliminate or reduce the dependence on unclean fuels, the price of petroleum-based fuel is expected to rise. 
         [0005]    Given the environmental factors and economic realities of petroleum-based fuel usage, alternative fuels sources have been developed. One such alternative fuel is biofuels, such as biodiesel. Biodiesel is one of the fastest growing alternative sources in the country. Biodiesel is a domestically produced, renewable fuel that can be manufactured from new or used vegetable oils, animal fats, and restaurant oils. The use of biodiesel, in conventional diesel engines has been shown to substantially reduce emissions of pollutants such as all green house gasses when compared to use of petroleum-based fuels up to 86%. Air contaminants reduced include unburned hydrocarbons, carbon monoxide, sulfates, polycyclic aromatics hydrocarbons, nitrated polycyclic aromatic hydrocarbons, and particulate matter. The carbon dioxide released in biodiesel combustion is offset by the carbon dioxide sequestered while growing the feedstock from which biodiesel is produced. Biodiesel is safe to handle and transport due to its biodegradability and non-toxic nature. If released to the environment, biodiesels degrade almost four times faster than petroleum-based fuels. Biodiesels have similar physical properties as petroleum-based fuels, and therefore, can be blended with diesel fuel in any proportions, such as B20 which is a commercial blend of fuel containing 20% biodiesel and 80% petroleum-based diesel. Biodiesel can have a great environmental and economical impact as a partial substitute for petroleum-based fuels. By being blended into current petroleum-based mixtures, reduction of the amount of diesel fuel used daily can be accomplished. While biodiesel is a renewable source, obtaining enough of it to be a direct fossil-fuel replacement is unrealistic at this time. Improvements to the processing of biodiesel may be important for public usage and ultimate commercial success. 
         [0006]    Developing better systems for producing biodiesel, such as reducing the total amount of energy it takes to produce a gallon, is of primary importance if such a fuel is to become an important alternative to petroleum-based fuels. 
       DESCRIPTION OF THE PRIOR ART 
       [0007]    Various methods of providing biodiesels are known in the art. Biodiesel is generally produced by a process known as transesterification. In the transesterification process, an alcohol is reacted with the triglycerides contained in the vegetable oils/animal fats/grease to form fatty acid alkyl esters, which makes up biodiesel, and a by-product, glycerin. The reaction further requires heat and use of a strong base catalyst. 
       SUMMARY OF THE INVENTION 
       [0008]    The instant invention describes a method and system for producing biodiesel which increases energy efficiency by reducing the overall amount of energy associated with producing the biodiesel. Unlike the current systems which use a batch procedure, in which the oil precursor is mixed with a catalyst and alcohol and allowed to react in large reacting tanks, the instant method and system utilize a continuous flow sonification procedure which provides for reactions to take place in tubes as the biodiesel moves along through the process. As one gallon is put into the continuous flow system, one gallon is produced. The continuous flow sonification procedure is performed in several main stages, utilizing the steps of acid esterification, transesterification, and a waterless washing. While the method of producing biodiesel uses common chemical stoichiometry, it is produced using half the energy consumption as standard procedures. 
         [0009]    The continuous flow sonification procedure can be used as a stand alone system or can be designed in multi-stage applications. Accordingly, new plants do not need to be constructed as existing facilities can be retro-fit to bring those facilities up to systems with high levels of efficiency. According to current GEET (Global Environmental Energy Technology) lifecycle analysis, the National Biodiesel Board and the U.S. Department of Agriculture state that, based on national surveys, the average amount of energy used in the production of biodiesel is 4,192 BTU. Even using new oil sources, such as virgin oils, it is shown that approximately 3,184 BTUs are needed to produce a gallon of biodiesel. The amount of energy required to produce a gallon of biodiesel using the method and system in accordance with the instant invention is approximately 2,000 BTUs, a reduction of over 50% when compared to the national averages. Additionally, the method and system uses low pressure, low temperature, and no open flames, thereby providing a much safer design than currently used systems. 
         [0010]    Accordingly, it is an objective of the instant invention to teach a method and system for producing biodiesel which increases energy efficiency by reducing the overall amount of energy associated with producing the biodiesel. 
