Devices and Methods for Automated Mobile BioDiesel Production

Abstract

At least one exemplary embodiment is directed to a device that uses a co-axial oil and methoxide flow to near real time mix the two flows into biodiesel.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims the priority benefit of 60/744,848, 60/744,945, 60/745,060, and 60/745,176, under 35 U.S.C. § 119(e), all of which are incorporated herein by reference in their entirety.

FIELD OF THE INVENTION

The invention relates in general to devices and methods of for the automation of biodiesel production and in particular, though not exclusively, for the mobile production of biodiesel.

BACKGROUND OF THE INVENTION

Biodiesel has several manual elements such as titration as part of the production process. Additionally the formation time can take up to 8 hours.

The current method (FIG. 1A) of biodiesel production involves picking up F1 a feedstock oil (e.g. soybean oil, waste oil) delivering (FT1) the feedstock oil to a storage facility (SF1), then to processing plant (PP1), then to a biodiesel storage tank (BD1), then shipping D1 (e.g., via tanker trucks) the finished product (e.g., biodiesel) back to the regional areas to serve as fuel. A business method that would locally process collected feedstock oil would significantly decrease transportation costs involved with biodiesel production and improve the overall efficiency of the market delivery.

SUMMARY OF THE INVENTION

At least one exemplary embodiment is directed to an automated titration system.

At least one exemplary embodiment is directed to an automated methoxide process.

At least one exemplary embodiment is directed to a near real time biodiesel production mixing process.

Further areas of applicability of exemplary embodiments of the present invention will become apparent from the detailed description provided hereinafter. It should be understood that the detailed description and specific examples, while indicating exemplary embodiments of the invention, are intended for purposes of illustration only and are not intended to limited the scope of the invention.

BRIEF DESCRIPTION OF THE DRAWINGS

Embodiments of the present invention will become apparent from the following detailed description, taken in conjunction with the drawings in which:

FIG. 1A illustrates the conventional business method of biodiesel production and delivery;

FIG. 1B illustrates a business method of biodiesel production and delivery in accordance with at least one exemplary embodiment;

FIG. 2 illustrates a mobile biodiesel production facility in accordance with at least one exemplary embodiment;

FIG. 3 illustrates a mobile biodiesel production facility in accordance with at least one exemplary embodiment;

FIG. 4 illustrates a mobile biodiesel production facility in accordance with at least one exemplary embodiment;

FIG. 5 illustrates a schematic of an automated titration system in accordance with at least one exemplary embodiment;

FIG. 6 illustrates an example of an automated titration device in accordance with at least one exemplary embodiment;

FIG. 6a illustrates a schematic of the steps of an automated titration process in accordance with at least one exemplary embodiment;

FIG. 7 illustrates an example of a titration chamber in accordance with at least one exemplary embodiment;

FIG. 8 illustrates a schematic of an automated titration system in accordance with at least one exemplary embodiment;

FIG. 9 illustrates an example of a sampling chamber and/or mixing device and/or methoxide production device in accordance with at least one exemplary embodiment;

FIG. 10 illustrates an example of a sampling chamber and/or mixing device and/or methoxide production device in accordance with at least one exemplary embodiment;

FIG. 11 illustrates a schematic of a mixing/separating system in accordance with at least one exemplary embodiment; and

FIG. 12 illustrates a porous mixing system in accordance with at least on exemplary embodiment.

DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENTS OF THE PRESENT INVENTION

The following description of exemplary embodiment(s) is merely illustrative in nature and is in no way intended to limit the invention, its application, or uses.

Processes, methods, materials and devices known by one of ordinary skill in the relevant arts may not be discussed in detail but are intended to be part of the enabling discussion where appropriate.

Additionally, the size of structures formed using the methods and devices of exemplary embodiments are not limited by any discussion herein (e.g., the sizes of structures can be macro (centimeter, meter, size), micro (micro meter), nanometer size and smaller).

Additionally, examples of mixing/separating/sampling device(s) are discussed, however exemplary embodiments are not limited to any particular device for mixing, separating, and sampling.

Additionally, other fluid besides those used in biodiesel production can be used with the exemplary embodiments including gases.

FIG. 1A illustrates the conventional business method of biodiesel production and delivery.

