Documentos de Académico
Documentos de Profesional
Documentos de Cultura
1 MT / HOUR 24 MT / Day
METHANOL DISTILATION
BIODIESEL DISTILATION
Page 2 of 16
INDEX
1.
2.
3.
4.
5.
6.
7.
8.
About us
System Overview
Ultrasonic Reactors
Process Description
a. Advantages of using solid catalyst
b. Explosion Proofing ATEX
c. Methanol Rectification
Feedstock, Utilities and Reagents
a. Feedstock specification
b. Utility specification
c. Reagent specification
d. Product Specification
Plant Performance Guarantees
a. Capacity
Specifications
a. Technical Certificates and Regulations
b. Plant layout example
c. Scope of Supply
d. Work Not Included
e. Plant Commissioning, Start-Up and Training
f. Documentation
g. Factory Acceptance Test (FAT)
h. Warranty
Commercials
a. Price
b. Payment Schedule
c. Payment Terms
d. Taxes
e. Schedule
f. Transport and Installation
g. Proposal Validity
Address: Rua Simo Bolvar 311, 1 Andar Sala 4, 4470-214 MAIA, PORTUGAL Phone: +351 220 171 082 Email: info@incbio.com Web: www.incbio.com
Page 3 of 16
1. About Us
Incbio is a brand owned by Incalculvel, which was founded in Portugal in 2006 with the production
of domestic Biodiesel processors and small scale commercial Biodiesel processors. Having since grown
to become the largest Biodiesel equipment provider in the country, since 2008 the company started
working on the construction of large scale Biodiesel equipment, with ultrasonic Biodiesel reactors, a
pioneering equipment which will revolutionize the Biodiesel industry in years to come.
With a continuous investment in R&D, we aim to be pioneers in this sector, developing innovative
systems and methods. The introduction of our ultrasonic Biodiesel reactors is evidence of this
mentality, making us stand out from our competition. Our innovative multi-feedstock Biodiesel
processors, which are able to process feedstock with up to 100% FFA with yields of up to 100% and
exceeding the international quality standards - further prove this point. Our clients say that in
comparison with us, our competition offers analogue solutions in a digital world!
From Design, Engineering, Consultancy and Construction we are able to assist you in as little or as
much as you require. From retrofitting of existing units with state of the art ultrasonic or multifeedstock technology to design, manufacture and start-up of complete industrial units, we are ideally
placed to make your Bio-project a reality.
Because we understand very well that profitability is the name of the game, all of our units are
designed to be as efficient as technically possible, helping you maximize your profits. But we also
understand that this very profitability starts with the initial capital expenditure on equipment, which
is why we offer what we believe to be the most competitive prices that can currently be found on the
market.
Address: Rua Simo Bolvar 311, 1 Andar Sala 4, 4470-214 MAIA, PORTUGAL Phone: +351 220 171 082 Email: info@incbio.com Web: www.incbio.com
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2. System overview
The Incbio 1TA 1a1b is a fully automated, continuous 1 MT/hour degumming, bleaching, acid
esterification and transesterification plant. It uses technology that is both innovative and widely
proven in the field in a large number of commercially operating plants.
The plant works with ultrasonic reactors, allowing our processors to continuously produce Biodiesel
with optimum conversion rates (>99%) and of consistently high quality.
Methanol recovery module is integrated in the plant as well. As a result of this, we ensure that
methanol usage is kept to a bare minimum.
All components are provided by market leading manufacturers, to ensure the seamless and constant
operation of the plant, and also to ensure that if faults do occur, they can quickly and easily be
addressed.
All wet components are AISI 304 Stainless Steel (except esterification reactor, which is AISI 316L
Stainless Steel), and the plant is fully built in a skid, to reduce to a minimum the time of installation
and commissioning. The methanol distillation and biodiesel distillation columns structure are built in
Carbon Steel.
