Grantee Research Project Results
Final Report: Closing the Biodiesel Loop: Self Sustaining Community Based Biodiesel Production
EPA Grant Number: SU833203Title: Closing the Biodiesel Loop: Self Sustaining Community Based Biodiesel Production
Investigators: Ramsdell, Jeff , Raichle, Brian W. , Scanlin, Dennis , Martin, Jack , Ramey, Michael , Carroll, Terry
Institution: Appalachian State University
EPA Project Officer: Page, Angela
Phase: II
Project Period: September 1, 2006 through August 31, 2008
Project Amount: $75,000
RFA: P3 Awards: A National Student Design Competition for Sustainability Focusing on People, Prosperity and the Planet - Phase 2 (2006) Recipients Lists
Research Category: Pollution Prevention/Sustainable Development , P3 Awards , P3 Challenge Area - Air Quality , Sustainable and Healthy Communities
Objective:
These students assisted with this project:
Appropriate Technology:
Paul Feather, Chris Jude, Jeremy Ferrell, Brooke Frazer, Jon Ruth, Justin Stiles, Chris Curtin, Yonatan Strauch, Ryan Hiller, Chris Krezmien, Andrew Fulton, Ged Moody, Brian Taddonio
Interdisciplinary Studies:
Alyssa McKim, Clark Heldman, Julia Fondren, Kaitlin Marone, Joel Atchison, Billy Schweig, Mary Rogers
Biology and Chemistry
Rachael Hoch, Laura Hamm
Construction Technology
Sean Pendergast, Jared Toon, Ben Lee
Technology Education
Jay Trombower
Anthropology
Blake Atchison
Highlights from Phase II 
· “Biofuels Technology” Course implemented
· Installation of 1.7kW PV system, 1st Gridtied system for Local Power Company
· B20 adopted for University and Public Transportation vehicles in town of Boone
· Installation of Data-Acquisition System
· Appalachian State Biofuels Initiative, $1.5 million in additional funding since Phase II award
The P3 project at Appalachian State University has been a student-led effort to demonstrate a closed-loop biodiesel processor, and create a research and educational facility to teach about biodiesel production and use. Through Phase I and Phase II funding, the Biofuels Initiative has evolved into a significant research effort at Appalachian State. The tremendous success of this project has had far reaching effects and created a positive environment for $1.5 million in further funding. We have been awarded funding from the following:
· ASU Renewable Energy Initiative for installation of our 1.7kW PV system,
· NC Biotechnology Center for oilseed crop research,
· Merck Scholarship for Algae research,
· ASU administration for B20 in university vehicles, and
· Golden Leaf Foundation for the development of a Modular Biodiesel Testing Facility located at the Catawba County EcoComplex
· Department of Energy, On-board Emissions testing
· University of North Carolina Research Competitiveness Fund: Data Regulated Processing of variable alternative feedstocks
Our goal with this Initiative is to continue to provide unique opportunities for research and education in the growing field of Biofuels while promoting renewable and sustainable production technologies.
Summary/Accomplishments (Outputs/Outcomes):
Biofuels Technology TEC 4700/5700 
Highlights
· 1st Time Offered Course
· Utilize BEReL as Teaching Tool
· Student Projects in conjunction with Lab
· Formal Inclusion in Appropriate Technology Curriculum
“Biofuels Technology” was offered for the first time in the Spring 2007 semester through the Department of Technology. The course was team taught by the Collaborative’s Faculty Advisor, Dr. Jeff Ramsdell, and Phase II project coordinator, graduate student Jeremy Ferrell. The course features integration of the Lab to provide students with unique hands-on educational and research opportunities. The course is dual-listed, offered to both graduate and undergraduate students from various departments.
The goal in developing this course has been to utilize the closed-loop facility that was built in Phase I. We have successfully incorporated a laboratory component of the class where students can learn about community-scale batch production of biodiesel while exploring underlying concepts of eco-industrial and closed-loop.