FIG. 1B illustrates a business method of biodiesel production and delivery in accordance with at least one exemplary embodiment. In the embodiment illustrated a mobile processing plant PP2 (also referred to as processing centers) include devices to process feedstock oil into biodiesel. Hence in this exemplary embodiment the processing plant PP2 travels to the remote feedstock oil storage sites (e.g., Remote sites 1, 2, and 3), processes the feedstock oil into biodiesel and stores the biodiesel locally. This facilitates redistribution into the community.

FIG. 2 illustrates a mobile biodiesel production facility in accordance with at least one exemplary embodiment. The feedstock oil storage 110 pumps feedstock oil into the mobile processing plant 100. A sample of the feedstock oil is used in titration (e.g., 130 automatic titration) to determine the useful catalyst levels, e.g., from a catalyst device 135). The useful level of catalyst is added to methanol 140 to form methoxide, which is mixed with the feedstock oil in the mixing device 150. The products from the mixing device includes a mixture which includes glycerin, unused feedstock oil, and biodiesel. The unused portion of feedstock oil can be separated in a separating device 170, and recycled in a recycling loop 160 and injected back into the mixing device. The glycerine/waste can also be separated via the separating device 170 and stored for later use 180. The separated biodiesel can be pumped into a biodiesel storage tank 120.

FIG. 3 illustrates a mobile biodiesel production facility in accordance with at least one exemplary embodiment, where the glycerin is also stored externally 180B and separately from the remaining waste 180A.

FIG. 4 illustrates a mobile biodiesel production facility in accordance with at least one exemplary embodiment where water (for example stored externally 190) can be used to purify the biodiesel prior to tank storage. Additionally in place of an automated titration system a user can enter titration parameters 130 A into a logic circuit that can control the amount of catalyst used in the mixing device 150.

FIG. 5 illustrates a schematic of an automated titration system in accordance with at least one exemplary embodiment, while FIG. 6 illustrates an example of an automated titration device 130 in accordance with at least one exemplary embodiment. Feedstock oil, which can be heated (e.g., via a heating circuit 525 as measured via a temperature gauge 527) can flow HO into sampling chamber 520 along with products from a titration chamber TC, a catalyst (e.g., ISO or Isopropyl), and some methanol via the catalyst chamber 550. Upon measurement of properties of the combined sample (e.g., PH meter 530) a useful level of catalyst 550 to add to methanol 590 can be determined to form methoxide 595 to add to the remaining feedstock flow HO1 in the mixing device 570.

FIG. 6a illustrates a schematic of the steps of an automated titration process in accordance with at least one exemplary embodiment, where a value of K is used to determine the difference between good feedstock oil (less contaminants), and poor feedstock oil, while determining the catalyst level.

FIG. 7 illustrates an example of a titration chamber in accordance with at least one exemplary embodiment, where an automatic precision feed system 135 injects various levels of measured catalyst 565b into a titration solution 565a. In this exemplary embodiment the flow from the titration solution chamber TC is injected into the sampling chamber 520.

FIG. 8 illustrates a schematic of an automated titration system in accordance with at least one exemplary embodiment and as can be seen illustrates the flow of TC into the sampling chamber 520.

FIG. 9 illustrates an example of a sampling chamber and/or mixing device and/or methoxide production device in accordance with at least one exemplary embodiment. Flows HO, ISO and TC can be injected into the sampling chamber 900, where parallel feed tubes and/or holes 910b, 920b, and 930c can more uniformly inject the flows. Optionally mixing arms 940a, attached to a rotatable mixing shaft 940b (e.g., controlled by a mixing control unit 940). The characteristics of the resultant mixed sample can be measured (e.g., via PH meter 950).

FIG. 10 illustrates an example of a sampling chamber and/or mixing device and/or methoxide production device in accordance with at least one exemplary embodiment. In the exemplary embodiment a co-axial flow of feedstock oil (e.g., HO1) and Methoxide (e.g., MO1) can be set up to increase interaction area. Optionally the co-axial flows can be impinged upon one or more mixing grids (e.g., 1050, 1060). The co-axial flows (e.g., 1030c and 1030b) can interact at their interface forming biodiesel, and can additionally break up into aphronated droplets. The co-axial flows can be used to maximize interface area. The cross-section of which can be varied to obtain a near zero relative velocity or a relative velocity to maximize mixing.

FIG. 11 illustrates a schematic of a mixing/separating system in accordance with at least one exemplary embodiment and illustrates in block form the relationship between the mixing device 1140 and it's inputs and the separation device 1170 and it's exports.

