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  Continuous flow biodiesel processorUSPTO Application #: 20070175092Title: Continuous flow biodiesel processor Abstract: A continuous flow biodiesel processor utilizing high turbulence mixing of oil being processed and a flow-through separation tank with distinct zones and recirculation draw tubes is described, along with methods for using same. (end of abstract)
Agent: Wesley B. Ames - Escondido, CA, US Inventor: Randall S. Ames USPTO Applicaton #: 20070175092 - Class: 044629000 (USPTO) Related Patent Categories: Fuel And Related Compositions, Apparatus For Making Or Treating Fuel Composition The Patent Description & Claims data below is from USPTO Patent Application 20070175092. Brief Patent Description - Full Patent Description - Patent Application Claims
RELATED APPLICATIONS [0001] This application claims the benefit of Ames, U.S. Provisional Appl. 60/740,346 filed Nov. 28, 2005, which is incorporated herein by reference in its entirety, including drawings. FIELD OF THE INVENTION [0002] The present invention relates to the production of lower alkyl fatty acid esters from glycerides, and in particular to the production of biodiesels. BACKGROUND OF THE INVENTION [0003] The following discussion is provided solely to assist the understanding of the reader, and does not constitute an admission that any of the information discussed or references cited are prior art to the present invention. [0004] A number of systems for producing alkyl esters from fatty acid solutions have been described. Most such systems are batch processing systems, in which the feed oil is mixed under low or medium mixing rates with a basic catalyst (e.g., NaOH or KOH) and a lower alcohol such as methanol or ethanol. The mixture is placed in reaction and separation tanks where the fatty acids are allowed to react. The product alky esters and glycerin are allowed to separate by gravity and the glycerin is removed from the tank. [0005] A number of systems are described in patent documents. For example, Hooker, U.S. Patent Appl. Publication 2005/0027137 indicates that it describes an "apparatus and method for producing fatty acid alkyl esters from fatty acids derived from vegetable oils and animal fats" in which a mixture is emulsified as a means to reach a completed reaction state in a reaction section and "transesterification occurs when the natural boundary surfaces of the immiscible mixture are enlarged by ultrasonic cavitation in the reaction section and the transesterification is performed at, or near, atmospheric pressure." (Hooker, Abstract.) [0006] Ergun, U.S. Pat. No. 6,440,057 describes a method for producing fatty acid methyl ester from at least one of vegetable and animal with an alkaline solution dissolved in alcohol to form a mixture and emulsifying the mixture to reach a chemical balance state in a reaction section, wherein fats are transesterified into fatty acid methyl ester, wherein border surfaces of the mixture are enlarged by dynamic turbulence in the reaction section and the transesterification is performed under pressure, and wherein the pressure is reduced during transesterification. The method further includes separating residues from the fatty acid methyl ester in a phase separation section after reaching a chemical balance state. [0007] Certain systems are described that are indicated to produce biodiesel in a continuous flow manner. [0008] Lastella, U.S. Patent Appl. Publ. 2005/0081435 states that it "achieves continuous flow through all the reaction vessels and separation tanks without the need for additional pumps." Further, the system "preferably employs preferably closed tanks (though preferably not sealed) to provide for methanol recovery, and may include vertical rotating feed tubes having separators and inlet and outlet openings." (Lastella, paragraph 12.) [0009] Connemann et al. U.S. Pat. No. 5,354,878 describes a process wherein an "oil phase of fatty triglycerides or natural oils or fats containing free fatty acids is subjected to catalytic transesterification", in which the improvement involves a multistep sequential process of a) introducing a reaction mixture into the top of a reaction column, b) transferring the column transesterification product to a second reactor, c) washing the reaction mixture with an aqueous extractant in a first separator, d) introducing the washed reaction mixture with additional alcohol and catalyst into a third reactor, e) introducing the resulting mixture into a fourth reactor and maintaining the mixture under stirring for a further transesterification forming a reaction product having a degree of transesterification of at least 99.2%, f) introducing the resulting transesterification product and hot, aqueous extractant into a second separator, and g) drying the transesterification product. [0010] Hanna, U.S. Patent Appl. Publ. 2003/0032826 describes a transesterification process for the production of biodiesel, where the process involves introducing the triglycerides and a catalyst into a reaction zone and introducing an alcohol into the feed stream within the reaction zone, where the triglyceride feed stream is characterized by having a Reynolds number of at least about 2100. [0011] Connemann et al., U.S. Patent Appl. Publ. 2005/0204612 describes "a process for the continuous production of biodiesel from a biogenic initial feedstock mixtures containing fat or oil with a high content of