Biodiesel High Shear Reators
Biodiesel Batch Process
 
High Shear Biodiesel Reactors

ULTRA SHEAR and HIGH SHEAR Mixing:
De-gumming
Neutralization
Transesterification
Water Wash
24/7 Continuous In-Line Process
     
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    HIGH SHEAR and SHEAR-PUMP Mixing:

    • Acceleration of conventional batch processing
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    Compact Process Technology

    Save time, save money

    Many vegetable oils have similar fuel properties to diesel fuel, but must undergo the Methanol – Catalyst process to be suitable for Diesel Engines. Ultra High-Shear and High-Shear Mixing Technology can significantly improve and shorten this process.
    Most Bio-diesel produced is made from soybean oil in the United States and canola (rape) seed in Europe. Other possible sources of bio-diesel are various organic oils such as corn oil, cottonseed oil, mustard oil, palm oil, algae, jatroba, animal fats, and blends of the later.

    The major process steps to produce Bio-diesel which meets the current ASTM D6751.

    Each process step includes mixing and separation.

    1. Physical crude oil / fat refining:

    During the physical refinery process, the Ultra High-Shear mixer facilitates in conjunction with a centrifuge  the removal of impurities e.g. proteins, gums, free fatty acids, oxidation compounds, and color bodies which will result in improved yield rates and improved quality within the production process of Edible Oils and Bio-Diesel.

      1. De-gumming (Mixing of crude oil and acid). Separation of gums and impurities
      2. Neutralization (Mixing of de-gummed oil and caustic). Separation of FFA.

    This operation consists in neutralizing the free fatty acids, using caustic soda.

    A centrifuge is recommended for the separation processes.
    This process is also most common for the pre-production of edible oil.
    Bleaching and deodorizing are important steps for the production of edible oil but not so much for the production of bio-diesel

     

    1. Transesterification:

    Converting any feedstock, Methanol (or Ethanol), and catalyst to Methyl-Ester and Glycerin.

      1. Primary Transesterification (mixing of feedstock, Methanol, and catalyst)
      2. Secondary Transesterification (mixing of Methyl-ester, Methanol, and catalyst)

    Decant (settling) tank, separator, or centrifuges can be use for Glycerin removal

     

    1.      Washing of crude Bio-diesel:

    There are several common methods used such as

      1. Primary- and secondary water-wash

      Mixing of Fatty-Acid-Methyl-Ester (FAME), water, and citric acid (primary only)
      Separation of last impurities and water. IKA high-shear process lowers the water amount needed down to 3% if water-wash is the preferred method. A centrifuge is recommended for the separation process.

      1. Dry Wash
      2. Ion exchange
     

    De-gumming Process / Removing of impurities and gums
    De-gumming Process / Removing of impurities and gums
    Neutralizations Process Removing FFA


    IKA Transesterification Process
    Transesterification Process

    Biodiesel Mixing System

    IKA Plants & Turnkey Systems

    Highly sophisticated designs, using IKA dispersing and mixing equipment.

    IKA - Process has been renowned the world over for many years as a manufacture of high-shear mixing and dispersing machines.

    IKA – Engineering provides the capability to design and fabricate complete turnkey systems incorporating the IKA High-Shear technology.

    As a result, IKA plant programs are created to precession with engineering expertise.

    Biodiesel Mixing System

    Biodiesel Mixing System
     
     

    Batch Agitation vs. Batch High-Shear

    Conventional batch agitation for the transesterification process takes between 2 – 4 hour per batch to convert the feedstock, methanol, and catalyst to methyl ester and glycerin.  Precise designed batch high-shear mixer (not batch shear-pump mixer) accelerates the conventional batch mixing process down to 10 - 30 minutes depending of quality of refined oil, temperature, pressure and amount of methanol.

    For mixing tanks above 1000 Gal. a recirculation process with in-line mixer is recommended instead of top-entry mixer. Multiple sets of rotor and stator combined in one machine can adopt the process in max. two passes.  High-shear mixers with up to tree sets of rotor/stator and flow-rates up to 1,500 GPM are available.  In addition, these mixers can operate with tanks after tanks.

       

    Batch Process vs. Inline Process

    Continuous flow processing is favored by larger facilities. Continuous flow facilities usually process at high temperatures and with Ultra-Shear to shorten the processing time and ensure highest quality. The equipment (e.g. biodiesel reactor, inline - high shear, centrifugal separators) for continuous flow processing does not usually require a lot of space, and it can be scaled-up to provide increased capacity without taking a corresponding increase of space.

    Current manufacturing status

    The leading oil refining manufactures have adopted the more cost effective in-line ultra shear process.  The same manufactures are adopting this process within the new in-line transesterification process.  More and more Bio-diesel producer realizing that the conventional batch agitation process is to time consuming and expensive.
     