Address: Rua Simo Bolvar 311, 1 Andar Sala 4, 4470-214 MAIA, PORTUGAL Phone: +351 220 171 082 Email: info@incbio.com Web: www.incbio.com
Page 5 of 16
3. Ultrasonic Reactors
When sonicating liquids at high intensities, the sound waves that propagate into the liquid media
result in alternating high-pressure (compression) and low-pressure (rarefaction) cycles, with rates
depending on the frequency. During the low-pressure cycle, high-intensity ultrasonic waves create
small vacuum bubbles or voids in the liquid. When the bubbles attain a volume at which they can no
longer absorb energy, they collapse violently during a high-pressure cycle.
This phenomenon is called cavitation. During the implosion very high temperatures (approx. 5,000K)
and pressures (approx. 2,000atm) are reached locally. The implosion of the cavitation bubble also
results in liquid jets of up to 280m/s velocity.
Ultrasound has been proven to generate very homogenous emulsions by the high cavitational shear.
As the parameters of ultrasonication are fine-tuned, particle size and distribution is well adjustable
and repeatable.
The ultrasonic reactors are the heart of our systems. Incbio has been conducting extensive R&D in
ultrasonic Biodiesel reactor technology. After a long time spent in testing with a variety of feedstocks
we have now got fully functional reactors specifically developed to process Biodiesel on both batch
and continuous plants, applied as a flow-through reactor. These ultrasonic Biodiesel reactors are fully
ATEX compliant and can be retrofitted to any operational Biodiesel plant.
In this configuration the ultrasonic reactor is used to blend methanol with feedstock homogeneously
prior to the esterification
Address: Rua Simo Bolvar 311, 1 Andar Sala 4, 4470-214 MAIA, PORTUGAL Phone: +351 220 171 082 Email: info@incbio.com Web: www.incbio.com
Page 6 of 16
4. Process Description
The feedstock comes from storage and is blended with water and phosphoric acid, and fed into a CSTR
(continuous stirred reactor), in order to release the gums from the oil. Once the reaction is complete
(continuously, as it goes through the CSTR) the feed is sent into a self-cleaning centrifuge to
continuously separate the water and the gums from the oil. After degumming the feedstock is sent to
a second CSTR where it is blended with bleaching earth, in order to remove metals, polymers and
other contaminants, once reacted it goes through a filter press to remove all bleaching earth from the
feedstock. After the previous pre-treatment steps the feedstock is heated to 144C using steam, mixed
with methanol and sent through the ultrasonic reactor in order to be completely emulsified. The
ultrasonic reactor is installed inline on the piping. The mix is then sent to the guard bed to remove any
remaining contaminants which may affect the performance of the acid esterification catalyst.
After the guard bed the medium is sent directly to the acid esterification reactor (120C, 8 bar), filled
with a solid catalyst (Lanxess GF101), being esterified continuously as it goes through the resin.
Upon exiting the reactor, the temperature of the medium is adjusted once more to 140C and fed to
a flash column, so the water and methanol can be removed.
The mixture of TG, methyl esters and residual FFA is then sent directly to the transesterification
equipment. Temperature at this time is approximately 120C, and medium is cooled using the cold
feedstock entering the process, thus maximizing energy recovery in the process.
The feedstock is heated to 65C using steam, mixed with methanol and sodium methylate, and sent
through the ultrasonic reactor (The ultrasonic reactor is installed inline on the piping). During this very
small contact time (approximately 5 seconds), there is an instantaneous conversion of more than 80%.
The mix is then sent to the CSTR (Continuous stirred-tank reactor), for the reaction to be completed,
for 60 minutes. CSTR is kept at the correct temperature with double wall heating, with hot condensate
water.
After the CSTR, the mix is sent through a disk stack centrifuge, to separate the Biodiesel (light phase)
from the Glycerol (heavy phase).
The light phase is then heated to 120C, and sent through a flash evaporator, to remove methanol and
any water present. The almost finished biodiesel is then sent through a lead-lag system of ionexchange resins towers, to remove any traces of glycerol and other contaminants.
Finished biodiesel is then sent to distillation. In distillation, using a WFE evaporator, biodiesel is
vaporised at an extremely high vacuum, and impurities are left behind, producing biodiesel with
excellent quality.
The heavy phase stream is heated to 120C, and sent through a flash evaporator, to recover methanol.
Glycerol is then sent to storage, or to distillation.