FIG. 12 illustrates a porous mixing system in accordance with at least on exemplary embodiment. Instead of using co-axial mixing flows another method in accordance with at least one exemplary embodiment is to have a porous block (e.g., lava stone) that saturates the block 1200 with methoxide (e.g., MCM). Channels (e.g., feedstock mixing channel 1210) can be drilled or otherwise formed (e.g., molding) into the block 1200 allowing feedstock oil to pass through. The channel wall being porous allows MCM to seep in at the channel walls interacting with the feedstock oil. A smaller channel will increase the % of penetration depth in the transverse direction (perpendicular to the channel axis). Thus channel lengths and widths, flow rates and pressure, can be tailored to derive a % mixing along a standard length (e.g., 10 cm).

Centrifugal Separator

At least one exemplary embodiment is directed to a biodiesel processor system including a mixing region, spin separating region, and a flow separating region, with optional recycling loops feeding back into the system. Note that if a feedback system is used then in at least one exemplary embodiment titration is not used to determine the appropriate amount of catalyst. Instead an amount is assumed to correspond to poor oil, combined to form methoxide, and then recycled through the system through the waste tubes until used.

The spin separator system can be cylindrical or slightly expanding (to have a velocity component along the wall driving the fluid forward axially). As it spins the portions with a higher specific gravity will tend toward the walls while the lower specific gravities will accumulate toward the central portions of the flow. For example if the entire spin separator region if filled with mixed biodiesel, methanol, methoxide, waste, then the parts will separate as they start to spin inside the rotating cylinder (Note, internal fins can be provided to aid the spinning). As the flow travels down the fluid portions start to separate axially. When a useable amount has been separated, e.g. determined by simple experiments, (for example the first 3 mm near the wall are 95% glycerin, 10 cm along the spin axis) then co-axial bleed tubes (flow separator system) can take those portions of the flow out of the recycling flow and further purified if needed (e.g., the axial spin water washing system illustrated in FIG. 3, where a similar spin system as the spin separator system can be used with initial grid walls to collect particulates and contaminates, with optionally water delivered axially, which the spin will move toward the wall. Note the water can be injected near the axial line toward the beginning of the spin and that's it. Along the axial direction the water which was near the center will be spun to the walls cleaning the biodiesel, which can be bled through another axial bleed tube, and the system can go through a feedback loop).

Porous Mixing Device

FIG. 12 illustrates a porous mixing system in accordance with at least one exemplary embodiment. The porous block 1200 can of course be any shape. The material of the block is one that will absorb methanol and/or methoxide and/or recycled fluids and catalyst so as to be present at the surface of feedstock mixing channel 1210 passing through the porous block. FIG. 12 illustrates four feedstock mixing channels (tubes) 1210, although any number and size can be drilled or fabricated. The feedstock oil passes through an interface containing sub-tubes which are constructed to match at least some of the tubes drilled in the block. The sub-tubes (feedstock oil feed channels 1230) delivery the feedstock oil through the interface (1220 feedstock interface plate) into the block. The feedstock oil has associated with it a pressure, that in accordance with the methanol and/or methoxide and/or waste fluid pressures feeding the porous block reservoir can be varied.

The pressure of the fluid saturating the porous block can be varied to minimize feedstock absorption by the porous block while encouraging the fluid in the porous block lining the tube surface to enter the feedstock oil stream. Thus the fluid absorbed in the porous block can then enter the feedstock oil stream, mix and reacts to produce a chemical product (e.g., biodiesel). The size of the block, tube diameters, porosity of the block, and pressures can be easily varied to maximize reaction.

Any non converted feedstock oil, catalyst, methanol, methoxide, and any other fluid used in the process can be recycled in a feedback loop.

FIG. 12 illustrates an example of the external connection of a porous mixing system with other devices in a biodiesel processing facility in accordance with at least one exemplary embodiment, in addition to a figure illustrating optional one way flow layers, and a figure illustrating the pressure relationships between various flows and reservoirs. The porous mixing system can be operatively connected to a fluid separator, pumps, valves and other fluid support systems necessary to deliver the feedstock oil, and vary the fluid flows.

