This Small Business Innovation Research (SBIR) Phase II project proposes to develop, as a pilot, a highly efficient, high throughput, and compact continuous flow structured catalyst fixed-bed reactor unit for cost-effective algae biodiesel production. Successful establishment of the technical feasibility of the integrated fixed-bed technology for algae biodiesel production will be a step forward in addressing the high capital costs, high production costs, and waste stream produced by using a traditional homogeneous alkali-catalyzed biodiesel production process. It will further demonstrate the commercial viability of the technology.
The broader/commercial impact of the proposed project will be economic biodiesel production using algae oil as feedstock, leading to the substitution of petroleum diesel with domestically produced alternative fuel, the reduction of diesel emissions and waste stream generation, the mitigation of global warming, creation of jobs, and the reduction of U.S. dependence on foreign oil imports. Algae biodiesel has the potential to provide a breakthrough solution to both energy security and global warming concerns.
This SBIR Project was performed to develop a highly-efficient, high-throughput, and compact continuous flow structured catalyst fixed-bed plant for cost-effective and environmentally friendly algae oil biodiesel production. Algae oil has emerged as one of the most promising sources for biodiesel production. With an oil-per-acre production rate 100-300 times the amount of soybeans, algae offers the highest yield feedstock for biodiesel. Currently, biodiesel is made commercially by an energy and labor-intensive process. After transesterification, the homogeneous alkaline catalyst stays with the biodiesel and byproduct glycerol. Purification of the biodiesel and glycerol, by removing the homogeneous alkaline catalyst, involves a precise neutralization process with strong acids, such as hydrochloric acid, and extensive washes with water to remove the resulting sodium chloride salt, which produces a waste solution. This current homogeneous catalyst based transesterification process has not changed much in the last two decades. To meet the mass algae oil production requirements and achieve an algae biodiesel economy, a new highly energy efficient and high throughput biodiesel production process was developed under this Project. The technical feasibility and scalability of this technology were demonstrated. The optimal plant configuration and operating conditions were determined. The engine performance of the algae biodiesel was tested in the engine laboratory using a four-cylinder, turbocharged John Deer diesel engine to assess the effects of algae biodiesel on engine performance, including fuel efficiency and emissions. The performance of the catalytic material was fully studied. An economic analysis was conducted and the economic variability was demonstrated. Algal biodiesel has enormous potential and offer a breakthrough solution to both energy security and global warming concerns. The technology developed during this Project has significant advantages compared to the traditional biodiesel production process, including simplified product separation and purification, compact plant size, removal of the need for a constant feed of catalyst, improved glycerol quality, elimination of the washing step and associated waste stream, and reduced capital and processing costs. The success of this project will expedite the substitution of petroleum diesel with domestically produced alternative fuel, reduce U.S. dependence on foreign oil imports, reduce diesel emissions, reduce waste stream generation, mitigate global warming, benefit consumers economically by reducing their vulnerability to petroleum price fluctuations, and enhance energy security in the U.S.
