Tonight Rachel and I are staying in Grande Prairie, awaiting an early flight home after a couple of days in Peace River Country.
This is a bizarre and wonderful place. Farmers, homebrewers, academics, and canola growers trudged through the cold (20 below C) to take in a conference on renewable energy.
Rachel held court with a session on backyard analytics. And I was asked to do a talk on biodiesel side streams.
Here is what I said:
This is my second trip to Powering the Peace, and as the conference date approached I took a long look in the mirror to see if I could figure out the appeal of this gig.
Of course it feels natural to fly from Raleigh to Toronto, Toronto to Calgary, Calgary to Grand Prairie, and then to catch a ride to Fairview so that I could talk about sustainability.
And it makes equally perfect sense for me to leave the seventy-degree weather of Pittsboro, North Carolina to come to the twenty below temperatures of Fairview.
Looking in the mirror didnt help.
I think the reason I came back here was because of the crushing equipment that was on display last year. I saw innovation, and fearlessness, and I talked to a bunch of farmers who were happy to improvise as they went along.
In the past year I have come to realize that in North Carolina we have lost our vernacular knowledge of crushing. Its largely a mystery to us. Today in North Carolina we can get oilseed crushed at either the Cargill plant in Raleigh, or the Cargill plant in Fayetteville.
After which we are pretty much out of tricks.
Yet this part of the world is a farm scale crushing paradise.
North Carolina, on the other hand, is a haven for home brewers. And farm scale biodiesel makers. And small scale commercial biodiesel producers. Today we have 7 biodiesel plants operating in our stateall of them 5 million gallons per year or less. We have a half dozen active biodiesel Coops, over a hundred biodiesel home brewing operations, and a community college system that has a biofuels curriculum that is offered statewide.
We know a lot about making biodiesel. But virtually every operation I just mentioned is powered by waste fats oils and greases. Today there is no bridge from our biodiesel production to the farm.
I believe we are learning to grow canola, although we havent quite figured out how we are going to get the oil out of it when we take the crop off.
Before you leave this conference fearing North Carolinas entry into the global canola marketsbewarewe might have as much as 250 acres under cultivation statewide. We are pretty much soy countryand as far as soy producing states go, we are a big dog on the eastern seaboard.
By the way, I was born and raised in Canada. And whenever I was in the audience, listening to some bozo from the United States, nothing would make me angrier than when all the currency references were in U.S. dollars. Full disclosure: I dont do hectares, metric tones, liters or any other measurements that make sense. I am firmly locked into the weights and measures that I trade in all day every day. The other day we shipped a truckload of sweet peppers off of the sustainable farm we operate on our project, and yes, we really did pick them in pecks
Although, now that I think about it, any Canadian dollars that come my way up here are sure going to go a lot further than the ones I got last year. Perhaps I should learn to adapt.
Adaptation is something we have accomplished at Piedmont Biofuels. We started out as a class at our local community college, and went from backyard brewing of biodiesel to a coop. With just over five hundred members, some say we are the largest biodiesel coop in America today.
Our Coop operation is what I call a farm scale plant. It kicks out a few hundred gallons of fuel a week, from waste vegetable oil it collects from local sources. Most of it has been used for frying something or other.
I work at our Industrial wing were we can make and ship around 4,000 gallons per day. Google tells me that is around 15K liters. We think of it as a 1.3 million gallon facility. You are welcome to call it a 5 million liter facilitywhich in my mind sounds much more impressive.
Today we are running on chicken fat and waste vegetable oil, but we have run soy, back in the day. I have a bid in on a load of peanut oil right now, and I have my fingers crossed. We are a multi-feedstock facility. You give us some fat, well make you some fuel.
Outside of biodiesel production we do a mountain of education and outreach, we run a design-build business that builds farm scale processors, and we have a couple of acres of sustainable produce under cultivation. We are about to launch a farm-incubator project, we have a small canola trial underway, and this winter we are building a mobile crushing plant to go with our mobile biodiesel reactor.
On any given day we might have 25 people across all projects, and combined we represent about a two and a half million dollar per year enterprise.
Its pretty good growth for a group of passionate volunteers who started out in a metal drum with a canoe paddle.
Weve done a good job of demystifying small-scale biodiesel in our state, and one of the jobs that lie ahead for us is to do the same thing with oilseed crushing. Thats one of the reasons we are here.
Another reason we are here is the one on the agenda. Im not supposed to be talking about us. Im supposed to be addressing biodiesel side streams.
So here it goes.
When you are making biodiesel you create fuel, and what amounts to a worthless glycerin cocktail. Its part water, part methanol, part free fatty acids, and part glycerin. Trying to find a market for the cocktail is exceedingly difficult, as you will find what one party desires is not desired by the next.
