BIODIESEL PRODUCTION PRODUCTION : A FEASIBILITY FEASIBILITY STUDY
BIODIESEL A TRUE GREEN FUEL
TECHNICAL ASPECT
iodi iodies esel el is an este esterr deri derive ved d from from plan plantt and/ and/or or anim animal al oils oils that that is us use e to substitute or blend with diesel fuel. Biodiesel can thus be produced from the oils of coconut, peanut, sunflower, palm, jatropha, soya, corn, wheat, canola, algae, chicken, pork, beef, fish and many more. Peanut oil was the first oil use by German Engineer Rudolf Diesel in his 1892 diesel engine invention. To prod produc uce e biod biodie iese sell from from thes these e oils oils,, the the fatt fatty y comp compon onen entt call called ed glycerol has to be reacted-out and extracted from the oil component called triglyceri triglycerides des through through Transesterif ransesterificati ication on Reaction. eaction. This reaction reaction was first done and patented patented by Swedish Swedish scientists scientists Duffy and Patrick Patrick wayback 1853 when gasoline and diesel engines were not yet invented ( source : Grosser, Morton Morton (1978), (1978), Diesel: The Man and the Engine, New York: York: Atheneum, Atheneum, ISBN 978-0-689-30652-5 ; LCCN 78-006196 ). Thus we can see, that biodiesel is older than its fossil fuel counterpart. Biodie Biodiesel sel has physic physico-c o-chem hemica icall attrib attribute utes s more more potent potent than than diesel diesel itse itself lf.. Unli Unlik ke dies diesel el,, it is nonnon-to toxi xic, c, biod biodeg egrad radab able le,, rene renewa wabl ble e fuel, fuel, environment friendly, has higher cetane number, fuel efficient ( Biofuel Phils, 2008 ) and most of all to produce it, it doesn’t need going into war or invading a country. You don’t need to modify your engine to use it. By using it, you likewise contribute to the reduction of the global warming’s threat to humanity. Biodiesel nomenclature depends on the feedstock used to make it. For instance, a biodiesel made from coconut oil using methanol is called Coco Methyl Ester or CME for short. A biodiesel made from soya oil using ethyl alcoho alcoholl is there therefor fore e called called Soya Soya Ethyl Ethyl Ester Ester or SEE. SEE. See biodie biodiesel sel sample samples s made made from from differ different ent feedsto feedstocks cks below below.. The coconut coconut oil used used by Philip Philippin pine e army during during WWII to replace replace the depleted depleted diesel diesel inventory inventory is not an actual actual biodiesel biodiesel,, but was called called cocodiesel. cocodiesel. Because Because glycerol glycerol was not reacted out, these 6 X 6 army trucks all bogged down after 6 months of usage due to glycerol clogged nozzles. This is different than the real biodiesel tested by DOST and DOE in actual cars, vans, trucks and buses starting 1972 which became the basis and foundation f oundation why Republic Act 9367 or the BiofuelsAct of 2006 was enacted.
A sample sample of biodiesel biodiesel made from coconut, coconut, sunflower, sunflower, jatropha jatropha curcas curcas and peanut oils As shown in the figure below, below, the carbon chain of diesel diesel and biodiesel biodiesel are similarly structured. Diesel has carbon 8 to carbon 22, while biodiesel depending on the feedstock used fall within these carbon lengths. CME for instance, claimed to be the best biodiesel in the world ( DOE, Biofuels Phils and Biofue Biofuels ls Ac Actt of 20 2006 06 ) has carbon chain perfectl perfectly y suited suited in the lower lower carbon chain of diesel fuel. Combining different oil, like what is being done by the cooking oil industry, say coconut, palm and soya oils, extend the fit of carbon length to the carbon length of diesel chemical structure. Although chem hemistr istryy-w wise ise, the lower ower the carbo arbon n chai chain n leng length th,, the bett bette er the combustibility. combustibility. Carbon 20 to 22 hydrocarbons are the culprit why diesel burns very soothy.
