Biodiesel Process instrumentation for the manufacturing process

process INSTRUMENTATION

Process instrumentation for the manufacturing process

A growing number of larger and more efcient plants are being constructed worldwide for the production of biodiesel another chemical term for which is fatty acid methyl ester (FAME). This can either be used directly as a fuel (B100) or added in certain proportions to mineral diesel. The ratio in which biodiesel is added often depends on the political, economic and technical boundary conditions. The trend toward biodiesel, however, is not to be dismissed if the efcient use of regenerative energy sources is to be made more independent of the mineral oil industry.

Raw materials and end products In most cases, the manufacture of biodiesel uses vegetable oils (e.g. oilseed rape, palm, soya) or possibly animal fats. In addition, about 10 % methanol and a catalyst are required. The end products of the manufacturing process are biodiesel and glycerol. Production process Biodiesel is produced according to a relatively simple principle: By mixing oils or fats with methanol, with the assistance of a catalyst, a process of transesterication is started in which biodiesel and glycerol are obtained. A majority of the methanol that is still contained in the glycerol is often separated again and returned to the manufacturing process. The glycerol that accumulates in the production is generally reused in the pharmaceutical industry. As methanol is used, almost all the production areas for biodiesel are classied as hazardous (Ex). Size of the plant Production plants for the manufacture of biodiesel can vary considerably in their size: There are small container-sized production plants which do not recover the methanol as well as large plants that include oil mills for optimum extraction of the raw material. As a rule, however, the raw materials (oils, fats) are delivered to the site and containers are lled with the nished biodiesel and processed glycerol for removal. Instrumentation A host of measurement tasks must be performed in a plant for the production of biodiesel starting with the

delivery of the raw materials and nishing with the shipment of the end product. In order to determine the process states in the plant, there is a continuous need for information about temperatures, ows, levels, pressures or valve positions. For this reason, the selection of the right instrumentation is of considerable importance for the efciency of the whole plant. Apart from purely technical criteria, it is particularly important that the instruments can be reliably integrated with the process automation. In addition, they must offer excellent reliability, long life cycle and ease of operation. And if anything should go wrong, a fast and efcient supply of replacement parts must be guaranteed.

So make sure you talk to the right supplier from the very start As different approaches to the solution can produce good results, the selection of the ideal measurement procedure is particularly important in order not only to achieve reliable measurement, but also to keep operating costs as low as possible. Is level measurement with radar more

economical than hydrostatic measurement with a differential pressure transmitter? How reliable are the measured values obtained in this way? What are the advantages of each procedure? There are many examples of questions that highlight how sensible it is to talk at an early stage to a partner who has the appropriate expertise in processing and instrumentation.

Oils/greases

Transesterication

Biodiesel

Methanol

Glycerol

Catalyst

Schematic diagram of materials used and the base products in biodiesel production 3

Biodiesel the right measurement technology for all stages of the process
We understand your process! Regardless of which stages of your process require instrumentation, Siemens has the products to meet your needs.
Level measurement (radar) using SITRANS LR Delivery Premixing

Flow measurement (Ultrasonic) using SITRANS FU

Oil

Truck weighing using SIWAREX

Oil Limit level detection (capacitive) using POINTEK CLS Flow measurement (Coriolis) using SITRANS FC

Catalyst

Catalyst

Methanol

Bioethanol production(schematic diagram)

Methanol Level measurement (hydrostatic) using SITRANS P DS III

Vessel weighing using SIWAREX

Cooling Magneto-inductive flow measurement using SITRANS FM

Manufacture of biodiesel (continuous process)

Transesterification

Washing

Storage Level measurement (Ultrasonic) using SITRANS Probe LU

Valve control using SIPART PS2

Flow measurement (Coriolis) using SITRANS FC

Biodiesel

Limit level detection (capacitive) using POINTEK CLS

Limit level detection (capacitive) Mixer/Settler using POINTEK CLS Valve control using SIPART PS2 Mixer/Settler Temperature measurement using Biodiesel SITRANS T Biodiesel Washing column Valve control using SIPART PS2 Water

