The following is the original operations manual for operating the intended processor and washing the biodiesel.  Once on the ground we made changes and modified the operations based on available materials.  The following is offered only as a guide as an accurate manual is being developed and will replace the following shortly.  Please use this only to see how we anticipated operating this processor.  We expect to replace this shortly

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The Ghana Project assembled a biodiesel Processor for converting palm kernel oil (SVO – Straight Vegetable Oil) into biodiesel.  The process, using this processor involves:

v      Loading the processor with 200 liters of raw palm kernel oil

v      Starting the heating element of the processor.

v      Measuring the KOH.

v      Filling the methoxide mixing tank with 40 liters of methanol

v      Mixing the KOH with the methanol

v      Blending in the methoxide once the SVO has been heated in the processor,

v      Setting the timer for the pump for 2 hours

v      Draining the glycerin after the solution in the processor has settled for 8 hours. 

v      Draining remaining biodiesel into the wash tank

v      Filling the wash tank with water to the line indicated

v      Starting the bubbler and setting the timer for 2 hours with the air bleed valve mostly open (gentle bubbling)

v      Draining the water from the wash tank after the wash tank timer has stopped and the biodiesel has had at least 30 minutes to settle.  Then filling the wash tank with water to the indicator line and starting the process again.

o        First wash – 2 hours

o        Second wash – 4 hours (more vigorous)

o        Third and forth wash – 6 –8 hours

v      Letting final wash settle for at least 6 hours (to dry the fuel), then draining the biodiesel into the finished barrel.

v      Starting the process again!

 The steps above are generic.  The following pages will detail each step and some best practices. As with all things, nothing is ever constant so these instructions are always subject you the user’s best judgment and things in the state of change.

Loading the Processor:

The feedstock, palm kernel oil, comes in a 200 liter drum.  This drum should be left in the sun to warm the oil before pumping it into the processor.  The current processor comprises two 200 liter metal drums welded together to create a single 400 liter drum.  The batch size is 200 liters of SVO and 40 liters of methanol.

The processor should be empty.  And the ball valve (5) leading from the processor to the 4 way should be closed – thereby isolating the processor from the pump.

Ball Valve Directions:

Steps to fill processor

1. Put feed tube into top of the drum of palm oil. This is the clear vinyl hose that leads to the center feed of the 4-way going to the pump.
2. Check valves to be in the above positions
3. Open the pressure relief valve on top of the tank.
4. Turn on pump using switch on wall outlet
5. Open ball valve leading to the 4 –way

The pump should labor slightly until it can build up enough pressure to start the flow of SVO.  Continue filling until the 200 liter drum of palm kernel oil is empty.

6. Stop the pump
7. Close the ball valve on the 4-way from the SVO tote.

Starting the heating element of the processor.

1. Turn on the switch for the heating element of the processor. 

Filling the methoxide mixing tank with 40 liters of methanol

1. Disconnect the mixing barrel from any hoses
2. Wearing gloves and goggles use the bung wrench to open and remove the 2” bung on the methanol barrel.  Step back from the opening and DO NOT breathe the vapors.  Open the bung slowly incase there is pressure inside.  Watch out for any spray from the barrel.
3. Place the yellow barrel pump into the 2” opening.  You need to secure the bung fitting to seal the pump to the barrel.
4. Place the hose from the drum pump into the methoxide mixing barrel.
5. Open valve on methanol barrel to vent while filling.
6. Pump out methanol until the barrel is filled to the indicator line.
7. Drain the methanol in the hose into the mixing barrel and then carefully remove the hose.  Be careful not to drip any methanol on yourself or your clothing.
8. Unscrew the holding bung, if used, and remove the pump from the barrel.  Hold the pump so that the end is still in the barrel and let it drain.
9. Hang the pump up
10. Replace the 2” bung on the methanol barrel and close tightly.

Mixing the KOH with the methanol

Since we are using virgin palm oil, there is no need to do a titration to determine how much additional KOH will be needed.  We will use 7.5 grams per liter of oil which translates to 200 liters of oil and 52 ounces of KOH.  The KOH will be mixed with 40 liters of methanol to make the methoxide for the process.

Mixing the KOH into the methanol should be done with the greatest caution.  Make sure to wear gloves and goggles. 

