PureFire BD06 Automatic Biodiesel Processor

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PureFire BD-06Automatic Biodiesel Processor

• Senior Design 2
• Midterm Presentation
• Spring 2007

PUREFIRE
Simplifying home production of quality biodiesel.
BD-06
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Team Members
Dr. Noel SchulzAdvisor
Mark DavisProgramming
Blane SteelyChemistry/Programming
John Short Plumbing/Wiring /Documentation
Jeremiah SealCircuit Design
3
Overview

• Problem/Solution
• Technical Constraints
• Practical Constraint
• Packaging
• Testing
• Conclusions/Questions

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PROBLEM

• Simplify home production
• of biodiesel
• Current solutions inadequate
• Processors require hands-on time
• User must test oil, mix and measure chemicals
• Fuel produced does not meet ASTM standards

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SOLUTION
PureFire BD-06

• A fully automatic biodiesel processor that does
  not require any hands-on time.
• A processor that produces high-quality biodiesel
  that meets all ASTM standards.

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Technical Specifications

• Must generate one batch in lt48 hrs.
• Must occupy lt15 sq.ft.
• Chemical measurements accurate within 5 of
  calculated amount
• Must produce 25 gallons per batch
• Biodiesel must meet ASTM standards

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Practical Specifications

• Economic Must be competitively priced.
• Other processors range from 2500-8000
• PureFire BD-06 approx. 5000
• Uses economical parts without sacrificing quality
• Valves
• Level measurement

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Practical Specifications

• Health and Safety Must minimize hazards.
• Eliminate handling chemicals
• Eliminate risk of fire
• Level switches
• Low watt-density heating element
• Materials must withstand exposure to chemicals
  and heat

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Contract

• Determination of the success and effectiveness of
  the PureFire BD-06 shall be based upon the
  following operating constraints.
• The Process must be completed within 48 hours.
• The PureFire BD-06 must fit within 15 square
  feet.
• Chemicals must be measured to within 5 percent
  of the calculated value.
• Each process must produce 25 gallons of
  biodiesel.
• Biodiesel produced must meet ASTM standards as
  verified by MSU.
• Achievement of these constraints corresponds to
  complete success by the team in construction of
  the PureFire BD-06.

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Packaging and Assembly

• Wires routed through PVC conduit
• Circuit board mounted in weather proof
  fiber-glass box
• Skid mounted
• Thermocouple, heating element, level switches are
  welded into tanks

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Packaging and Assembly

• Circuit
• Fabricated by Advanced Circuits
• Total size is 11.9 x 9
• High voltage is isolated from low voltage

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Packaging and Assembly

• Circuit components
• Protection
• Opto-isolators
• Used to isolate microprocessor from external
  components
• With stand fast transients and surges up to 1500V
• Transient Absorbers
• Metal Oxide Varistor (MOV)
• Absorbs transients caused by collapsing magnetic
  fields from solenoid valves

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Packaging and Assembly
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Packaging and Assembly
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Packing and Assembly
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Packaging and Assembly
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Packaging and Assembly
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Packaging and Assembly
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Packaging and Assembly
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Packaging and Assembly
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Packaging and Assembly

• Bill of materials summary
• Electronics
• Circuit board - 70
• Components - 250
• Processor Materials
• Plumbing, conduit, electrical - 480
• Tanks, switches, valves, power supply - 1915
• Total amount - 2715

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Packaging and Assembly

• Parts
• Goal was to use parts that could be readily
  available
• Easy change out in case a part fails
• Use most economical parts

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Health and Safety

• PureFire BD-06 was designed to eliminate the user
  from exposure of harmful chemicals
• Eliminate hands on mixing of chemicals
• Each processor will come with a fire extinguisher
  

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Health and Safety

• Labeling
• Warning label placed on front of control box
• Tanks are labeled to ensure less confusion of
  what its contents are

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Health and Safety

• PureFire BD-06 will come with an instruction
  manual explaining safety, operation, and
  troubleshooting

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Tests for contract fulfillment
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Time

• Time to produce batch must be lt 48 hrs.