The methanol and water mixture is sent to the methanol rectification column to concentrate the
methanol to 99.5% purity, so it can be reused in the reaction. The rectification column is either a tray
column or a packed column, depending on project specifications.
Address: Rua Simo Bolvar 311, 1 Andar Sala 4, 4470-214 MAIA, PORTUGAL Phone: +351 220 171 082 Email: info@incbio.com Web: www.incbio.com
Page 7 of 16
Also, the water created in the chemical process will not have sulphuric acid present, thus removing
the necessity of processing a major contaminant.
c. Methanol Rectification
A successful commercial Biodiesel production can only be achieved by keeping the operating costs
down. Methanol is by far the most expensive consumable, and especially due to the acid esterification
requirement of high FFA feedstock (which requires high excess usage of methanol) this excess
methanol must be recovered. To this effect a methanol distillation system must be in operation and
is included in this proposal. The rectification column is either a tray column or a packed column,
depending on project specifications.
Address: Rua Simo Bolvar 311, 1 Andar Sala 4, 4470-214 MAIA, PORTUGAL Phone: +351 220 171 082 Email: info@incbio.com Web: www.incbio.com
Page 8 of 16
Specification
Up to 25%
51.0 Min
45 - 50 Max
1% Max
b. Utility specification
Utilities and chemicals having these characteristics are supposed to be made available at battery
limits.
Process water
Type
Pressure
Temperature
Hardness
Iron content
softened
3 bar g min.
ambient
1F max
max 5 ppm as Fe
Cooling water
Pressure
Temperature inlet
Temperature outlet
Hardness
3 bar g min.
20C max
25C max
Soft water with zero commercial
hardness, no suspended solids and
Chloride content <50ppm
5 bar g min.
Instrument air
Type
Pressure
Dew point
Address: Rua Simo Bolvar 311, 1 Andar Sala 4, 4470-214 MAIA, PORTUGAL Phone: +351 220 171 082 Email: info@incbio.com Web: www.incbio.com
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Nitrogen
Type
Pressure
Max Oxygen
99,5 % purity
8 bar g min.
0,1%
Electric power
Driving power
Control and auxiliary circuit
Lamps
c. Reagent specification
Methanol - Technical grade, 0.15 % max. water content.
Sodium Methylate - Technical grade, 30 % sodium by weight.
d. Product Specification
If the feedstock used in the plant is as per the specification above, biodiesel will be according to Annex
IV Mass and Energy Balance.
Address: Rua Simo Bolvar 311, 1 Andar Sala 4, 4470-214 MAIA, PORTUGAL Phone: +351 220 171 082 Email: info@incbio.com Web: www.incbio.com
Page 10 of 16
a. Capacity
1.000 kg/h (24 TPD) of processed product.
Address: Rua Simo Bolvar 311, 1 Andar Sala 4, 4470-214 MAIA, PORTUGAL Phone: +351 220 171 082 Email: info@incbio.com Web: www.incbio.com
Page 11 of 16
7. Specifications
a. Technical Certificates and Regulations
The plant will be fully tested by Incbio and will be CE marked to demonstrate the manufacturers
compliance with European directives. Furthermore the plant will be fully ATEX Explosive Atmospheres
Regulations (Directive 94/9/EC ATEX) compliant, whilst all electrical components will be ATEX
certified. All technical rules regarding pressure tanks, piping, plant assembly and installation will be
complied with by Incbio.
In this example of a plant layout, the following major structures can be observed:
A Tank Farm, with loading and unloading capabilities (for trucks only, or for trucks and/or
trains and/or boats).
Utilities room
Process room, with INCBIO processing equipment, and optional feedstock and biodiesel
processing tanks
Control room, with INCBIO computers, with SCADA to control processing equipment
Laboratory, with optional testing equipment
Offices
Essencial utilities (not included, that can be quoted, upon request) are:
Address: Rua Simo Bolvar 311, 1 Andar Sala 4, 4470-214 MAIA, PORTUGAL Phone: +351 220 171 082 Email: info@incbio.com Web: www.incbio.com
Page 12 of 16
c. Scope of Supply
Incbios scope of supply of the present proposal is the following:
Address: Rua Simo Bolvar 311, 1 Andar Sala 4, 4470-214 MAIA, PORTUGAL Phone: +351 220 171 082 Email: info@incbio.com Web: www.incbio.com
Page 13 of 16
f. Documentation
All engineering documents will be in the English language, using metric system.