Waste aste vegeta vegetable ble oil oil or WVO WVO can be conver converted ted to biodie biodiesel sel in the same manner as that of virgin oils. Special formulation and chemical techniques are used for these to become successful. successful. Capistrano, Capistrano, R. hasdone rigorous rigorous research on this both in the Philippines and Australia ( Making Biodiesel from Used and New Cooking Oils, Anvil Publishing, Publishing, 2008 ). Using the appropriate appropriate methodology, a much better biodiesel con be produced as seen below. The figure shows the clarity of biodiesel made from waste cooking oil in comparison with commercial premium biodiesel and oil giant’s diesel.
Quality chemicals at reasonable price are available here to produce biodiesel. Chemical suppliers like Alyson, Atkimson, Chemsetters and Sytengco offer these chemicals to a would-be biodiesel producer, whether for his own or commercial use. Equipment or reactor set-up is available imported or locally manufactured. Freedom Fueler from the USA ship their set up at a cost of $3,000 for a 200 L reactorto $8,500 for a 568 L complete set up ( excluding freight charges and Tax ). A local fabricator can provide would-be biodiesel producer , 200 L complete set up at a cost cost of only only P8 P80T 0T only only. This This incl includ udes es the the tech techno nolo logy gy ( 3 powe powerp rpoi oint nt presentations, professional coaching and provide a list of chemical suppliers with quality but guaranteed lowest price ). He’s the author of the book mentioned above “ Making Biodiesel from Waste and New Cooking Oils “ located in Calamba City and can be contacted at 09214688050. The The advant advantage ages s of biodi biodiese esell given given above above are amplif amplified ied and given given actua actuall implemented experiences by Biofuels Phils. ( website : http://www.biofuels.com.ph ) . Alon Along g with with vari variou ous s gove govern rnmen mentt agen agenci cies es,, lik like DENR DENR,, DOST DOST,, DOE, DOE, PCCA PCCARD RD,, PhilForest, they were consulted and has become the foundation why RA 9367 was passed and and enacted year year 2006. Some of the advantages are summarized below below..
Among the notable positive contributions of biodiesel is its combustibility or the much higher cetane number ( octane rating for gasoline). This is clearly shown in the picture of biodiesel flame on page 16. Cetane number of diesel is only 45 while, biodiesel biodiesel has 68, and the the reason for this this is, the oxygen oxygen part of the chemical chemical structure structure of biodiesel biodiesel where where diesel doest doest have. We know that for combustion combustion to kindle, oxygen is necessary and for biodiesel, part of the molecule is providing this and not all anymore coming from the air intake of the engine.
Diesel tailpipe heavy emissions Observing the tailpipe of biodiesel fed engine, one will immediately notice the drastic decrease in black emissions ( see the picture above of diesel muffler and some pictures below under environment aspect ). This definitely is the low cost solution to lots of smoke belching violations in the cities. In a test Mercedes Benz
engine in # 1 Mercedes Ave., Mercedes Estate Pasig City, freshly made biodiesel from waste cooking oil is an SOP Quality Control Control Actual Usage Test being done for each batch process. With so many batches and tests conducted, this has been prove proven n a convin convincin cing g factor factor for Jeepne Jeepney y cooper cooperati atives ves and and associ associati ation on to accept accept categorically biodiesel as a better alternative to the dirty diesel fuel. This engine is pictured below.
Mercedezs Benz Quality Control Actual Test engine as SOP for biodiesel production in Pasig In the above Mercedes benz engine, the muffler was deliberately removed and samples are tested without it. Biodiesel compare to diesel was extra smooth and remarkably remarkably silent. silent. This proved that the research research conducted conducted by Malhotra Malhotra ( RK Malho Malhotra, tra, 2001 2001 Devt Devt of Alterna Alternativ tive e Fuel in India by /ADB /ADB May200 May2001 1 Region egional al Workshop on Fuel Quality and Alternate Fuels ) was confirmed correct, saying in a 100 pages pages resea research rch report report that that biodi biodiese esell produ produces ces “ LESS, LESS, NOISE NOISE & SMOOTH SMOOTH RUNNING OF ENGINE”. This plus the reduction of ignition vibration during start up, according to him is the best contribution of using this alternative green fuel. Using diesel diesel in the engine engine without without a muffler muffler produces produces an excrutia excrutiating ting and ear piercing piercing rattle and clanking noise, but using biodiesel the sound was radically improved and the vibration minimized. Doing these two trials before an audience is really very convincing. The The reaso reason n why the engine engine runs runs smooth smoothly ly and suave suave was was expla explaine ined d by th Schumach Schumacher er and Adams Adams [10 Biennial Biennial Bioenerg Bioenergy y Conferen Conference ce – Bioenerg Bioenergy y 2002, 2002,
Boise, Idaho, Sept. 22-26, 2002]. The fine lubricity characteristic was responsible and this was shown in the graph below ;
Lubricating power of biodiesel which can be felt even at 0.5 % additive, Schumacher & Adams, 2002
Biodiesel Provides Substantial Savings in M&R : Because it also cleans up the engine and the fuel system as well as providing lubricity in moving parts, coco-biodiesel solves many engine problems and will spare the motorist a lot of mainte mai ntenan nance ce expense expe nse and potent pot ential ial repair rep air downt do wntime ime (Biofue Bio fuels ls Phils Phi ls ). All these along with the so many drivers of government and private companies prove that biodiesel is technically and positively viable and better alternative fuel to diesel.
