Biodizel ishlab chiqarish & Biodizel konversiyasi

When you make biodiesel, slow reaction kinetics and poor mass transfer are lowering your biodiesel plant capacity as well as your biodiesel yield and quality. Hielscher ultrasonic reactors improve the transesterification kinetics significantly. Therefore lower excess methanol and less catalyst are required for biodiesel processing.

Biodiesel is commonly produced in batch reactors using heat and mechanical mixing as energy input. Ultrasonic cavitational mixing is an effective alternative to achieve a better mixing in commercial biodiesel processing. Ultrasonic cavitation provides the necessary activation energy for the industrial biodiesel transesterification.

Ultrasonically Improved Transesterification of Biodiesel

Biodiesel production typically involves a chemical reaction called transesterification, in which a triglyceride (such as vegetable oil, animal fat, spent cooking oils) reacts with an alcohol (such as methanol) in the presence of a catalyst to produce biodiesel (fatty acid methyl esters) and glycerol. Ultrasonic reactors can be used to enhance the transesterification process in several ways, leading to several benefits:

• Improved mixing: Ultrasonic waves can create cavitation bubbles that collapse violently, causing intense mixing and agitation of the reaction mixture. This leads to better contact between the reactants and the catalyst, resulting in faster and more complete transesterification.
• Accelerated reaction kinetics: The high-energy conditions generated by ultrasonic waves can activate the reaction, increasing the reaction rate and reducing the reaction time needed to reach a given level of conversion. This can result in higher yields and lower costs.
• Reduced catalyst usage: Ultrasonic reactors can improve the efficiency of catalyst use by providing more active sites for the reaction. This means that less catalyst is required to achieve the same level of conversion, reducing costs and environmental impact.
• Improved product quality: Ultrasonic reactors can produce biodiesel with lower free fatty acid content, higher purity, and better cold flow properties. This is due to the improved mixing and faster reaction kinetics, which minimize the formation of unwanted byproducts and impurities.

These advantages of ultrasonic biodiesel processing make the use of an ultrasound reactor setup highly economical since the use of ultrasonic reactors significantly improves the efficiency, speed, and quality of biodiesel transesterification. This means in summary that ultrasonication turns the transesterification into a more economically and environmentally sustainable process.

Problems of Conventional Biodiesel Mixing: The conventional esterification reaction in batch processing tends to be slow, and phase separation of the glycerin is time-consuming, often taking 5 hours or more.
 
Ultrasonic reactors help you to accelerate your biodiesel process and simultaneously increase your biodiesel yield and quality at lower processing costs!
 

Industrial-grade ultrasonicator UIP2000hdT with flow cell FC2T500k for inline biodiesel esterfication and transesterification.

The Advantages of Ultrasonic Biodiesel Transesterification

Ultrasonics for Biodiesel Production

Biodiesel is often produced in batch reactors. Ultrasonic biodiesel conversion allows for the continuous inline processing. Ultrasonication can achieve a biodiesel yield in excess of 99%. Ultrasonic reactors reduce the processing time from the conventional 1 to 4 hour batch processing to less than 30 seconds. More important, ultrasonication reduces the separation time from 5 to 10 hours (using conventional agitation) to less than 60 minutes. The ultrasonication does also help to decrease to amount of catalyst required by up to 50% due to the increased chemical activity in the presence of cavitation. When using ultrasonication the amount of excess methanol required is reduced, too. Another benefit is the resulting increase in the purity of the glycerin.
 
Ultrasonic Biodiesel Production Step-by-Step:

1. the vegetable oil or animal fat is being mixed with the methanol (which makes methyl esters) or ethanol (for ethyl esters) and sodium or potassium methoxide or hydroxide
2. the mix is heated, e.g. to temperatures between 45 and 65degC
3. the heated mix is being sonicated inline for 5 to 15 seconds
4. glycerin drops out or is separated using centrifuges
5. the converted biodiesel is washed with water

 
Most commonly, the sonication is performed at an elevated pressure (1 to 3bar, gauge pressure) using a feed pump and an adjustable back-pressure valve next to the flow cell.

