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BIODIESEL PROCESSOR: MODERN BIODIESEL PRODUCTION TECHNOLOGIES


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Unlike companies which manufacture biodiesel production equipment (biodiesel processor) based on outdated, tank technologies, which have been used for over a century, our company uses the high-frequency magnetic impulse cavitation principle, previously used in classified technologies, allowing us to achieve some significant advantages:

  • Low demands on the quality of the raw oil
    High-frequency magnetic impulse cavitation reactors work successfully and steadily with both raw and purified oil, and with all types of animal fats and fat mixtures with vegetable oils. This wide range of oils (sunflower oil, rapeseed oil, linseed oil, palm oil, mustard oil etc.) can be used for biodiesel fuel production with almost any acid number and it is also possible to use waste from livestock and poultry processing plants. The equipment does not need to be adjusted when the type of oil is changed.
  • "One pass" reaction procedure
    Unlike in outdated "tank" technologies, no re-etherification reaction is needed in magnetic impulse cavitation technology. This innovation means that the time taken to obtain biodiesel is reduced by a factor of 8-10.
  • Purifying sorbates, washing and drying are not required
    When using conventional technologies, it is not possible to obtain proper quality biodiesel fuel immediately. Therefore a process of impurity elimination, involving washing or purifying using sorbates, is needed. This requires additional equipment for primary biodiesel product washing (a mixture of water and alcohol is usually used for this purpose) and additional units for what is known as vacuum drying. When the cavitation biodiesel manufacture method is used there is no need for the finished product to be washed or dried, and this therefore eliminates waste water and sorbate utilization processes.
  • Minimal alcohol and catalyst quantity. No alcohol recovery process
    One of the main problems with"tank" technologies is the need to add, and consequently to recover, additional methanol to the reactor. This requires additional equipment and wastes electric power. In cavitation technology, the alcohol quantity used for the reaction conforms precisely to the stochiometric composition, i.e. the minimum volume. There is no need for a re-etherification reaction. The use of expensive and dangerous equipment for methanol recuperation is excluded from the process. Any inevitable alcohol losses during recovery are eliminated, which improves the environmental conditions and explosion-proof characteristics.
  • Minimum energy consumption
    Conventional biodiesel production methods are based on heating the oil to 67-70°C. This involves significant electric power costs; in addition, the methanol recovery process (required when the reaction is carried out using conventional technologies), additional re-etherification and also vacuum dehydrating lead to considerable electric power consumption. The use of cavitation processing eliminates all the stages mentioned above, which means that 5-7 times less electric power is used.
  • Low-temperature reaction
    In high-frequency magnetic impulse cavitation, processing takes place in the reactor on molecular level. All components are exposed to magnetic-directed cavitation pulses. Fatty acid molecules are split using micro-explosions; this results in a decrease of viscosity, a cetane number increase, an improvement in the energetic parameters of the future fuel and a considerable acceleration and improvement of the etherification reaction quality. It must be noted that the reaction takes place at room temperature and there is no need to heat the oil.
  • Minimal overall module dimensions
    Our automatic modules take up 5-10 times less floor space than conventional equipment of a similar capacity.

BIODIESEL MADE OF ANIMAL FAT


Biodiesel derived from animal fat (waste from the processing of livestock) using the cavitation reactor PULSAR-CT 215-B. Animal fat was first liquefied (heated up to 60°C).
Source components ratio:
Animal fat - 5350 ml
Methanol - 700 ml
Catalyst (potassium methylate) - 50 g
Processing time - 50 seconds
Separation time (gravity method) - 20 minutes

BIODIESEL MADE OF CRUDE SUNFLOWER OIL


The picture shows the source oil (crude non-refined sunflower oil) and the result of source product treatment in the cavitation reactor PULSAR-CT 215-B.
Test conditions:
Crude sunflower oil - 7000 ml
Methanol - 900 ml
Catalyst (potassium methylate) - 65 g
Processing time- 50 seconds
Separation time (gravity method) - 20 minutes

DEMONSTRATION OF PULSAR-CT 215-B CAVITATION REACTOR (Biodiesel Processor) BEING USED IN THE COMPANY'S LAB

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AUTOMATIC MODULES BIOTRON-CT 500 AND BIOTRON-CT 1000

Technical parameters

 
BIOTRON-CT 500
BIOTRON-CT 1000
Capacity (rated), liters per hour
500
1000
Rated power, kW
16
32
Weight (approximately), kg
700
1100
Maximum allowed liquid temperature in module, °C
90
90
Automation level
ultimate
ultimate
Operation mode
continuous
continuous
Processing efficiency, kW hour/liter
0.032
0.032
Capacity adjustment
yes
yes
Processed liquid special requirements
no
no
Floor space occupied with one module, sq.m.
3.0
4.0
Overall dimensions (L x W x H), mm
2200x1400x2300
2900x1400x2300
Explosion proof certificates
ATEX
ATEX

 

AUTOMATIC MODULES BIOTRON-CT CONSIST OF THREE MAIN UNITS:

1. PULSAR-CT 215-B: THIRD-GENERATION MAGNETIC IMPULSE REACTORS (Biodiesel Processor)

PULSAR-CT 215-B is a third-generation hydrodynamic high-frequency magnetic impulse cavitation reactor - state-of-art technology in biodiesel fuel production. A very high level of reliability, modern design, process automation, stable results with any oil types, minimum power consumption - all of these features make PULSAR-CT 215-B cavitators the undisputed leader in high-tech biodiesel fuel production. PULSAR-CT 215-B cavitation reactors are the core elements of BIOTRON-CT automatic biodiesel production modules.