For example: We all know you can burn crude biodiesel glycerin as a boiler fuel. It has 40% of the BTUs of most fuels, so it is generally not used at 100% strength, but it does make a nice additive to fuel oil. Want to sell your product to the boiler market? Get your water out. Leave your methanol in. The more BTUs the better.
Want to sell your glycerin into the animal feed market? Get the methanol out. In the United States the FDA and USDA has granted crude biodiesel glycerin GRAS status. Thats their way of saying Generally Regarded as Safe to include into animal rations.
To hit the feed specification, you need to be less than 150 parts per million. Which we have found hard to hit.
Want to sell to water remediation companies? They pay dearly for pharma and food grade glycerin that they dump into holes in the ground to clean up aquifers. But they need the methanol out, and they need the metals out. If you have traces of selenium, or nickel from your stainless steel piping, you need to get that out before entering the water remediation market. They need a product that is safe to drink.
Want to sell to the digester folks? They are the wastewater treatment plants. When you find a municipal treatment plant that has more treatment capacity than it has gallons coming at it, you have a customer who needs your glycerin to feed their bugs. Some want methanol in. Some want methanol out. After all, methanol is sold in the scientific markets as microbial starter.
The point is dont build a biodiesel operation without a way to sort out the glycerin cocktail. Methanol is currently at the highest price it has been for the past five years. When you run the numbers today, you cant afford to build a biodiesel operation without including methanol recovery.
And when you do that, by the way, rig it up so that you pass both your fuel phase and your glycerin phase through methanol recovery. You are not going to get much methanol out of the fuel, but you are going to reduce water washing on down the line. Most of the excess methanol comes out in the cocktailand you want that back so that you can reuse it.
That will not only help the carbon footprint of your plantit will also help your wallet.
We have engineered a bio-refinery that we intend to use to sort out the cocktail. It includes methanol recovery, and a glass lined reactor in which we will be able to strip out the free fatty acids. We will ship those back to the rendering company that provides us with feedstock, where they will find their way into animal feeds.
Most biodiesel plants in America today are water washing. After you have separated your fuel from your glycerin, you go about washing the fuel. And you wash out soaps, and crud, and glycerin that you missed, and you wash, and wash, until your hit the on road specification.
How many times you wash is largely dependent on the fuel maker. If you are a multi-feedstock plant, it is largely a function of getting the recipe right and knowing what you are doing. The more experience you have making biodiesel, the less washing required.
Wash water then becomes an important side stream. If you plan to discharge to a municipal treatment plant, you will probably need to build pre-treatment into your thinking. Our pre-treatment includes a neutralization step, a pass through an oil water separator (which often catches biodiesel for us to put back into the system), followed by a sparging with diatomaceous earth.
Sparging, by the way, is simply adding air to water (or fuel) to make bubbles.
At Piedmont Biofuels we ran into trouble on the water front. Our small town wastewater treatment plant is at capacity. It cant handle us. We slowly poisoned all of the towns bugs, discharging a mere 3600 gallons day into a plant with a 500K gallon per day capacity.
So our town made us pump and haul all of our waterand our profitsoff to compost.
Combine that with the fact that we are in the worst drought in recorded history, and we faced water problems coming and going.
Which is why we switched to ionized beads. We plumbed in a lead-lag ion exchange system that grabs soaps, and moisture, and stuff that we want out of our fuel. And it does it without water. Ion exchange is our new best friend. It knocked our water consumption down by 80%. We now do a quick pre-wash as fuel is coming out of the reactorto help knock glycerin outand one wash cycle to knock the methanol out, and off we go to our ion exchange columns.
Every time I see the water truck pull in, I see 500.00 pull out of the gate. Its refreshing seeing it around the place 80% less. And it is nice to see our water bill drop on the incoming side.
Ionized beads are rechargeable which means you can find a vendor who will take them back, wash them up, and get them back into action for you. Reusable resins not only earn you a sustainability pointthey also save you money.
You can buy talc that serves a similar purpose to ionized beads, but I do not know of any that can be rechargedso if you move to polishing your fuel with talc, you will have a biodiesel soaked powder side stream to deal withmost of which is sent to the landfill at this point.
We have one other annoying side stream to contend with, and that is what the chemical industry refers to as the one way tote. The damn things are ubiquitous. These are plastic 250 gallons vessels ensconced in aluminum cages with a built on pallet that makes them easy to toss around with a forklift.
We use them for sodium methylate and potassium methylate. By having our catalyst pre-mixed at the chemical distributor we avoid making water in the methoxide stage of biodiesel manufacturing. Less chemical water equals a higher biodiesel yield, and a cleaner glycerin cocktail.
But the one-way totes drive me nuts. We sell them off for rain water harvesting, but to do so we need to neutralize, and scrub, and lose money on every container. We havent figured it out yet, but we may find ourselves buying a fleet of round trip totes, or installing a bulk methylate tank in order to shed this oppressive side stream.
And that is biodiesel side streams, as I know them.
Original post by Lyle