    Biodiesel Process Systems 

    KA    ® is a global company that manufactures in Wilmington, NC. IKA provides a complete line of batch, in-line high-shear mixing process equipment, and biodiesel reactors for a variety of applications in the Bio-Diesel, Ethanol and Petroleum-Oil industry, such as de-gumming, neutralization, bleaching, transesterification, esterification, water washing, wet-grinding of cellulose solid, catalyst reactions, and fuel-blending

    The comprehensive IKA program emphasizes on scale up from Laboratory to Processing plants, with applications for ultra-shear and high-shear mixing, dispersing, homogenizing, grinding, emulsifying, and particle size reduction IKA has a fully equipped testing facility for testing, and also has trial machines available for on-site testing in Wilmington, NC

     
    Biodiesel Process Systems

    1 GPM primary and secondary transesterification system (left)
    1,500 GPM multiple stage biodiesel reactor (below)
    transesterification system

     

    BioReax
     
    Proven Technology for Biodiesel Production!
    Biodiesel Production
    Features of the BR
    Continuous capacity of 1 gpm, or optional 2 gpm
    Capacity is suitable for pilot plants or production
    Ultra High Shear mixer technology - used in reactions for over 50 years
    Two stage transesterification process ensures 100% conversion to M.E. & Glycerin
    Accurately meters the feedstock, methanol and catalyst with precision gear pumps and high accuracy mass flow meters

    Connect the inlets to supply tanks, and outlets to the separation process, and start producing biodiesel !
    A Complete Line of IKA Systems are Available for Transesterification, as well as Degumming, Neutralization and Water Wash.

    BIOREAX System Capacities

    BR 2000/04

    BR 2000/05

    BR 2000/10

    BR 2000/20

    BR 2000/30

    BR 2000/40

    BR 2000/50

    2 gpm

    10 gpm

    40 gpm

    100 gpm

    180 gpm

    300 gpm

    550
     
    BIOREAX
     
    Biodiesel System Technical Specifications

    Technical Specifications BR 2000/04

    System Type:

    Transesterification

    Capacity:

    1 or 2 gpm

    Classification:

    Class I, Div I, Grp D

    High Shear Mixers (2):

    IKA LP 2000/04

    Number of Stages:

    3

    Wetted materials:

    Stainless Steel

    HP (each):

    3

    Sealing:

    Lip seal

    Pumps (6):

    Rotary Gear

    Wetted materials:

    Stainless Steel

    Sealing:

    Mag Drive

    Flow Meters (6):

    Coriolis / Mass Flow

    Wetted materials:

    Stainless Steel

    Piping:

    Seamless Tubing

    Material:

    Stainless Steel

    Base Frame:

    Two piece, stackable

    Material:

    Stainless Steel

    Controls:

    Optional

    Type:

    Automatic or Manual

    Enclosure:

    NEMA 12
       
     
    Pricing
    BR 2000/4-T, Two Stage Transesterification, 1 gpm................... $109,000
    Control Package for BR 2000/4, Fully Automatic........................... $49,000
    Special Show Pricing Valid Through April 1, 2008
    Options  

    :BR 2000/4-T, Two Stage Transesterification, 2 gpm....................

    		 On Request
    Crude Oil Refining - Degumming and Neutralization ..................... On Request
    Washing Process – Two Stage Water Wash.................................. On Request
    Control Package Options:  Manual, Refining, Wash, etc............... On Request

     
    Biodiesel Mixing System Biodiesel Mixing System


    2007 History

    Advantages of the continuous and Ultra-Shear refining process:
    Continuous flow processing is favored by larger facilities. Continuous flow facilities usually process at high temperatures and / or with (W. Farr Technology) IKA Ultra-Shear to shorten the processing time and ensure highest quality. The equipment (e.g. inline - high shear, centrifugal separators) for continuous flow processing does not usually require a lot of space, and it can be scaled-up to provide increased capacity without taking a corresponding increase of space.


    Edible Oil and Biodiesel Refining

    Continuous Pre-treatment of Vegetable Oils for the Production
    of Edible Oils and Biodiesel / Bio-fuels.

    IKA® manufactures High Shear Mixing and Homogenizing Equipment for the continuous pretreatment of Crude Vegetable Oil and Animal Fats. During the physical refinery process, the IKA Mixer facilitates the removal of impurities e.g. proteins, gums, free fatty acids, oxidation compounds, and color bodies which will result in improved yield rates and improved quality within the production process of Edible Oils and Bio-Diesel.

    IKA offers in-line High Shear Mixer from 0.5 GPM up to 550 GPM (250,000 lbs. per hour). IKA High-Shear Machine selection range from Ultra-Shear design with multiple, extreme high-shear rates (e.g. de-gumming process), Single stage Ultra-Shear and High-Shear design (e.g. neutralization process), to High-Shear-pump design (e.g. water-wash).

    The wide variety of oils and process steps requires equally varied practice-oriented production processes and technologies. To cover this demand, IKA has designed and manufactured proven and customized solutions. The heart of the plant is always the High- Shear Mixer. Whether it is a Shear-Pump, a single stage High-Shear Mixer or a multiple stage Ultra-Shear Mixer, every customer will find the best economical and technological solution for his production duties. Satisfied customers invest their trust in this know-how and technological potential. Solutions are worked out jointly with the customer, leading engineering firms, and IKA under real production conditions.