Technical parameters

 
PULSAR-CT 215-B
Capacity (rated), liters per hour
500
Rated power, kW
15
Weight, kg
235
Operation mode
continuous
Processing efficiency, kW hour/liter
0.032
Flow rate adjustment
yes
Overall dimensions (L x W x H), mm
1050x450x550
Explosion proof certificates
ATEX

2. PPS-CT 1200 : ELECTRONIC SYSTEM FOR THE PRELIMINARY DOSING AND PROCESSING OF SOURCE PRODUCTS

Technical parameters

 
PPS-CT 1200
Capacity (rated), liters per hour
1200
Number of components mixed
3
Rated power, kW
2
Explosion proof certificates
ATEX
Automation level
Fully automatic

Modern dosing systems, used by other companies are not able to guarantee the steady dosing of source ingredients if ambient conditions (temperature, liquid level in source ingredients and prepared products tanks, oil viscosity, etc.) change. The system which our company has designed does not include these disadvantages and has an extremely high dosing precision - 0.1%. In addition, the system is equipped with a pre-mixing unit, there is the option of adjusting flow rate and pressure at the system output and there is also a source components dosing feature. The equipment uses original software and high-reliability electronics produced by the company FANUC. The PPS-CT 1200 system also includes a biodiesel fuel production safety tracking function. The processor tracks the source component availability, their filling speed, mixing intensity, ability to pass through pipelines and valves, etc. If there is an emergency, the processor will stop the whole system; send an audible signal to operator and show the error code on the display, together with a detailed description and possible causes. In this way, for example, if there is an oil shortage in the source products storage, the following message will be displayed:

The operator should identify the exact cause of the system stop and eliminate it. The system also features test reaction procedures i.e. test processing of small volumes (up to 10 liters) of source components. This feature may be useful for new oil or animal fat changeover.

3. ELECTRONIC TRACKING SYSTEM OF THE FILLING, SEPARATION AND DISCHARGE OF FINISHED PRODUCTS

Our automatic unit contains the separation process tracking system in order to eliminate the human factor in biodiesel availability evaluation ("by-sight"). The supersensitive sensors monitor the state of the glycerol and biodiesel in the separation tank. Data obtained by the sensors is transferred to the computer, which evaluates the readiness of the source products and also controls biodiesel and glycerin discharge from the separation tanks to the finished product storage. The entire process takes place in continuous mode.

If any unforeseen situation occurs, and, for any reason, the separation does not take place or takes place at a poor speed, the computer will stop the entire system and send a signal to the operator about the need to analyze and correct the situation.

USER-FRIENDLY INTERFACE SOFTWARE, WHICH DOES NOT REQUIRE THE OPERATOR TO HAVE SPECIAL SKILLS

All processes which take place in the automatic module are controlled by the microprocessor. The interface that our software team has developed is very simple and self-explanatory. The operator is able to control the whole system just by clicking a mouse button. In the adjustment mode, the operator can control any module mechanism separately, set the necessary sensor response value, etc. In the automatic mode, just click the START button – the BIOTRON-CT system will do the rest itself.
One computer can serve up to five BIOTRON-CT automatic modules at once.

Software and electronic components are designed based on the software and electronic components produced by the Japanese company FANUC, one of the world market leaders in this area.

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PRODUCTS FAMILY

 
Automatic equipment
Semi-automatic equipment
Reactor
BIOTRON-CT 500
BIOTRON-CT 1000
BIOTRON-CT 500-S
BIOTRON-CT 100-S
PULSAR-CT 215-B
Capacity (rated), liters per hour
500
1000
500
1000
500
Rated power, kW
16
32
16
32
15
Overall dimensions (L x W x H), mm
2200x1400x2300
2900x1400x2300
1400x1400x1350
2100x1400x1350
1050x450x550
Weight, kg
700
1100
375
650
235

The number of modules that can be mounted together into one hyper-productive complex is practically unlimited. This allows flexible, high-technology biodiesel production of any capacity to be achieved. One operator is able to control one complex, which consists of number of modules.


LAYOUT OF THE PRODUCTION AREA WITH 10 BIOTRON-CT 1000 AUTOMATIC MODULES
with a total capacity of 80,000,000 liters of biodiesel per year


  • The intelligent tracking system which we have designed is intended for tracking the entire biodiesel production process in real time and is now able to eliminate the possible influence of the human factor. The discharge of prepared products (biodiesel and glycerol) takes place in continuous mode.
  • Modules are equipped with dosing devices, which are able to supply components to the reactor with a high level of precision and can also carry out quantity measurements in online mode, according to current processing requirements.
  • BIOTRON-CT automatic modules are suitable for processing vegetable oils, animal fats and any mixtures thereof. They offer a high stability of quality parameters for the obtained biodiesel fuel - which cannot be achieved in any other kind of equipment.
  • The modules are not equipped with the expensive and energy-consuming elements used in conventional technology, such as equipment for excess methanol recover, primary biodiesel washing, prepared product vacuum drying, because they are not needed.

 

 

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