Many students in “Biofuels Technology” have conducted hands-on components of their individual research projects at the lab. Student projects include heated water washing, hydronic distillation, biofiltration, biogas production, bench top algae production, aerobic composting, and developing a manual for standard operating procedures. We feel that this course will continue to refine and develop the resources of the lab.
Biofuels Technology has become a mainstay of the Appropriate Technology curriculum. It has been officially included in the course catalog and will become a hard number course for Fall 2008. We believe that this course will be one of the greatest legacies of the P3 Phase II award.
Data Acquisition & Automation 
Highlights
· PC-Based LabView System
· Monitors and Captures Real-Time Processor Data
· Remote Monitoring & Control Capability
We created a PC-based data acquisition and control platform utilizing LabView software from National Instruments. Hardware included a new Core-Duo processor PC, a LabView data acquisition card, a network switch and a printer. Utilizing LabView version 8.2, we developed a data acquisition system that collects temperature data from 6 our key tanks in the processor facility (hot water, processor, settling, wash, oil storage 1 & 2). This data is displayed realtime and is also stored for future research. In addition we capture various ambient temperatures from our facility.
By installing relays on various valves, we can control the flow of hot water from our solar thermal system to the desired tank in our processor. These valve can be controlled automatically, based on desired temperature and priority setting, or manually through the computerbased control screen.
Additionally, all of the monitoring, control and automation features of our system can be accessed remotely utilizing the Internet.
Future data acquisition and control functions in planning include: solar thermal data, solar insolation, infrared spectroscopy data, remote video monitoring, various data probes and relay-controlled valves.
Photovoltaic System 
Highlights
· 1.7 Kilowatt Array (10-170 watt Sharp Panels)
· Utility Inter-Tied System
· Sized to meet Current/Planned Demand
· Real-Time Web-Based Data Monitoring
Students from the biodiesel collaborative obtained $17,500 in funding from Appalachian State University’s Renewable Energy Initiative for the installation of a 1.7 kilowatt photovoltaic array. The system was completely designed and installed by Appropriate Technology students from ASU’s Photovoltaics course taught by Dr. Dennis Scanlin. The array is sized to offset the current and projected utility demand for the biodiesel facility. The system features 10 regionally made 170-watt Sharp modules, real-time web-based monitoring, and an SMA Sunnyboy 2500 grid interactive inverter. The grid-tied system is the first of its kind for the local utility, New River Power & Light. It was necessary for the collaborative to work closely with the utility to pave the way for future photovoltaic installations in the community. The system was selected to optimize annual production. Due to the scholastic year, the facility will be used the least during the summer when the solar resource is best; therefore, a grid-tied system was chosen over one that relied on battery storage. The PV array is expected to produce about 2,600 kilowatt hours of electricity annually and offset 5,743 lbs. of CO2 and 2,235 lbs. of coal every year.
Near Infrared Spectroscopy 
Highlights
· State-of-the-art NIR spectrometer and transmission dip probe unit.
· Provides real-time monitoring and analysis of the transesterification process
We have ordered and received a state-of-the-art Near-Infrared Spectrometer package. The full system includes a Near-Infrared Spectrometer measuring wavelengths between 900-2500 nm, a single pass transmission-type dip probe, cross-platform Spectroscopy operating software, and an optical bench for the Spectrometer.
The probe will be installed on the side of the processor and will allow for real time monitoring of the biodiesel process. The on-line monitoring feature will allow for quantifiable results on changes made during the reaction. We will be able to adjust the parameters of the process (i.e. temperature, concentrations, time, rate of addition of reactants, etc.) and determine the combinations that have the highest yield of product and lowest waste. The NIR Spectrometer and probe will also be able to detect the amount of contaminants in the final product. The 900-2500 nm spectrum will allow for determination of methanol, free fatty acids, glycerin, and esters.
In the future, we hope to expand on research of the reaction parameters by testing the initial feed stock. The instruments will also allow us to test the difference in the reactions and products from based on the initial feed stocks.