Flow measurement (Coriolis) using SITRANS FC

Flow measurement (cylindrical-piston meter) using SITRANS FR

Distillation Condenser
Biodiesel

Methanol (recycled) Glycerol, water and surplus methanol Temperature measurement using SITRANS T Flow measurement with metering orifice using SITRANS P Glycerol filling Level measurement (radar) using SITRANS LR 250

Magneto-inductive flow measurement using SITRANS FM

Wastewater

Condenser

Column

Vaporizer Heating steam Vaporizer Heating steam

Level measurement (radar) using SITRANS LR 250

for further processing Glycerol, water Glycerol

Examples of application in main plants

Example of methanol/catalyst dosing

Weighing dosing The mixture ratio as well as the quantities of methanol to be introduced and of the catalyst used (for example KOH or NaOH) are dependent on the vegetable oil or animal fat that is used. As a rule, the methanol and the catalyst are dosed in an agitator tank. In order to be able to determine exactly the quantities added in a batch process the container is weighed with its contents. For this purpose, load cells are mounted under the container that are connected to an electronic weighing circuit. After subtracting the tare weight, this method produces very precise information about the combined quantities regardless of any uctuations in density caused by temperature changes. The SIWAREX electronic weighing systems are a component of the SIMATIC S7 automation system and already fully integrated. This reduces, for example, the engineering costs and also provides extensive diagnostic functions.

Determining the weight in a steel container with a SIWAREX R load cell

Temperature measurement in a storage container with SITRANS T

SIPART PS2 positioners in the methanol extraction stage

Example of methanol recovery

Valve control The methanol that remains in the biodiesel is recovered by a process of rectication and returned to the production process either directly or after intermediate storage in specially provided containers, depending on the manufacturing process used. The containers are lled and emptied by opening and closing valves. The valves are controlled by the SIPART PS2 positioners. Its main task is to ensure the precise positioning of the valve and to diagnose immediately any valve faults that may occur. The electro-pneumatic SIPART PS2 positioners for lifting and part-turn actuators can be used with valves from almost any valve manufacturer. By means of its negligible internal air consumption and the numerous diagnostics options for example, with regard to pipe deposits or wear in the valve seat or cone it contributes to lower operating costs.

Example of glycerol processing

Temperature In order to be able to use the raw glycerol in the pharmaceutical industry, it must be processed further into purest glycerol. The procedure to separate the majority of residue in the raw glycerol is partially carried out at high temperatures. In order to accelerate and optimize this process, the procedure must be kept within a specic temperature range. To achieve this, the temperature is measured and then the appropriate amount of heat is fed to the process. The temperature is monitored by measuring instruments from the SITRANS T series that transmit the measured values quickly and reliably. Thanks to their sophisticated design detail, they are suitable for even the most difcult applications in biodiesel plants.

Example of glycerol processing

Level The production of biodiesel can produce considerable quantities of raw glycerol, depending on the process. This in turn, contains various other chemicals such as methanol, potassium salts or fatty acids. It is particularly economical to separate methanol from the aqueous glycerol specically at the point of its production, in order to feed it in puried form back into the production cycle. The water is then removed from the glycerol as far as possible, so that it can be utilized, for example, in the pharmaceutical industry. The glycerol is often stored in steel or stainless steel containers for this purpose. To determine the level in these storage tanks, a contactless method of measurement is particularly suitable, such as that implemented by the SITRANS LR radar level meter.

Contactless level measurement in the glycerol processing on a storage container using SITRANS LR

Flow measurement with SITRANS FC Coriolis owmeter

Example of transesterication
Flow rate In a biodiesel production plant specic ow rates must be maintained at very different positions whether for dosing the raw materials used or for the exact measurement of the end product for customer billing. The optimum measuring procedure must be selected in each case, depending on the medium owing through the measuring instrument. To allow optimum transesterication, it is important to keep to exactly the right amounts of raw material and catalyst. For this reason, the dosing for the mixing ratio must be extremely precise. The more accurate the dosing with the calculated quantities, the better the result. As a number of different base products are used in the transesterication process, different measuring procedures are used. A very precise indication of the quantity of catalyst to be dosed is delivered by the Coriolis measuring procedure using a SITRANS FC. This not only determines weight, but also density which gives precise information on the volume at the same time. This enables the prescribed quantities to be dosed for the transesterication allowing the process to be carried out more economically. Dosing of vegetable oil using SITRANS FU ultrasonic owmeter

