Introduction:
Springboard Biodiesel is committed to simplifying and expanding the role of small-scale biodiesel production. We continually strive to both improve our existing products and produce innovative new products that maker it easier, safer and cheaper to make ASTM quality biodiesel from a wide variety of vegetable and animal feedstocks.
That is why Springboard Biodiesel is excited to announce the introduction of the GL-95, our innovative, automated glycerin demethylation system. The GL-95 is the first of 4 new products that Springboard Biodiesel plans to introduce in early 2012, and is specifically designed to minimize biodiesel processing waste while recapturing valuable inputs for reuse and subsequent reduction in the overall operating costs of our customers.
We believe that the GL-95 is a unique product that combines automation, a small physical footprint and a unique set of functions that will dramatically improve the small-scale biodiesel producer’s system economics while continuing to support the substantial environmental benefits that accrue to biodiesel production.
The GL-95 with Shared Condensor – What Does It Do?
This system processes the raw glycerin that is created in biodiesel production. Methanol is extracted from the glycerin, reducing the volume of the glycerin and eliminating any risks or hazards posed by the presence of methanol. The saponification option for the GL95 processes this glycerin further, generating solid cubes of glycerin soap which can easily be disposed of as solid waste.
How Does it Work?
Simply connect the GL-95 to your BioPro™ via the included glycerin hose and pump the glycerin into the GL-95’s primary processing chamber. Over an 8-hour period, methanol vapors are extracted from the glycerin under deep vacuum and high temperatures. These vapors are drawn into the sub-zero methanol vapor condensing system, where they are safely and completely returned to liquid form and then pumped out into a vessel of the user’s choice (below left).
The GL-95 features a magnetically driven agitator within its integrated vacuum tank to eliminate the possibility of vapor leakage and to remove any long term issues with seal wear. Low density heaters ensure safe heating of the glycerin and methanol.
The reclaimed methanol is typically about 80%-90% pure (the rest being water) and is suitable for refining and reuse in biodiesel production. (Refining can be accomplished using a methanol purification machine.)
The remaining raw glycerin (the overall volume of which has now been reduced by some 20% or more), can then be discharged into a waiting storage vessel in its viscous liquid form. Or, with the saponification option, it can be cast into solid 15” x 15” x 10” glycerin soap cubes and removed via the steel handling cart that accompanies the unit. (below right)
The control systems of the two machines are totally integrated, allowing easy operation from a single touch screen (see photo at bottom).
The shared condensing system can simultaneously condense methanol vapors extracted from the GL95 as well as from the soon to be released BD380 biodiesel demethylation unit.
GL-95 Processing Capacity
The GL-95 will handle 25 gallons of glycerin (maximum) at a time. It takes 8 hours to process this glycerin and when it is finished an average of 4-6 gallons of methanol will be recovered at approximately 80%-90% purity (the remaining 10%-20% is water). Typically, 4-6 gallons of methanol will be reclaimed from 25 gallons of raw glycerin. The GL-95 is versatile in that it can also handle smaller batches of glycerin (as small as 10 gallons).
GL-95 Construction:
Both pieces of equipment are solidly built employing welded steel frames and heavy gauge panels with a powder coated finish. Wetted parts are stainless steel. Electrical components are in compliance with UL or other equivalent NRTLs. It was designed with durability and safety as the highest priorities. Numerous interlocks and process monitoring sensors continuously check for issues and take appropriate actions should issues arise. The GL-95 is automated and can be controlled from the touch screen located on the Shared Condenser unit. This automation includes significant self-diagnostic features to ensure reliable operation.
Required chemicals:
Springboard Biodiesel GLDefoaming Agent (30 mL per batch)
For optional saponification: 3 kg NaOH for 25 gallon batch of glycerin
Power Requirements:
240V AC power (30 amp supply)
Standard 110V AC power (15 amps supply)
Footprint:
26” x 26” and 78”high (both units)
Total Equipment Costs:
Two unit system: $24,000
Two unit system less the soap cube functionality: $21,000
Warranty:
The GL-95 Demethylating system comes with a 1 year warranty for parts. After that, customer service support and troubleshooting will continue to be available for the life of the equipment, or the life of the owner, whichever ends last.
Summary
We have done some fairly exhaustive research into what other products are available on the market that perform the functions of the GL-95. We have not yet found anything that works at this capacity, that has this level of construction, and is automated, for anything less than 3 times the price.
FAQs:
Q: Does the 8 hour cycle time include filling and emptying the unit?
A: The 8 hour time does include filling and emptying the unit. There is an initialization process which the GL-95 must perform before it is filled, and this takes about a half hour or so, and is not included in the 8 hours. So if you know your BioPro will be ready to have its glycerin drained at 12:00, then you’d go out and start the GL95 initialization sometime prior to 11:30 so it’s ready as soon as you want to drain out the glycerin from the BioPro™.
Q: If you are running 2 BioPros™ and the GL-95 finishes with on load does it have to go through the 30 minute initialization again or can it start right into the next batch? Or can it do multiple batches without a cool down time?
A: You don't need to re-initialize; you don't need to cool down.
Q: How should this be positioned in relation to the BioPro™ 380or the BioPro™190? Can you fill directly from the BioPro™ or do you need to do something before it goes in?
A: The GL-95 can be positioned right next to the BioPro™ 380 (or BioPro™ 190) and can be filled directly from the BioPro™ 380. It was actually designed with this as the preferred method for filling. If you happen to have the glycerin in a separate vessel, this also works well. The GL-95 can vacuum up your glycerin into its tank.
Q: What happens if you get a little fuel in with the Glycerin?
A: If you’re planning on getting the saponification option, there’s no harm in getting a little fuel into the glycerin. This will saponify and harden with the rest of the block. If you’re not going with the saponification option, and you are just demethylating and storing the glycerin, then this fuel will eventually stratify to the top.
Q: If we get the saponification option can that be turned off and on? We understand the liquid maybe better for soap making if we decide to do that?
A: Yes, you can turn the saponification on and off. Keep in mind that saponification is basically a landfill strategy, and without the "cubing" you have more flexibility on the soap making side. We are not experts on soap production.
Q: Any water or drain lines needed?
A: No
Q: Do I need any other equipment?
A: Yes. The GL-95 requires a 5 SCFM 100 PSI air compressor (minimum) to generate the vacuum in which the methanol is condensed.
Q: What percentage of the saponified soap block is glycerin and what percent is soap?
A: After the methanol is removed from your glycerin, you are left with a cube of soap that is approximately 30-40% glycerin and approximately 60-70% soap. Trace salts (Sodium sulfates - Sodium sulfate are mainly used for the manufacture of laundry detergents) are also present.
Q: Do you recommend that people use the glycerin block (left after the methanol is removed) as soap?
A: No. We do not make any recommendations regarding soap. We are NOT soap experts.
Q: What percentage of the methanol is removed and recaptured from the original glycerin by-product?
A: More than 99% of the methanol is recaptured making this a uniquely efficient system.
Q: After the methanol has been removed from the glycerin and a soap cube has been made, what is in that soap cube?
A: The GL 95 will typically produce a cube that contains approximately:
-52% Glycerin
-44% Soaps (Sodium Linoeleate, Sodium Stearate, etc.)
-2% Sodium Sulfate Salts
-2 % Moisture, particulate contamination, tiny traces of residual methanol, etc.
Note that the figures above can vary significantly based on the exact recipe used in the initial biodiesel making process, the length of time that the GL95 is allowed to run, how thoroughly the glycerin layer was drained from the biopro, and other related factors.