FINANCIAL ASPECT
he worldwid worldwide e acceptanc acceptance e of biodiesel biodiesel as renew renewable able altern alternative ative fuel fuel to diesel diesel is gaining momentous and sharp increase. This is shown in the two succeeding figures below, below, represe representi nting ng biodie biodiesel sel demand demand in the United United States States and produ producti ction on in Germany. Both showed a sharp increase and continuously growing industry starting 1990s.
In the Philippines, the biodiesel industry started and rigorously tested on vehicles starting 1972 as reported by Biofuels Philippines. Republic Act 9367 mandated its 1 % usage and gradually increasing with every passing years. In 1999, DOE statistics showed that the Philippines is consuming close to 36,000 MMtonsof diesel as shown in the table below.
Source : DOE 1999 Statistics, Values in MMT MM Tons
Fuel consumption in the Philippines, where diesel plays a major part in the transport industry
Merely Merely,, 1 % of this this figur figure e incorp incorpora orated ted into into commer commerci cial al diesel diesel is alrea already dy equivalent to 360 MMtons of B100 biodiesel. This is the current demand for biodie biodiese sell from from the five five major major oil player players s and ex expla plains ins why why the curre current nt price for it is ranging from P70 /L to P140/L. This price range will therefore soar further when the the Act raised its its usage to 3 % this 2009. Shown in the next succeeding pages is a Projected Profit and Loss Statement, P&L and following it are the 6 graphical interpretations. The P&L gives the extent of profit per liter and per batch when ; 1. the price of used cooking oil per balde from free and increases to P200 until P500 2. the selling price of biodiesel is competitive with diesel at P32/L, P35/L, P40/L and P50/L 3. the corresponding cost of your biodiesel as the cost of oil and selling price pr ice of biodiesel increase. 4. the Gross Product Return or GPR for a daily production output of 1000 L 5. the net income per batch of 200L, 277L, 500 L and 1000L at various conditions When When the the last last row row in the the P & L Stat Statem emen entt is grap graphe hed, d, the the figu figure re belo below w showed showed the proje projecte cted d prof profit it as diese diesell price price increa increases ses.. If your your using using your your own ( company waste, factory waste, mall grease traps, restaurant’s etc. ) used oil ( light blue line in the graph ), meaning free of charge, your profit range from P27/L to P45/L. This is way too high compare compare to gasoline gasoline station’s profit profit of P0.50 maximum per liter. If your buying used oil at P500 per balde ( dark blue line ), you will only gain profit if you sell your biodiesel at P35/L with a minimal profit of P0.28/L. It is therefore important to use the brown line as a reference in buying oil at a cost lower than P400 per balde to t o remain competitively profitable.
The graph below represents the last 4 columns in the P & L Statement. It shows the income per batch if oil is bought at P500 per balde. This again shows profit minimal gain if biodiesel is sold at P35/L but negative profit at the current diesel price of P32/L. This is actually the break even point for the business and will be very useful to use to keep track of your used oil purchases. purchases.