         [0011]    It is a further objective of the instant invention to teach a method and system for producing biodiesel which utilizes ultrasonic shear mixing to increase energy efficiency by reducing the overall amount of energy needed to produce the biodiesel. 
         [0012]    It is yet another objective of the instant invention to teach a method and system for producing biodiesel which utilizes ultrasonic shear mixing and which reduces the amount of energy needed to produce the end product by up to 50% over conventional biodiesel production processes. 
         [0013]    It is a still further objective of the instant invention to teach a method and system for producing biodiesel which eliminates the use of water in purifying the biodiesel produced. 
         [0014]    It is yet another objective of the instant invention to teach a method and system for producing biodiesel utilizing ultrasonic shear mixing which reduces the amount of energy needed to produce the end product by 50% over conventional biodiesel production processes and which eliminates the use of water in the final purification steps. 
         [0015]    It is a still further objective of the instant invention to teach a method and system for producing biodiesel which minimizes the risk of electrical hazards. 
         [0016]    It is yet another objective of the instant invention to teach a low pressure, low temperature method and system for producing biodiesel. 
         [0017]    Other objects and advantages of this invention will become apparent from the following description taken in conjunction with any accompanying drawings wherein are set forth, by way of illustration and example, certain embodiments of this invention. Any drawings contained herein constitute a part of this specification and include exemplary embodiments of the present invention and illustrate various objects and features thereof. 
     
    
     
       BRIEF DESCRIPTION OF THE FIGURES 
         [0018]      FIG. 1  is a schematic flow chart of the first stage of the biodiesel producing process and system in accordance with the instant invention; 
           [0019]      FIG. 2  is a schematic flow chart of the second stage of the biodiesel producing process and system in accordance with the instant invention. 
       
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
       [0020]    While the present invention is susceptible of embodiment in various forms, there is shown in the drawings and will hereinafter be described a presently preferred, albeit not limiting, embodiment with the understanding that the present disclosure is to be considered an exemplification of the present invention and is not intended to limit the invention to the specific embodiments illustrated. 
         [0021]    The instant invention describes a method and system for producing biodiesel using a continuous, multi-step process. The overall method for producing such biodiesel can be performed generally in several stages. The combination of equipment and the method are used to manufacture ASTM International grade biodiesel or any alkyl methyl ester/FAME or alkyl ethyl ester from fatty acids. The method exemplified uses fatty acids from vegetable oils, animal oils, fish oils, plant oils, and fats, but can be adapted to produce biodiesels using other sources of fatty acids as well. In addition, the method can be used to convert algae oil feedstock and/or algae lipids into biodiesel. The combination of equipment and the method increases the energy efficiency of the overall production process by reducing the energy levels needed to produce the high quality biodiesel and reduces the GEET lifecycle analysis model for biodiesel production. It is further estimated that the method according to the instant invention can reduce the energy needed to produce each gallon by up to fifty percent (50%). 
         [0022]    The chemical reactions for carrying out the production of biodiesel are well known and have been described previously. Briefly, production of alkyl esters from fatty acids is achieved by transesterification of vegetable or animal fats or oils. The transesterification process involves reacting triglycerides with an alcohol in the presence of a catalyst. For some fats having high levels of free fatty acids, pre-treatment reactions with alcohol in the presence of acids is required (esterification). The chemical reactions and stoichiometric chemical balances used in manufacturing biodiesel according to the instant invention do not differ from standard industry practices. While the method described herein uses standard chemistry, the method and system has resulted in the unexpected achievement of manufacturing standard, ASTM grade biodiesel using up to about 50% less energy as compared to other methods. 