Storage containers of a biodiesel plant

Example of distillation
Pressure The glycerol that accumulates during the production process still contains constituents of water and methanol. The proportion of methanol is so high that it makes economic sense to separate it from the glycerol. This is done by distilling the mixture in a column. In its gaseous state, methanol is explosive. For this reason, the relevant area in the production plant is designated as a hazardous zone. All the process instruments installed in the distillation plant must therefore be designed for hazardous zones for example, the differential pressure measurement during the rectication. The SITRANS P DS III pressure transmitter is the ideal instrument for measuring pressure in hazardous zones. It has all the necessary certicates, operates extremely reliably and has a host of safety and diagnostics functions that contribute to a safe and economical process.

Differential pressure measurement on a distillation column using SITRANS P DS III

Applications example in auxiliary plants

Example of the storage of wastewater

Limit level The water used in the production process becomes so contaminated in the course of time that it is necessary to remove it from the production circuit. The water is then pumped into appropriate wastewater tanks for temporary storage. To prevent these wastewater tanks from overowing and thus reducing the risk of costly cleanup and removal operations, a built-in overow protection device continuously monitors the level in the wastewater tank a good solution that is often also a legal requirement. The device best suited for this task is the Pointek CLS capacitive limit monitor, which reliably indicates whether the limit has been reached. On contact with the wastewater, the dielectric on the sensor changes so that the limit switch reliably signals the attainment of the maximum level and the operating personnel can initiate the appropriate measures.

Limit level monitoring with Pointek CLS

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Selected process instruments for the production of biodiesel

Measuring instruments for temperature
The most frequently required measurement in biodiesel production plants is the temperature measurement. Here Siemens offers an extensive range of temperature measuring instruments for the whole plant, for all typical processes. High-precision, intrinsically safe and connectable to all established sensor types. Our SITRANS T temperature measuring series gives you sensors, transmitters, eld and head transmitters individually or as a complete measuring station.

Measuring instruments for pressure

Filling level, pressure, differential pressure and ow: The SITRANS P pressure measuring instruments cover all these applications, as they are found everywhere in biodiesel production plants. We offer the appropriate version for the widest range of operating conditions. Measurement precision, ruggedness, userfriendly operation and excellent diagnostic and safety functions: with these properties, SITRANS P supports a high level of economic production.

Field transmitter SITRANS TF

Pressure transmitters SITRANS P DS III

Remote mounting possible 3-key operation Housing made of aluminum or stainless steel IP68 3-key operation Extensive diagnostic functions HART, PROFIBUS, Foundation Fieldbus High precision Measuring cells for critical media

SITRANS TH SITRANS P 300 pressure transmitter

HART, PROFIBUS, Foundation Fieldbus For connection head Form B Galvanically isolated Diagnostic LED (green/red/ashing) Test sockets for multimeters Stainless steel housing as standard Flush-mounted diaphragm 3-key operation Extensive diagnostic functions HART, PROFIBUS, Foundation Fieldbus Wide range of thermoelements or resistance thermometers Versatile attachment options Customized designs High precision

Sensors

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Flowmeters
Wherever the ow has to be determined in the biodiesel plant, we have the right solution for every phase of the process from the raw material to the end product. Our SITRANS F series owmeters handle all the measuring methods required for the production of biodiesel. SITRANS F includes electronic devices with different measurement principles: magnetic-inductive, ultrasonic or mass measurement according to the Coriolis method. Mechanical owmeters such as rotary piston meters or a measuring orice in conjunction with a SITRANS P pressure transmitter complete our range of devices.

Limit and lling level meters

For applications used in the manufacture of biodiesel, Siemens offers a perfectly coordinated portfolio of products including the SITRANS L devices for continuous lling level measurement and the POINTEK sensors for recording limit levels. We therefore offer the ideal solution for every application be it ultrasonic or radar, capacitive, hydrostatic or electromechanical.