The graph below shows the income per batch for used cooking oil bought at P400 per balde or when processed to biodiesel costs P28.77/L. At this point when the current price of diesel is at P32/L, a P3/L margin can only be lucrative and costeffective if either or all of these three will be employed ; 1. sell in large volume like gasoline and diesel stations and/or 2. sell to major oil player at P70/L. In this case your profit will jack up to P41.23/L and/or 3. sell as additive to diesel at P140/L. In this case your profit will be boosted to P111.23/L These three makes makes your biodiesel biodiesel business even more profitable, profitable, but even without these at minimum minimum production production volume per day of 1000 1000 L , huge GPR of 36 % is achievable as shown in the P & L Statement at selling price of P32/L. A GPR of 5% to 10 % is considered progressive and profitable already.
In the two succeeding figures below, at P300 and P200 per balde ( 17 kg can ), the profit margins are evidently augmented and became profitably profitably enhanced. At this point, specially for P200 per balde, the selling price of biodiesel can even be lowered below P32/L diesel price mark and still remain profitable at a tolerance or monetary leniency range of P9/L and P18/L mark up respectively. respectively.
Maximum profit and competitive financial leniency is achieved when the oil is free. The total cost per liter of biodiesel biodiesel inclusive inclusive of labor, transport and chemicals, chemicals,
is less than P5 only, thus you can sell it at P30/L and still achieved a whopping P25/L net profit. Having a GPR of 305 %, this is translated to P550,000 per 22 worki wo rkingng-da day-m y-mont onth h at a produ producti ction on volume volume of 1000 1000 L per per day day. This This is technically achievable achievable using a 200 L set up at a t 5 batches per day output.
The basic reason why I extended the Profit and Loss Statement up to P50 /L is simply because of the diesel trendline published worldwide by Finance Manila as shown in the graph below. This study was based on the research and statistics made availa available ble by relia reliable ble sourc sources es like like Ibon Ibon Found Foundati ation, on, Depart Departmen mentt of Energ Energy y and Technistock. Diesel price is moving bumpy from 1998 to 2008, but observe the trendline, the slope is stable and continuously rising. This means that biodiesel will have a profitable future if this diesel trendline will be the reference basis. Population Population growth, diminishing diminishing arable lands, lands, food and water scarcity, economic economic instability and oil reserve shelflife ( which according to Klebnikov , Paul and Forbes (2002)in ”When the Oils Runs Out”.Acade Out”.Academic mic Search Elite. Issue 9 will last for only 30 years ) will definitely tip this slope to a higher degrees.
ENVIRONMENTAL ASPECT
B
iodiesel is a renewable and sustainable fuel, meaning by mere planting and growing animals, we will have continuous source of non-toxic and green fuel. This is illustrated by the biodiesel cycle below.
It also emits minimal pollutants because of its physico-chemical properties as explained in the technical aspect above unlike the toxic, non-biodegradable and non-renewable diesel being emitted on the streets everyday.
Source : US EPA,
The series of studies conducted by United States Enviro Environme nment ntal al Prote Protecti ction on Agency Agency,, EPA EP A showed showed an interest interesting ing positive positive attributes of biodiesel. Using it even at minima minimall blend blend exhib exhibite ited d drasti drastic c reduction in particulate matter, PM, the toxic carbon monoxide, CO and hydrocarbons, hydrocarbons, HC. For soya biodiesel ( havi having ng high higher er prot protei ein n nitr nitrog ogen en content, a minimal increase of nitrous oxide, NOx was noted. This last characteristic however, however, is not true for cocobiod cocobiodiesel iesel,, being a saturated saturated biodiese biodiesel, l, emission emission of oxides of nitrogen is substantially reduced. Foremost, it Helps the Fight Against Global Warming and Climate Change: Every liter of cocobiodiesel consumed generates reduction of 3 kg of CO2.
Emi Emission sions s of thre three e eng engines nes tha that uses ses B10 100, 0, B2 B20 0 and and Diese iesell was was compar comparati ativel vely y studie studied d by Sharp, Sharp, C.A., C.A., S.A S.A.. Howell Howell,, and J. Jobe, Jobe, in their their in-de in-dept pth h research entitled "The Effect of Biodiesel Fuels on Transient Emissions from Modern Diesel Engines, Part I Regulated Emissions and Performance," SAE Paper 2000-01196, 2000.