Oil Feedstock 
Highlights
· 8 winter Trial plots of Rapeseed Established with local farmers
· Additional Funding through NC Biotechnology Center for planting and harvesting equipment
· Seed press for feedstock conversion to oil ready for processing
· Value-added by-product Experiments
Phase II has continued agricultural feedstock efforts by working with local farmers to plant and harvest appropriate oilseed crops for the climate of Western North Carolina. We have focused on trials of high-yielding, non-conventional oilseed crops including rapeseed, wild mustard, and sunflower.
We have are expanding the oilseed crop research as we received funding from the North Carolina Biotechnology Center for planting and harvesting equipment. A tractor “pull-behind” seed-driller will allow for planting larger plots, while a small grain combine will facilitate the harvesting of promising oil crops.
Our model for seed crushing is a trailer mounted press that can be transported to perform oil extraction on-site. We have installed a 10 ton/24 hour press appropriate for community scale processing. The valuable seed meal will stay on-farm to be used in a variety of applications. We are looking into the feasibility of using rapeseed and sunflower meal as a high protein supplement for animals, and mustard meal as a potential soil fumigant and pesticide. The true value of growing feedstock crops will be the economic benefit of secondary or value-added co-products.
By connecting with the local farming community, the Collaborative has successfully expanded the breadth of the project and is discovering another important avenue of the closed loop philosophy.
Algae Research Compost Bio-Reactor 
Highlights
· System Proto-type Developed
· Testing of salt and fresh water strains
· Merck Funding for Biology and Chemistry students to continue algae experiments.
· Wachovia award for Environmental Research
These simple organisms have been around for millions of years. We still have much to learn from nature’s simplicity. These organisms have been used to filter flue gas and can be grown for their oil content. The oil content of algae out-competes any other biomass used for processing biodiesel. Imagine overstepping the fuel versus food debate, saving acres of farm land to produce fuel. Small scale photo bioreactors could yield the same amount of usable oil as a few acres of land.
Organic matter when it decomposes releases CO2 and heat. Using renewable sources of carbon dioxide such as biogas or compost requires a way to harness and feed the algae. The escaped compost exhaust would otherwise be released to the atmosphere. Placing compost in a sealed container and pressurizing it with air introduces CO2 into the bioreactor system. The exhaust is filtered through water and exposed to UV light. Quantifying the amount of CO2 released will tell us how viable a source it will be for algae growth. It is then safe to bubble it through the algae in the sunlit bioreactors. This process has the potential to provide sustainable small-scale as well as commercial production of algae for biofuels.
Fuel Sampling Program 
Highlights
· Fuel usage by area Farmers
· Fuel Use at ASU Sustainable Development Farm
· Provided Fuel for Renewable Energy Tours
The Fuel Sampling Program has emerged as an effective tool to educate the public about biodiesel while providing fuel to key off-road sectors such as farm equipment and home heating oil systems.
During Phase II we have continued to partner with area farmers by providing them with fuel in exchange for land and equipment use in the preparation for oilseed plots. We have developed a feedback form to assess potential adoption and issues with transitioning older equipment to biodiesel.
We have provided biodiesel for diesel equipment at ASU’s Sustainable Development farm to get biodiesel into the hands of the community especially for agricultural use where emissions reductions are most felt.
Finally we have provided fuel for the annual “High Country Renewable Energy Tour” which transports participants in a diesel powered bus to various locations where they can learn about renewable energy. ASU BEReL has become an important stop to see the myriad of solar and closed loop technologies that hope to inspire the next generation of sustainable development.
Project Outreach 
Highlights
· 12 Workshops Held
· B20 in ASU Public Transit System
· Media Attention, ASU and Local Press
· Provided assistance to Universities seeking to develop on-campus closed-loop facilities
· Documentaries: NWF Campus Ecology & Open Aperture Film Competitions
· Workshop in WNC-REI Summer Series
Outreach continues to be a hallmark of the Collaborative Project. The Phase II team has held twelve “How to Make Biodiesel” workshops open to the public since the project inception. Our workshops utilize our Closed-loop facility and offer unique hands-on opportunities for participants to learn about sustainable biodiesel processing.