Incbio will provide an Installation, Operation and Maintenance Manual for the system (1 electronic
copy). The IOM Manual will include the following:
Operating Instructions.
Equipment Documentation
o Specification sheets
o Drawings
o Spare parts lists
o Manufacturer IOM manuals
o Test reports (i.e. hydro test reports, data sheets)
Instrumentation Documentation
o Specification sheets
o Spare parts lists
Manufacturer IOM manuals
P&ID drawings
Module layout drawings
Instrument loop drawings
Junction box drawings
Electrical drawings
Utility table
h. Warranty
All of Incbios equipment comes with a 12 month manufacturers warranty against defects in design,
workmanship and materials, counting from the date of commissioning, or 18 months counting from
the date of shipment, whichever is soonest. Details on this warranty shall be covered on a separate
document to be included in the Sale Agreement.
Address: Rua Simo Bolvar 311, 1 Andar Sala 4, 4470-214 MAIA, PORTUGAL Phone: +351 220 171 082 Email: info@incbio.com Web: www.incbio.com
Page 14 of 16
8. Commercials
a. Price
Our budget price for providing all the services as described on this proposal for a 24TPD system
(1MT/hour), with input feedstock with up to 25% FFA, 1% H2O, comprising of:
1.205.000 EUROS (One Million, Two Hundred and Five Thousand Euros), Ex-works Incoterms 2010.
b. Payment Schedule
c. Payment Terms
The first payment is due with the order, all other payments are due Net 7 days after the achievement
of the given milestone. If the Client does not fulfil the terms of payment set out above, INCBIO may
suspend performance of its services until such time as the Client has complied. This shall not affect any
other remedies available to INCBIO, included but not limited to legal action.
d. Taxes
The price excludes any and all taxes and/or duties, up to the moment the title to all Equipment supplied
by Seller shall pass to Buyer. Any taxes and/or duties due in the Buyers country are not Sellers
responsibility.
e. Schedule
The complete system will be ready for delivery 38 weeks from receipt of down payment and all
approvals. The schedule requires drawing approval in less than 1 week, each day that an approval
drawing is late will add to the overall schedule.
g. Proposal Validity
This proposal is valid for 60 days.
Address: Rua Simo Bolvar 311, 1 Andar Sala 4, 4470-214 MAIA, PORTUGAL Phone: +351 220 171 082 Email: info@incbio.com Web: www.incbio.com
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Price/hour
77,50
60,00
52,50
43,00
C1. Junior Engineer; Junior Architect; Senior Designer; Planning Technician; Cost
control Technician; Procurement Technician; Inspectors;
35,00
28,00
26,70
24,00
19,00
Note:
Regular Working Period:
Designers; Project Designers; Measurers: 37,5 hours/week (7,5h/day)
All Others: 40 hours/week (8h/day)
Coefficient Overtime:
Monday to Friday: 1st Hour: 1,25: Next hours to midnight: 1,34; After midnight per hour: 1,45
Saturday: 1,45
Friday and Holidays: 1,85
The travel expenses in public transportations train or plane shall be proven by appropriate
justification. In case of use of own vehicle the correspondent value shall be 0,40 Euros / Km.
Accommodation costs shall be covered by the Client. Sustenance wages per day are as follows:
Category
A;B
C;D;E;F
Portugal
32,50
25,50
Abroad
75,00
65,00
All values comply with Portuguese legislation, fixed at 50% of maximum values.
Address: Rua Simo Bolvar 311, 1 Andar Sala 4, 4470-214 MAIA, PORTUGAL Phone: +351 220 171 082 Email: info@incbio.com Web: www.incbio.com
Page 16 of 16
Address: Rua Simo Bolvar 311, 1 Andar Sala 4, 4470-214 MAIA, PORTUGAL Phone: +351 220 171 082 Email: info@incbio.com Web: www.incbio.com