Test Engine
Test Fuel
Transient Emissions, g/hp-hr
Cummins N14 Cummins N14 Cummins N14
B100
HC 0.01
CO 0.41
NOx 5.17
PM 0.076
B20
0.19
0.64
4.76
0.102
2-D
0.23
0.75
4.57
0.106
DDC Series 50 DDC Series 50 DDC Series 50 Cummins B5.9 Cummins B5.9 Cummins B5.9
B100
0.01
0.92
5.01
0.052
B20
0.06
1.38
4.66
0.088
2-D
0.06
1.49
4.50
0.102
B100
0.08
1.27
4.90
0.081
B20
0.21
1.61
4.79
0.109
2-D
0.31
2.05
4.70
0.128
The above experimental results of US EPA was verified in conformity with this rese resear arch ch indi indica cati ting ng posi positi tive ve redu reduct ctio ion n of poll pollut utan ants ts when when biod biodie iese sell is used used specifically when used as pure B100. These two results made agencies and private companies to encourage and recommend biodiesel. These are ASTM, US DOE, US EERE EERE ( Energ Energy y Effici Efficienc ency y and Renewab enewable le Energy Energy), ), AFDC AFDC ( Alt Altern ernati ative ve Fuel Data Data Center ), Boeing ( who made the first biodiesel flight in Chechs Republic ), John Deere, College of Alameda, Berkeley School, Florida Transit Buses, Lake Titicaca Tour Ships, Hawaii National Park Tours, San Francisco Bay Ferry, AOCS ( American Oil Chemist Society ), Austrian Biofuels Institute, Purdue University and many more to name a few. From among the countries that produce biodiesel, it is Germany who is the biggest and the largest consumer as well. Here in the Philippines, environmental environmental and technical related researches researches done by DOST and PCCARD for more than 20 years has led other government agencies like DENR, PhilForest, PNS, DTI, DOE, EUMB, Congr Congress ess,, Senate Senate and Execu Executiv tive e to use use and encour encourage age its its utili utilizat zation ion.. Priva Private te compan companies ies like like Prince Prince Shuttles Shuttles,, Chemre Chemrez, z, Biofue Biofuels ls Philip Philippin pines, es, Senbel Senbel Fine Chemicals, Romtron Phils., Freyvonne Milling, Zafra Rendering, Razsa Agro, Tapa Tapa King and more use this on a regular basis continuously. What What made made these these agenci agencies es and companie companies s switc switch h over over to biodies biodiesel el ? I believe, the most convincing factor factor still, is the saying to see is to believe, believe, as can be seen in the picture below. below. It shows the comparative flame and sooth residues left by burning diesel, diesel biodiesel blend and pure biodiesel.
One would immediately observe the thick residue left by burning diesel on the rightmost sooty container. Soothy and moderate smoke being emitted on the 50/50 diesel/biodiesel blend at the middle. Very nice clean but bright flame of pure biodiesel on the leftmost ceramic disc.
SOCIO-ECONOMIC ASPECT
estor estores es the Old Glory Glory of the Coconut Coconut Indust Industry ry : At prese present, nt, coconu coconutt oil cons consum umpt ptio ion n is dwin dwindl dlin ing g both both loca locall lly y and and abro abroad ad,, and and coco coconu nutt plan planti ting ng is declining. The coconut industry industry is not yet “out “out of the woods” of being being on the verge of collapse. The Biofuels Act Act will give the coconut industry, industry, through coco-biodiesel, coco-biodiesel, a new lease on life, very surely restoring its lost glory as the erstwhile agricultural champion of the country. country. The Biofuels Law will create create a demand for more coconut oil, thus providing coconut coconut farmers the incentive incentive to preserve and replant replant coconut trees rather than cutting them for coconut lumber ( Biofuels Phils website ). Helps the Philippine economy : By causing significant fuel savings, cocobiodiesel biodiesel will will save us 4 billions billions dollars dollars annually annually that normally normally go to petroleum petroleum diesel exports. By mitigating pollution and lowering emissions, cocobiodiesel will help government government save on the $450 million million it spends spends yearly yearly on pollutio pollution-rel n-related ated health disorders while contributing significantly significantly to slowing down climate change . By reviving the coconut industry, coco-biodiesel will help the livelihood of some 28 million Filipinos and 69 provinces that directly or indirectly depend on the coconut industry ( Biofuels Phils website ).
CONCLUSION
iodiesel production is highly feasible technically, financially, environmentally and socio-economically.