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Size

• Occupy less
• than 15 sq. ft.

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Batch Size

• Must produce 25 gallons per batch.

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Accuracy

• 5 accuracy
• Tested PIC
• Determined flow rates for valves
• Calculated time to drain 5 gallons and tested

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ASTM

• Must meet ASTM requirements
• Tested by MSU Chemical Engineering Department

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ASTM Carbon Residue

• 0.050 mass max.

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ASTM Cloud Point

• Report C

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ASTM Copper Corrosion

• No. 3 max

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ASTM Distillation Temp.

• 360 C max.

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ASTM - Sulfur

• 0.0015(15) 0.05(500) mass

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ASTM - Viscosity

• 1.9-6.0 mm2/s

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ASTM - Flash Point

• 130.0C min.

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Field Testing

• Reservoirs filled
• 4 Gallons methoxide added to catalyst tank
• 12 Gallons added to methanol tank
• Suction hose inserted into drum of vegetable oil
• Waste tank connected
• Processor started

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Field Testing

• Step 1 Adding 25 gallons of vegetable oil
• Step 2 Heat oil to 150F
• Step 3 Measure catalyst into mixing tank
• Step 4 Measure methanol into mixing tank
• Step 5 Pump mixing tank contents into process
  tank
• Step 6 Regulate heat mix vegetable oil,
  catalyst, and methanol (transesterification)

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• Step 1 Adding 25 gallons of vegetable oil

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Field Testing

• Step 1 Adding 25 gallons of vegetable oil
• Step 2 Heat oil to 150F
• Step 3 Measure catalyst into mixing tank
• Step 4 Measure methanol into mixing tank
• Step 5 Pump mixing tank contents into process
  tank
• Step 6 Regulate heat mix vegetable oil,
  catalyst, and methanol (transesterification)

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• Step 2 Heat oil to 150F

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Field Testing

• Step 1 Adding 25 gallons of vegetable oil
• Step 2 Heat oil to 150F
• Step 3 Measure catalyst into mixing tank
• Step 4 Measure methanol into mixing tank
• Step 5 Pump mixing tank contents into process
  tank
• Step 6 Regulate heat mix vegetable oil,
  catalyst, and methanol (transesterification)

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• Step 3 Measure catalyst into mixing tank

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Field Testing

• Step 1 Adding 25 gallons of vegetable oil
• Step 2 Heat oil to 150F
• Step 3 Measure catalyst into mixing tank
• Step 4 Measure methanol into mixing tank
• Step 5 Pump mixing tank contents into process
  tank
• Step 6 Regulate heat mix vegetable oil,
  catalyst, and methanol (transesterification)

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• Step 4 Measure methanol into mixing tank

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Field Testing

• Step 1 Adding 25 gallons of vegetable oil
• Step 2 Heat oil to 150F
• Step 3 Measure catalyst into mixing tank
• Step 4 Measure methanol into mixing tank
• Step 5 Pump mixing tank contents into process
  tank
• Step 6 Regulate heat mix vegetable oil,
  catalyst, and methanol (transesterification)

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• Step 5 Pump mixing tank contents into process
  tank

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Field Testing

• Step 1 Adding 25 gallons of vegetable oil
• Step 2 Heat oil to 150F
• Step 3 Measure catalyst into mixing tank
• Step 4 Measure methanol into mixing tank
• Step 5 Pump mixing tank contents into process
  tank
• Step 6 Regulate heat mix vegetable oil,
  catalyst, and methanol (transesterification)

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• Step 6 Regulate heat mix vegetable oil,
  catalyst, and methanol (transesterification)

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Field Testing

• Step 7 Allow byproduct to settle
• Step 8 Drain byproduct to waste tank
• Step 9 Add water and perform 1st wash
• Step 10 Add water and perform 2nd wash
• Step 11 Add water and perform 3rd wash
• Step 12 Increase temperature to 250F to Dry
  Fuel
• Step 13 Drain biodiesel from process tank
• Step 14 Add to vehicle and enjoy

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• Step 7 Allow byproduct to settle