    Advantages of the continuous and Ultra-Shear refining process:
    Continuous flow processing is favored by larger facilities. Continuous flow facilities usually process at high temperatures and / or with (W. Farr Technology) IKA Ultra-Shear to shorten the processing time and ensure highest quality. The equipment (e.g. inline - high shear, centrifugal separators) for continuous flow processing does not usually require a lot of space, and it can be scaled-up to provide increased capacity without taking a corresponding increase of space.
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    The Refining Process
    De-gumming, Neutralization, and Bleaching Process Steps:

    These are the common terms for the chemical or physical procedures.
    These procedures have one purpose: To improve the quality of the vegetable crude oil to edible oil or refined oil for the further process steps of making e.g. High quality - Margarine, Cooking Oil, other Oleo – Chemicals, and Biodiesel

    Impurities of materials are removed. Enhanced shelf-live even with longer storage times. For the subsequent treatment into other products it is important that the oil is to a large extent colorless, brilliant, and taste neutral.

    Biodiesel The Refining Process

    .

    De-gumming:
    When applied as the first step of physical refining, the process depends on the type and quality of the feed stock. Most oils can be treated in a fashion similar to neutralizing. The main difference is that the amount of caustic is reduced to the point that the acid added to the oil is neutralized and only a small amount of soap is created in the oil.

    There are several different de-gumming processes and IKA solutions such as:
    Water de-gumming IKA Single stage High – Shear
       
    Acid-water de-gumming IKA Multiple stage Ultra - Shear (up stream)
      IKA Single stage Shear Pump (down stream)
       
    Acid / base de-gumming IKA Multiple stage Ultra - Shear (up stream)
      IKA Single stage High - Shear (down stream)
       
    Ultra Shear de-gumming IKA Multiple stage Ultra - Shear (up stream)
    (The W. Farr Process) IKA Single stage Ultra - Shear (down stream) 
     

    The basic principle of these processes and IKA solution can be summarize as follows

    1.Water de-gumming with IKA Single Stage High Shear Mixer
     

    2. Acid – water de-gumming with IKA Multiple Stage Ultra Shear (up - stream)
        and IKA High Shear Pump (down - stream)

     

    3. Acid / Caustic de-gumming with IKA Multiple Stage Ultra Shear (up - stream)
        and IKA Single stage High Shear (down - stream)
     

    4. Ultra Shear de-gumming with IKA Multiple Stage Ultra Shear (up - stream)
        and IKA Single Stage Ultra Shear (down - stream)

    Neutralizing:

    This operation consists in neutralizing the free fatty acids, using caustic soda.
    The process transforms the free fatty acids into soaps.
    If Ultra Shear mixing is used to disperse the caustic soda far less neutralizing dose can be used, possibly less than 25% of the common neutralizing dose. This process dramatically improves the yield and quality.
    In addition, the volume of the soap-stock will be drastically reduced.

    This process is designed for neutralizing pre- de-gummed edible oils or oils which originally only have a low phosphate content. The free fatty acids are saponified with caustic soda, and the sodium soap is separated.


    Bleaching    :
    The bleaching process uses absorbents to remove color bodies, chlorophyll, and trace metals (to the non-detectable level). Common absorbents are silica, activated carbon, and bleaching clays. Recent work has proven that high shear mixing in the slurry tanks with high shear solid / liquid mixer improves the activity of the absorbents, allowing less dosage of these materials.
    Less dosage results in less disposal cost.

    When production quantities require a continuous process, the MHD 2000 can get the job done. Solids and liquids are instantaneously mixed and dispersed in one step, maintaining a dust free environment. The MHD accurately combines the solid and liquid, and disperses them into a homogeneous, final product. The MHD has a unique, patented design that doesn't require suction to draw in the powders, which essentially eliminates aeration. The MHD offers the greatest flexibility in production, and offers maximum product consistency. The MHD can also run in re-circulation mode as an enrichment process. The MHD avoids bridging and aeration. Maintaining a constant tip speed of 23 m/s throughout the product range ensures salability.



    Biodiesel Refining & Biodiesel Expansion

    Many vegetable oils have similar fuel properties to diesel fuel, but must undergo the Methanol – Catalyst process to be suitable for Diesel Engines. For biodiesel expansion the IKA Ultra High Shear and IKA High Shear inline transesterification prosess can significantly improve this process.

    Most bio diesel produced is made from soybean oil in the United States and canola (rape) seed in Europe. Other possible sources of biodiesel are various vegetable oils such as corn oil, cottonseed oil, mustard oil, and palm oil.

    Click here for Transesterification Process

    Shear Madness Article

    For more information please contact
    Michael Janssen
    Edb. Oil and Bio diesel Project Leader
    1(800) 733 3037
    mjanssen@ika.net