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Small Scale Bio-Fuel Production

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Small Scale Small Scale BioBio--Fuel Production:Fuel Production:Identifying the Identifying the Major IssuesMajor IssuesJoel Schumacher, M.S.Montana State UniversitySmall Scale Production: Small Scale Production: Major IssuesMajor Issues Seed Source Seed Processing Biodiesel Process Markets Government InvolvementSeed SourcesSeed Sources Questions to ask:• What is your current oilseed production?• If you expand your oilseed production, how will this affect your crop rotations?Seed SourceSeed Source Canola* Data obtained from NASSCanola Price and Production010,00020,00030,00040,00050,00060,00070,0001999 2000 2001 2002 2003 2004 2005 2006Acres$0.00$2.00$4.00$6.00$8.00$10.00$12.00PricePlanted Acres Price per Cwt.Seed SourceSeed Source Safflower* Data obtained from NASSSafflower Price and Production010,00020,00030,00040,00050,0001999 2000 2001 2002 2003 2004 2005 2006Acres$0.00$2.00$4.00$6.00$8.00$10.00$12.00$14.00$16.00PricePlanted Acres Price per Cwt.Seed SourceSeed Source Flax* Data obtained from NASSFlax Price and Production010,00020,00030,00040,00050,00060,0001999 20002001 2002 2003 2004 2005 2006Acres$0.00$2.00$4.00$6.00$8.00$10.00PriceAcres Price per BushelSeed SourceSeed Source Mustard* Data obtained from NASSMustard Price and Production05,00010,00015,00020,00025,00030,0001999 2000 2001 2002 2003 2004 2005 2006Acres$0.00$5.00$10.00$15.00$20.00PriceAcres Price per Cwt.Seed SourceSeed Source Camelina: • Average Yield: WestBred2006 Trials 1,200 lbs./acre• Average Price: ?????• 2006 Production Estimates: 7,000 to 20,000 acres• Limited Information about rotational effectsSeed SourceSeed Source Potential for Purchasing Seed• Average Montana Production (2002-2005)• Canola 11,517 Metric Tons• Flax 9,685 Metric Tons• Safflower 13,055 Metric Tons• Mustard 4,373 Metric Tons• Camelina Essentially no production until 2005Seed SourceSeed Source Contracted Production of Oilseeds• A 2004 Survey of MGGA Members indicated the following percentages of specialty crops were sold under some type of contract:• 46.8% of Canola• 73.2% of Mustard• 97.5% of Safflower• 11.6% of FlaxOilseed ProcessingOilseed Processing 4 ton per day (TPD) pressOilseed ProcessingOilseed Processing Questions to ask to determine the right equipment capacity:• How many tons of oilseed do you intend to process?• How much time are you willing to devote to oilseed processing?Oilseed ProcessingOilseed Processing Questions to ask when selecting equipment:• How many tons per hour (or day) can the equipment process?• What oil recovery rate(s) can be obtained with the equipment?• 65%-80% oil recovery rate is common• Is the equipment capable of pre-heating the seed?Oilseed ProcessingOilseed Processing Seed Preparation• All seed will need to be cleaned prior to processing• Some seeds require additional preparation• For Example: Sunflowers require dehulling• Equipment Manufacturers can provide information on seed preparationOilseed ProcessingOilseed Processing Required Equipment• Mechanical Press• Power source for the press• Seed Bins• Meal Bins• Oil Tanks• Pumps, Filters, PlumbingOilseed ProcessingOilseed Processing Installation Costs• Do you need to upgrade your electrical system?• Equipment Shipping Costs?Oilseed ProcessingOilseed Processing Operating Costs• Seed Costs• Labor Costs• Electricity Costs• Maintenance CostsOilseed ProcessingOilseed Processing Sample Oilseed Press Prices:• 1 TPD press without power source: $1,000• 2 TPD press without power source: $1,995• 5 TPD press with electric motor: $6,000• 10 TPD press with electric motor: $10,500Oilseed ProcessingOilseed Processing On-Farm Example:• If you plant 100 acres of canola,• with an average yield of 1,100 lbs per acre,• your production is approximately 55 tonsOilseed ProcessingOilseed Processing Processing Time• How many 12 hour shifts will it take to process your production?• 5 ton per day press: 22 shifts• 2 ton per day press: 55 shifts• 1 ton per day press: 110 shiftsOilseed ProcessingOilseed Processing The 55 tons of seed will yield approximately:• 4,200 gallons of oil• 36 metric tons of meal* Assuming: The seed has 38% oil content and press recovers 75% of the oil content in the seed.Biodiesel ProcessBiodiesel Process Biodiesel ProcessorBiodiesel ProcessBiodiesel Process Basic Overview• Inputs: Oil, Alcohol & Catalyst • Oil Input: Virgin, Recycled• Alcohols: Methanol, Ethanol• Catalysts: Sodium or Potassium Hydroxide, Sodium or Potassium MethoxideBiodiesel ProcessBiodiesel Process Basic Overview • Outputs: Fuel & Glycerin• Biodiesel• Crude GlycerinBiodiesel ProcessBiodiesel Process Sample Recipe• Oil 100 Parts• Alcohol 10 to 20 Parts• Catalyst 0.5 to 3 Parts* Manufacturers often provide a “basic” recipe to use asa starting point.Biodiesel ProcessBiodiesel Process Outputs• Biodiesel 100 Parts• Crude Glycerin 10-20 PartsBiodiesel ProcessBiodiesel Process Questions to ask to determine the correct equipment capacity:• How much oil do you intend to process?• How much time are you willing to devote to operating the equipment?Biodiesel ProcessBiodiesel Process• Questions to ask to determine the correct equipment capacity:• How does your production time relate to the timing of your fuel consumption?• Fuel quality may deteriorate as storage time is increasedBiodiesel ProcessBiodiesel Process Pre-Reaction Equipment• Oil Storage Tank• Alcohol Storage Tank• Catalyst Storage• Biodiesel “Reactor”• Pumps, Filters, PlumbingBiodiesel ProcessBiodiesel Process Post-Reaction Equipment• Settling tanks and/or Separating Equipment• Biodiesel Washing Equipment• Biodiesel Drying Equipment• Biodiesel Storage Tanks• Glycerin Storage Tanks• Pumps, Filters, PlumbingBiodiesel ProcessBiodiesel Process Biodiesel Equipment• Micro Scale Processors • 100 gallons or less per batch• Numerous Manufacturers• Some sold as “kits”• Others sold as “ready to use”• Accessories included in the package variesBiodiesel ProcessBiodiesel Process Micro Scale Biodiesel ProcessorBiodiesel ProcessBiodiesel Process Biodiesel Equipment• Small Scale Processors• 75 to 300 gallons per batch• Fewer Manufacturers• Usually not sold as “kits”• Typically higher quality materials• Accessories included in the package


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