The Renewable Energy Initiative (REI) at Appalachian successfully implemented a transition to B20 for the Appalcart Buses, the mass transit system for the town of Boone. Our outreach efforts played a significant role in the decision to adopt B20 for buses.
Our project has continued to garner media and press attention on ASU’s campus and beyond. Our project was the feature of the Fall 2006 “Appalachian Today” magazine which focused on our work in the greening of biodiesel. Numerous articles have been published in our school paper, local newspapers, as well as on-line forums and magazines. Additionally, several documentaries have been made about the project including the winner of the 2007 Open Aperture Film contest.
After widespread recognition, we have been contacted by Universities across the country seeking advise on how to develop an on-campus biodiesel processor that could utilize the school’s waste vegetable oil. We have provided a wide range of consulting from funding to student participation and have been willing to openly share methods and strategies that contributed to our success.
Side Streams & By-Product Recycling 
Highlights
· Passive Solar Greenhouse Performance
· Ecological Machine Development & Monitoring
· Glycerin: soap, aerobic composting, biogas feedstock
· Methanol recovery
A significant challenge to the emerging biodiesel industry is to develop sustainable and efficient handling of process side streams. Common side streams include glycerin, wash water, magnesium silicate adsorbent in waterless washing, excess methanol, and low quality feedstock. If handled improperly, these waste streams negate the positive energy balance and environmental benefits of biodiesel fuel.
Our efforts in closing the loop have resulted in the creation of an environmentally sustainable infrastructure. Our first step was the construction of an “industrial greenhouse” to allow for year-round production and house our waste water treatment system. Our passive solar greenhouse has maintained temperatures in the 40s on coldest winter nights when outside temperatures dropped to single digits.
Our Ecological Machine has been a fascinating “holistic” aspect of the project that has opened the doors for interdisciplinary collaboration for biology and chemistry students. Our initial findings show the system to be an effect in filtering and clarifying water, albeit at a slower rate than necessary for industrial scale production. A pretreatment of the waste water such as adding a flocculant like aluminum salts would improve the efficiency of bioremediating wash water with an ecological machine.
In addition to making soap from glycerin, we have begun experiments with glycerin composting. When combined with wood chip or sawdust, glycerin composts sufficient to give waste heat and ultimately produce valuable organic material.
We are currently developing a hydronic methanol recovery system for both glycerin and methyl ester layers. Preliminary distillations have produced high quality methanol (98% purity) for re-use in processing.
Supplemental Keywords:
Sustainable Industry/Business, RFA, Scientific Discipline, INTERNATIONAL COOPERATION, POLLUTION PREVENTION, TREATMENT/CONTROL, Technology for Sustainable Environment, Sustainable Environment, Environmental Chemistry, Chemicals Management, cleaner production/pollution prevention, Environmental Engineering, Technology, Energy, education, biofuel, alternative energy source, biotechnology, emission controls, environmentally benign alternative, waste vegetable oil, waste to fuel conversion, energy conservation, renewable fuel production, bio-based energy, energy efficiency, biodiesel fuel, alternative fuel, alternative to petroleum diesel fuel, waste cooking oils, engineering, green chemistryRelevant Websites:
Phase 1 AbstractProgress and Final Reports:
Original AbstractP3 Phase I:
Closing the Biodiesel Loop: Self Sustaining Community Based Biodiesel Production | Final ReportThe perspectives, information and conclusions conveyed in research project abstracts, progress reports, final reports, journal abstracts and journal publications convey the viewpoints of the principal investigator and may not represent the views and policies of ORD and EPA. Conclusions drawn by the principal investigators have not been reviewed by the Agency.