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Field Testing

• Step 7 Allow byproduct to settle
• Step 8 Drain byproduct to waste tank
• Step 9 Add water and perform 1st wash
• Step 10 Add water and perform 2nd wash
• Step 11 Add water and perform 3rd wash
• Step 12 Increase temperature to 250F to Dry
  Fuel
• Step 13 Drain biodiesel from process tank
• Step 14 Add to vehicle and enjoy

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• Step 8 Drain byproduct to waste tank

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Field Testing

• Step 7 Allow byproduct to settle
• Step 8 Drain byproduct to waste tank
• Step 9 Add water and perform 1st wash
• Step 10 Add water and perform 2nd wash
• Step 11 Add water and perform 3rd wash
• Step 12 Increase temperature to 250F to Dry
  Fuel
• Step 13 Drain biodiesel from process tank
• Step 14 Add to vehicle and enjoy

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• Step 9 Add water and perform 1st wash

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Field Testing

• Step 7 Allow byproduct to settle
• Step 8 Drain byproduct to waste tank
• Step 9 Add water and perform 1st wash
• Step 10 Add water and perform 2nd wash
• Step 11 Add water and perform 3rd wash
• Step 12 Increase temperature to 250F to Dry
  Fuel
• Step 13 Drain biodiesel from process tank
• Step 14 Add to vehicle and enjoy

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• Step 10 Add water and perform 2nd wash

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Field Testing

• Step 7 Allow byproduct to settle
• Step 8 Drain byproduct to waste tank
• Step 9 Add water and perform 1st wash
• Step 10 Add water and perform 2nd wash
• Step 11 Add water and perform 3rd wash
• Step 12 Increase temperature to 250F to Dry
  Fuel
• Step 13 Drain biodiesel from process tank
• Step 14 Add to vehicle and enjoy

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• Step 11 Add water and perform 3rd wash

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Field Testing

• Step 7 Allow byproduct to settle
• Step 8 Drain byproduct to waste tank
• Step 9 Add water and perform 1st wash
• Step 10 Add water and perform 2nd wash
• Step 11 Add water and perform 3rd wash
• Step 12 Increase temperature to 250F to Dry
  Fuel
• Step 13 Drain biodiesel from process tank
• Step 14 Add to vehicle and enjoy

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• Step 12 Increase temperature to 250F to Dry
  Fuel

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Field Testing

• Step 7 Allow byproduct to settle
• Step 8 Drain byproduct to waste tank
• Step 9 Add water and perform 1st wash
• Step 10 Add water and perform 2nd wash
• Step 11 Add water and perform 3rd wash
• Step 12 Increase temperature to 250F to Dry
  Fuel
• Step 13 Drain biodiesel from process tank
• Step 14 Add to vehicle and enjoy

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• Step 13 Drain biodiesel from process tank

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Field Testing

• Step 7 Allow byproduct to settle
• Step 8 Drain byproduct to waste tank
• Step 9 Add water and perform 1st wash
• Step 10 Add water and perform 2nd wash
• Step 11 Add water and perform 3rd wash
• Step 12 Increase temperature to 250F to Dry
  Fuel
• Step 13 Drain biodiesel from process tank
• Step 14 Add to vehicle and enjoy

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• Step 14 Add to vehicle and enjoy

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Closing Remarks

• Parts and tools 2800
• R D engineer, chemist, welder, electrician,
  pipefitter, millwright, woodwright, accountant,
  programmer, circuit board designer, information
  technology personnel, and official documentation
  personnel salaries 0
• Driving away from MSU on PureFire fuel with a
  degree priceless

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Acknowledgements

• Dr. Noel Schulz MSU ECE Dept.
• Dr. Rafael Hernandez MSU CHE Dept.
• Jimmy Chiles and David Franks of North
  Mississippi Biodiesel
• Willard Stapleton and employees of Collins Tank
  and Trailer
• Ran Lou and Billy Short
• Terry Steely and Robert Steely
• Bryan Seal Chief Knowledge Officer, Smart Sync
• Earl Dodd Browning - Kosciusko Auto Parts

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Questions ?
PUREFIRE
Simplifying home production of quality biodiesel.
BD-06