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process INSTRUMENTATION
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
Oil Limit level detection (capacitive) using POINTEK CLS Flow measurement (Coriolis) using SITRANS FC
Catalyst
Catalyst
Methanol
Transesterification
Washing
Biodiesel
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
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
Wastewater
Condenser
Column
Contactless level measurement in the glycerol processing on a storage container using SITRANS LR
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
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.
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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.
Magnetic-inductive SITRANS FM
For liquids, sludge, paste and pulp Extensive diagnostic functions HART and PROFIBUS NOVOLAK cladding for extreme requirements
Coriolis SITRANS FC
HART and PROFIBUS For the largest and smallest ows High-precision measurement Multiparameter functionality (volumes, masses, density, temperature)
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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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.
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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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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.