Industrial biodiesel conversion does not need much ultrasonic energy. The actual energy requirement can be determined at benchtop scale using e.g., a 1kW ultrasonic processor such as the UIP1000hdT. All results from such bench-top trials can be scaled up linear and without any problems. If required, ATEX-certified ultrasonic devices are available, such as the UIP1000-Exd.

Hielscher supplies industrial ultrasonic biodiesel processing equipment, worldwide. With ultrasonic processors of up to 16kW power per single device, there is no limit in biodiesel plant size or processing capacity.

Costs of Ultrasonic Biodiesel Manufacturing

Ultrasonication is an effective means to increase the reaction speed and conversion rate in the commercial biodiesel production. Ultrasonic processing costs result mainly from the investment for ultrasonic equipment, utility costs and maintenance. The outstanding energy efficiency of Hielscher ultrasonicators helps to reduce the utility costs and by this to make this process even greener. The resulting costs for the ultrasonication vary between 0.1ct and 1.0ct per liter (0.4ct to 1.9ct/gallon) when used on commercial scale.
Read more about the process efficiency and economical benefits of ultrasonic biodiesel production!
 

Ultrasonik aralashtirish gidrodinamik magnit aralashtirish va yuqori kesish mikserlaridan ancha yuqori bo'lgan inbiodizel ishlab chiqarishning o'ziga xos energiya sarfini kamaytiradi.

Small Scale Ultrasonic Biodiesel Setup

Ultrasonication can be used for the conversion of oil into biodiesel at any scale. The picture below shows a small scale setup for the processing of 60-70L (16 to 19 gallons). This is the typical setup for initial studies and process demonstration.

Ultrasonik esterifikatsiya va transesterifikatsiya ommaviy yoki doimiy inline jarayon sifatida bajarilishi mumkin. Ushbu diagrammada biodizel konvertatsiyasi uchun ultratovushli partiya jarayoni ko'rsatilgan.

• one ultrasonicator (e.g., UIP500hdT or UIP1000hdT) with booster, sonotrode and flow cell
• power meter for metering power and energy
• 80L processing tank (plastic, e.g. HDPE)
• heating element (1 to 2kW)
• 10L catalyst premix tank (plastic, e.g. HDPE)
• catalyst premixer (stirrer)
• pump (centrifuge, mono or gear) for approx. 10 to 20L/min at 1 to 3 barg
• back-pressure valve for adjusting pressure in the flow cell
• pressure gauge for measuring feed pressure

Ultrasonic Reactors for Superior Biodiesel Processing

Hielscher Ultrasonics offers high-performance ultrasonic processors and reactors, which will improve your biodiesel production by higher biodiesel yields, improved biodiesel quality, reduced processing time and lower production costs.

Small and Medium Scale Ultrasonic Reactors for Biodiesel Transesterification

For small and medium size biodiesel production of up to 9ton/hr (2900 gal/hr), Hielscher offers you the UIP500hdT (500 watts), UIP1000hdT (1000 watts), UIP1500hdT (1500 watts), and UIP2000hdT (2000 watts) as ultrasonic high-shear mixers with flow-through reactors for reliable and efficient inline biodiesel processing. These four ultrasonic reactors are very compact, easy to integrate or retro-fit. They are built for heavy duty operation in harsh environments. Below you will find recommended reactor setups for a range of production rates.

Juda katta quvvatli sanoat biodizel reaktorlari

For industrial processing biodiesel production plants Hielscher offers the UIP4000hdT (4kW), UIP6000hdT (6kW), 10000 (10kW), and UIP16000hdT (16kW) ultrasonic homogenizers! These ultrasonic processors are designed for the continuous processing of high flow rates. The UIP4000hdT, UIP6000hdT and UIP10000 can be integrated into standard sea freight containers. Alternatively, all four processor models are available in stainless steel cabinets. An upright installation requires minimal space. Below you find recommended setups for typical industrial processing rates.