Magnetic-inductive SITRANS FM
For liquids, sludge, paste and pulp Extensive diagnostic functions HART and PROFIBUS NOVOLAK cladding for extreme requirements

Filling level measurement using SITRANS LR 250

Graphic display for improved commissioning 25 GHz technology permits very narrow horn antennas for small tank openings Display for on-site echo prole

Coriolis SITRANS FC
HART and PROFIBUS For the largest and smallest ows High-precision measurement Multiparameter functionality (volumes, masses, density, temperature)

Ultrasonic SITRANS Probe LU

Contactless measurement For liquids and sludges For storage tanks

Ultrasonic SITRANS FU
Volume measurement for sound-transmitting uids Extensive diagnostic functions Approved by Weights and Measures Ofce

Capacitive SITRANS LC
For liquids and sludges For storage tanks and process containers

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Selected process instruments for the production of biodiesel

Limit level switch POINTEK
Capacitive, electromechanical or ultrasonic For liquids, powders, bulk goods, foams, viscous media, etc.

SIWAREX Electronic weighing systems

As function modules in SIMATIC or distributed via PROFIBUS Capable of calibration Extensive application software

Weighing technology
In a biodiesel plant it is necessary to measure weight in various applications. Using our SIWAREX weighing and dosing systems, weighing tasks can be integrated into the system easily and exactly. In addition, the systems are tailor-made for integration into the SIMATIC world ranging from a SIMATIC controller to the SIMATIC PCS 7 process control system.

Positioners
SIPART PS is the most widely used intelligent positioner for lifting and part-turn actuators. A biodiesel plant often sources valves from various different suppliers. Our positioner enables these to be programmed and operated on a standardized basis. In addition, its low internal air consumption allows considerable savings to be made. It will soon be available from stock. The corresponding installation kits are available for numerous valve manufacturers. In many cases, the valve can be purchased from the manufacturer with the SIPART PS2 already tted.

SIWAREX Load cells

Six different series to cover a vast range of applications Capable of calibration High precision Wide measurement range up to 280 t

Positioners SIPART PS2

Diverse diagnostic functions 3-key operation Plastic, cast aluminum or stainless steel housing Negligible air consumption in controlled state Remote mounting possible

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Key facts about our process instruments

Approvals
Various regulations apply in a plant. These state where process instruments must possess which specic approvals. In the distillation area, for example, only devices with hazardous zone approval may be used. Our process instruments come with all the necessary approvals.

Communication
The process instruments in a biodiesel plant supply their measurement data to the higher-level controller. This transfer either takes place conventionally via the 4 to 20 mA connection or by means of intelligent bus connections such as HART, PROFIBUS or Foundation Fieldbus.

ATEX

Diagnostics
If you are informed at an early stage about maintenance requirements and process states, you can also initiate the necessary measures promptly to minimize any damage and consequential costs. For this reason, our process instruments are equipped with extensive diagnostics options. These create the conditions for a prompt and correct response.
PROCESS FIELD BUS

Parameterization
The Siemens SIMATIC PDM (Process Device Manager) parameterization software is a standardized software tool for central access to all process devices in the plant that have communications capability. It permits the operation, setting, maintenance and diagnostics of the connected devices, regardless of the manufacturer.

Service
It goes without saying that we offer you rst-class servicing for our excellent process instruments: worldwide and 24 hours a day. Our specialists with their vast expertise and competence in automation and process engineering are at your service.

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Your Siemens partners worldwide

Subject to change without prior notice 11/ 07 | Order No. E20001-A720-P710-X-7600 | DISPO 27900 | 2100/7515 MK.SC.IM.XXXX.52.8.09 WS 12073.0 | Printed in Germany | Siemens AG

For further information, see: www.siemens.com/biodiesel www.siemens.com/processinstrumentation www.siemens.com/chemical

Siemens AG Automation and Drives (A&D) Sensors and Communication Process Sensors and Analytics 76181 KARLSRUHE GERMANY

The information provided in this brochure contains merely general descriptions or characteristics of performance which in actual case of use do not always apply as described or which may change as a result of further development of the products. An obligation to provide the respective characteristics shall only exist if expressly agreed in the terms of contract. All product designations may be trademarks or product names of Siemens AG or supplier companies whose use by third parties for their own purposes could violate the rights of the owners.