         [0023]    Referring to  FIGS. 1 and 2 , the method and system for producing biodiesel which utilizes ultrasonic shear mixing to increase energy efficiency by reducing the overall amount of energy needed to produce the biodiesel is illustrated as a three step-process shown in two stages. The system, generally referred to as  10 , produces ASTM grade biodiesel through the steps of 1) acid esterification, 2) transesterification, and 3) waterless washing purification. Typical sources of the fatty acids are derived from vegetable oils, animal fats, and/or grease from restaurants. Referring specifically to  FIG. 1 , such oils can be obtained from independent sources and delivered to the system  10  through delivery vehicles, such as trucks  12 . The vegetable/animal oil or fats and grease solution, collectively referred to as the pre-cursor biodiesel feedstock, is offloaded from the truck  12  to a holding tank  14  through the use of piping  16  and valves  18 . The holding tank  14  is fluidly connected to the rest of the system  10  through pipes  20 . The pre-cursor biodiesel feedstock is allowed to remain in the holding tank  14  for a pre-determined time period to allow any solid particles which may be mixed within to settle out and rest at the bottom. Accordingly, several holding tanks  14  (not illustrated) may be utilized to ensure that one or more sources of pre-cursor biodiesel feedstock can be fed into the system while newly delivered pre-cursor biodiesel feedstock has time to allow for solid particle separation. 
         [0024]    Once all solids from within the pre-cursor biodiesel feedstock has had the necessary time to separate out, the liquid solution is fed into system  10 . The first step  22  of the method involves acid esterification. The acid esterification steps allow the system  10  to accept a wide scope of oils, ranging from virgin oil solutions having low, i.e. less than 3% free fatty acids (FFA) to high FFA, i.e. greater than 3%, solutions. The system even allows for processing of animal oils and fats and other solutions that are not clean, such as restaurant grease. As the pre-cursor biodiesel feedstock is fed from the holding tank  14  to the acid esterification steps, it is heated to a required reaction temperature range of about 50 degrees Celsius to 65 degrees Celsius. In the preferred embodiment, the heating process is done via direct heating using, for example, a military surplus M-80 hot water furnace  24 . The hot water furnace  24  is generally a self-contained unit, except for the fuel tank. Preferably, the furnace uses biodiesel as a fuel source, and is designed to consume less than 2 gallons per hour, or about 10 gallons per 8 hour shift. Use of the hot water furnace has been found to be more energy efficient than use of electric or a water heat exchanger. 
         [0025]    The heated pre-cursor biodiesel feedstock is further moved through the system  10  via pipes  21  through a gallon totalizer meter toward pump  26 . As the pre-cursor biodiesel feedstock moves through the system, it is reacted with alcohol, such as methanol, in the presence of a strong acid, such as sulfuric acid. As illustrated in  FIG. 1 , the acid, which is stored in an acid tank  28 , is pumped into the pipes  21  through use injection point  30  and controlled by the pump speed. Additionally, methanol, or other suitable alcohols known to one of skill in the art, which is stored in an alcohol tank  32 , is pumped into pipe  21 . The flow of alcohol can be controlled by the pump speed. The methanol and sulfuric acid are injected in the suction side, or up-stream of the pump, in order to minimize or eliminate pressure on the injection points for safety. 
         [0026]    Pump  26  is preferably a pneumatic pump in order to reduce the amount of energy used during the process. To keep starting load and amperage down, a screw compressor is preferably used. Use of a screw compressor also reduces maintenance costs. The pump  26  feeds pre-cursor biodiesel feedstock through pipe  23  to a sonochemical mixer  36 , such as an ultrasonic mixer. The fluid output is restricted through use of a valve  37  to a constant, low pressure of 2 to 3 atmospheres. Preferably, the sonochemical mixer  36  is used at a single frequency, and at power levels greater than 20 W/cm 2 , preferably up to 200 W/cm 2  or greater. The pre-cursor biodiesel feedstock is placed into stage  1  storage tank  38  by way of pipe  25  for a time period, typically 8-12 hours, which is long enough for the reaction to be complete. The system  10  may include several stage  1  storage tanks  38  (not illustrated) in order to allow the process to continuously run. As new pre-cursor biodiesel feedstock is placed in the stage  1  storage tanks  38 , those that have completed the reaction time can be used for further processing. Once the reaction is allowed to run its course, free fatty acids will be broken down to levels of 2.5% or less of the pre-cursor biodiesel feedstock. No soaps, waste, or co-products are produced at this stage. All resulting product moves on to the transesterification process. 