FIG. 12 illustrates a close-up of a tube section passing through a porous block, where the pores contain Methanol and/or Methoxide and/or Waste (referred to as MMW or MMC). Note that the material of the porous block can vary depending on the physical porosity needed and resistance to the chemicals used. (e.g., fired clay, porous rock, and other absorbent chemical resistant materials as known by one of ordinary skill in the relevant arts and equivalents).

Additionally the exemplary embodiment can include a gear driven axial spin separator. In the non-limiting example a tube can be tight fitted through the hole of a couple of bearing rings. The tight fit can be fluid tight but can also include a sealant at an interface. The interface can include a sub-tube that delivers a first fluid (feedstock oil (FO)) into the tight fitted tube. For the tube to rotate there is a gap G between the plate and the tube (which has been tight fitted to the bearing ring). A seal on the plate can keep fluid from leaking radially along the plate. Note also that the plate will have to have clearance with respect to the inner portion of the bearing ring (the center rotating part). Thus depending on how close the clearance is there can be some fluid leakage. To minimize this the clearance is kept small and a positive pressure P* is exerted to aid in the surface tension retention of the fluid in the rotating tube.

Additionally at least one exemplary embodiment can include a magnetically driven internal separator. An internally contained spin separation system in accordance with at least one exemplary embodiment can include, bearing rings which are contained within a fluid chamber (note that the bearings will need to be reasonable resistant to the reactants (BD, FO, Methanol, Methoxide, waste, and catalyst). In the non-limiting example the outside surface of the rotating tube has attached permanent magnets that can be influences by and externally varying magnetic field. The externally varying magnetic field can be generated by an oscillating magnetic device M1, much like an electric generator is coerced to spin, except in this case there are no contact wires directly to the spinning portion, and the magnets reside on the spinning portion instead of the stationary portion.

Additionally, exemplary embodiments can include a cleansing unit comprising, a first chamber, wherein the first chamber includes unprocessed biodiesel; a second chamber, wherein the first chamber is connected to the second chamber via tubes; and a third chamber, wherein the third chamber includes water that is cycled through the third chamber, wherein the third chamber lies between the first and second chamber, wherein the tubes pass through the water of the third chamber, wherein the tubes are made of a material that facilitate the formation of an interface between the water and unprocessed biodiesel where water soluble contaminants in the unprocessed biodiesel become at least partially removed and dissolved into the water, and where the biodiesel entering the second chamber is processed in that at least a portion of the water soluble contaminants have been removed.

While the present invention has been described with reference to exemplary embodiments, it is to be understood that the invention is not limited to the disclosed exemplary embodiments. The scope of the following claims is to be accorded the broadest interpretation so as to encompass all such modifications and equivalent structures and functions.

Claims

1. A method of processing and delivering biofuels comprising:

unloading at least a first portion of a raw material in an at least one raw material storage location into a mobile processing biofuels plant, wherein the mobile biofuels plant has been transported to a region near the raw material storage location;

mixing the first portion with at least one second portion of a mixing substance, wherein the mixing of the first and second portions creates a third portion of biofuel; and

unloading from the mobile biofuels plant the third portion into a biofuels storage location, wherein the mobile biofuels plant can be moved from the biofuels storage location after unloading the third portion.

2. The method according to claim 1 wherein the mixing substance is methanol.

3. The method according to claim 2, further including a second mixing substance that is also mixed with the first and second portions.

4. The method according to claim 3, wherein the mixing of the mixing substance and the second mixing substance forms methoxide.

5. A spin separator comprising:

a spinning chamber, wherein the spinning chamber has a spin axis; and

a rotation support, wherein the rotation support is configured to spin the chamber at a predetermined rate that is related to a selected separation portion along the spin axis, wherein the spinning chamber separates flow inserted along the spin axis and expelled along the spin axis, into axially separated portions in accordance with their specific gravity.

6. A flow separation system comprising:

the spin separator according to claim 5; and

at least two co-axial tubes, a first tube and a second tube, configured to receive a portion of a first specific gravity fluid and a second specific gravity fluid respectively, wherein the first specific gravity and second specific gravity fluids are separated by the spin separator.

7. A biodiesel processing device comprising:

an inner flow of feedstock oil; and

an outer flow of methoxide, wherein the outer flow of methoxide is a co-axial sheath around the inner flow, and wherein the outer and inner flow at least partially mix forming a portion of biodiesel.

8. The biodiesel processing device according to claim 7, wherein the inner and outer flow impinge upon a mixing grate.