free fatty acids, as well as a device for the production of biodiesel." SUMMARY OF THE INVENTION [0012] In view of the great demand for oil-based fuels, and in particular for motor vehicle fuels, there is an increasing need for alternatives to petroleum products. One such alternative is biofuels, and particularly biodiesel. Biodiesel is generally produced from oils and/or fats from plant and/or animal origin by esterification of glycerides and/or free fatty acids under basic or acidic conditions in the presence of a lower alkyl alcohol. [0013] The present invention concerns simple systems typically operable at atmospheric pressure (although also adaptable for higher pressures) for producing biodiesel, especially from vegetable oils. These systems provide continuous flow systems, system components, and methods for processing glycerides (e.g., triglycerides) to produce alkyl esters, i.e., lower alkyl fatty acid ester solutions useful as biodiesel, from vegetable and/or animal oils and fats. Certain embodiments of the present systems include a high turbulence processor mixer and/or a functionally linked zonal flow-through separation tank. [0014] Thus, in a first aspect the invention provides a continuous flow biodiesel processor for producing a lower alkyl fatty acid ester biodiesel from a glyceride solution that includes a high turbulence flow-through processor mixer, a glycerol/biodiesel separator (e.g., a zonal flow-through separation tank), and a biodiesel cleaner. In this processor, the glycerol/biodiesel separator receives output (e.g., at least partially reacted glyceride solution mixed with a lower alkoxide in alcohol solution (e.g., methanolic sodium methoxide) or a lower primary alcohol and a catalyst (e.g., a base catalyst such as NaOH or KOH)) from the processor mixer. The biodiesel cleaner receives biodiesel separated in the separator tank and removes contaminants, e.g., polar components such as residual glycerol, unreacted alcohol, water, and/or other components soluble in the alcohol and/or water, from the biodiesel. [0015] The present components (e.g., high turbulence processor mixers and/or flow-through zonal separator tanks) can be incorporated or combined in a variety of systems and used in various methods. Thus, in a related aspect, the invention concerns a system for production of biodiesel, where the system includes an oil (i.e., glyceride solution) supply (e.g., an oil storage tank), a high turbulence flow-through processor mixer (e.g. as described herein), a glycerol/biodiesel separator (e.g., a flow-through zonal separation tank as described herein) that receives reacted glyceride solution from the processor mixer, a biodiesel cleaner, and a biodiesel receiver. [0016] In another aspect, the invention concerns a scalable processor for production of biodiesel from glyceride solutions; the processor includes a plurality of parallel-linked high turbulence flow-through processor mixers (e.g., as described herein) which can be operated or idled independently, at least one flow-through glycerol/biodiesel separator (e.g., a flow-through zonal separator tank) functionally linked with those processor mixers to accept a glycerol/biodiesel mixture processed through at least one of the processor mixers, and at least one biodiesel cleaner functionally linked with the glycerol/biodiesel separator to separate contaminants, e.g., polar components from the biodiesel solution. [0017] In many cases, the plurality of processor mixers is 2-4, i.e., 2, 3, or 4, processor mixers. [0018] In certain embodiments, the system includes a plurality of separator tanks; the plurality of tanks includes a separate tank functionally linked with each of a plurality of processor mixers (e.g., with each processor mixer); one or more separator tanks is supplemented with one or more centrifuges; one or more separator tanks are replaced with a centrifuge; each separator tank is replaced with a centrifuge. [0019] Processor mixers can also advantageously be linked in a sequential manner with residence chambers between each. Thus, another aspect provides a processor for production of biodiesel from a glyceride solution that includes a sequentially linked plurality of processor units (e.g., 2, 3, 4, 5, 6, 7, 8, 9, 10, 2-5, 6-10, 11-15 sequential units) where each processor unit includes a high turbulence flow-through processor mixer and a residence chamber following the processor mixer. The system further includes a linked glycerol/biodiesel separator receiving processed glyceride solution from the processor unit (which may be integral or separate from the residence chamber), and a biodiesel cleaner receiving biodiesel from the separator. [0020] In certain embodiments, the glycerol separator includes a centrifuge, flow-through separation tank, and/or a cyclone; a plurality of processor units (e.g., each processor unit) include a glycerol separator, such as a separator including or consisting of a centrifuge, a separation tank, and/or a cyclone. Continue reading... Full patent description for Continuous flow biodiesel processor Brief Patent Description - Full Patent Description - Patent Application Claims Click on the above for other options relating to this Continuous flow biodiesel processor patent application. ###  How KEYWORD MONITOR works... a FREE service from FreshPatents1. Sign up (takes 30 seconds). 2. Fill in the keywords to be monitored. 3. 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