         [0027]      FIG. 2  illustrates the second stage of the method and system for producing biodiesel which utilizes ultrasonic shear mixing to increase energy efficiency by reducing the overall amount of energy needed to produce the biodiesel. The second stage contains the transesterification process  40  and a waterless wash stage  42 . From one of the stage  1  storage tanks  38  which has had the proper amount of time for complete reaction to occur, the pre-cursor biodiesel feedstock is pumped into a smaller heating reservoir  44  via pipe  27 . Pumping the solution into reservoir  44  brings the solution back to a temperature of between 50 degrees Celsius and 65 degrees Celsius. In order to prevent any methanol from evaporating, the temperature of the solution must not reach above 68 degrees Celsius. As the solution is moved towards pump  46 , a catalyst, stored in catalyst tank  48 , is injected into pipe  29 . The catalyst, including but not limited to sodium hydroxide or potassium hydroxide methylate, or other catalysts known to one of skill in the arts, is injected on the suction side, or up-stream of the pump, for safety reasons. The solution is pumped into a second sonochemical mixer  50 , such as an ultrasonic mixer, through pipes  31 . As described previously, the output of the sonochemical mixer  50  is restricted to preferably 2 to 3 atmospheres in order to bring the power level to greater than 20 W/cm 2 , preferably up to 200 W/cm 2  or greater. The solution is transferred to a stage  2  tank  52  via pipe  33 . The solution is allowed to remain in the stage  2  tank  52  to finish the reaction process. Once the reaction is complete, glycerin, a co-product, falls out of solution. The glycerin is pulled out of the stage  2  tank  52  and allowed to collect in a glycerin storage tank  54  through pipe  35 . 
         [0028]    Floating top suction is established and used to continually pull off the biodiesel from the top of the stage  2  tank  52  and further processed through a waterless wash stage  42 . The pre-cursor biodiesel feedstock is moved from the stage  2  tank  52  to a separating unit through pipes  39  and  41  to separate the soap/glycerin by-products that have formed and not previously been removed. Temperatures in the range of 100 to 140 degrees Fahrenheit should be sufficient for separation. As the pre-cursor biodiesel feedstock moves downstream, it may be heated to the necessary temperature through use of a smaller heating reservoir  56 . The pre-cursor biodiesel feedstock is transferred through a centrifuge  58 . By-products, such as the soaps/glycerin, are transferred to the glycerin storage tank  54  via pipes  43 . Once centrifugation has been completed, the alkaline biodiesel must be neutralized and is transferred to ion exchange units  60  trough pipes  45  and  47 . Any remaining methanol and glycerin is removed by passing the biodiesel through the resin exchange towers or vessels of the ion exchange units  60 . Once the ion is exchanged, the biodiesel is passed through a final filtration unit, such as an EPA tier  3  and  4  specifications, through pipes  49 . The finished biodiesel product is than transferred (using pipes  51 ) to one or more biodiesel storage tanks  64  and ready to be used as a fuel source according to ASTM standards. 
         [0029]    All patents and publications mentioned in this specification are indicative of the levels of those skilled in the art to which the invention pertains. All patents and publications are herein incorporated by reference to the same extent as if each individual publication was specifically and individually indicated to be incorporated by reference. 
         [0030]    It is to be understood that while a certain form of the invention is illustrated, it is not to be limited to the specific form or arrangement herein described and shown. It will be apparent to those skilled in the art that various changes may be made without departing from the scope of the invention and the invention is not to be considered limited to what is shown and described in the specification and any drawings/figures included herein. 
         [0031]    One skilled in the art will readily appreciate that the present invention is well adapted to carry out the objectives and obtain the ends and advantages mentioned, as well as those inherent therein. The embodiments, methods, procedures and techniques described herein are presently representative of the preferred embodiments, are intended to be exemplary and are not intended as limitations on the scope. Changes therein and other uses will occur to those skilled in the art which are encompassed within the spirit of the invention and are defined by the scope of the appended claims. Although the invention has been described in connection with specific preferred embodiments, it should be understood that the invention as claimed should not be unduly limited to such specific embodiments. Indeed, various modifications of the described modes for carrying out the invention which are obvious to those skilled in the art are intended to be within the scope of the following claims.