1. Unscrew the large bung on the methoxide barrel
2. Using a funnel, pour the methoxide SLOWLY into the methanol.
3. DO NOT BREATHE THE VAPORS
4. DO NOT SPLASH THE LIQUID ON YOU OR YOUR CLOTHING
5. After you have poured the entire KOH contents into the barrel replace the large bung and secure it so that it doesn’t leak.
6. Open the valve on the other bung to vent the vapors and relieve the pressure.
7. Gently rock the barrel from side to side to help the KOH dissolve
8. Depending on the formula and the temperature, it may take 15 minutes or more for all of the KOH to dissolve.
9. After 10 minutes or so close the valve.  Continue to agitate.  Open the valve slowly to see if there is any more pressure. If the KOH has dissolved, there should be no additional pressure.  Close the valve but continue to agitate now and then.

Blending in the methoxide.

Once a temperature of 120 degrees of the oil has been met, turn off the heating element switch. 

1. Turn on the pump to mix the heated oil for 2 or 3 minutes
2. Hook up the tubing from the methoxide feed to the pump and the top of the methoxide barrel.
3. CLOSE THE VALVE.
4. Lift the barrel onto another barrel and lay it horizontally.  The barrel should be higher than the input tubing ball valve.
5. With the pump running, slowly open the valve on the barrel until the tubing begins to fill.
6. Slowly open the ball valve on the pump side until you see the color in the tubing on the discharge side of the pump turn creamy.
7. Open the valve on the barrel completely
8. Open the other bung on the barrel slightly to allow air in as the methoxide is emptying.
9. Keep the valve on the processor side of methoxide open enough to have a constant flow of methoxide to the pump but you want to have it enter slowly. 
10. You may have to close the ball valve coming from the processor to the 4-way slightly to increase the flow from the methoxide side.
11. Once the methoxide barrel is empty close the valve on the barrel and open the valve on the processor to the pump tubing all the way.
12. Disconnect the barrel and make sure the bung and the valve are both completely closed.

Setting the timer for the pump for 2 hours

1. Move the pump plug to the timer and set the timer for 2 hours.  Make sure to only have one trip thing in the timer so that once it turns off it will not turn back on.
2. Leave the pump running.  You can clean up and leave the processor to do its thing.

Draining the glycerin

After the solution in the processor has settled for 8 hours, drain the glycerin into a cubie.  Drain until the color of the liquid is golden or amber but without any glycerin coloration.

1. Using the tubing connected to the outflow of the processor, position a cubie such that the hose is in the cubie. 
2. Open the pressure relief vent on the top of the processor.  Make sure you are not in the way of the valve as methanol will be exhausted.
3. Close the ball valve near the sight tube and to the left of the pump. This will stop the biodiesel in the hose above the pump from draining.
4. Slowly open the ball valve at the bottom to drain the glycerin.
5. Watch the tube.  The color of the draining liquid will change from dark amber to a lighter shade.  Close the ball valve slightly to slow the flow.  Due to the position of the drain hole in the bottom of the processor biodiesel and glycerin begin to drain together and you want to minimize the mixing.
6. When the color becomes lighter than maple syrup continue to drain until the color becomes more golden.  Stop draining.  The biodiesel that drained with the glycerin will be recovered later.
7. Close the valve at the bottom of the processor.
8. Now open the valve above the pump and the valve to the left of the 4-way.  You want to drain the glycerin in this section before pumping the biodiesel into the wash tank.
9. Open the ball valve used to empty the glycerin.  You should only get a small amount.  When the flow stops, close this valve.
10. You have now drained the glycerin and some biodiesel and gotten ready to drain the biodiesel. Close the top of the cubie and set this aside.

Drain remaining biodiesel into the wash tank

1. You should now have the ball valve at the bottom of the processor closed, the ball valve to drain glycerin closed, the ball valve to the left of the 4 way open and the ball valve above the pump open.
2. Close the ball valve above the ‘T’ above the pump.
3. Open the ball valve at the bottom of the processor.
4. Now open the ball valve to the right of the pump that connects the wash tank.  Make sure that the ball valve at the base of the stand pipe in the wash tank is also open.
5. Gravity should allow some biodiesel to flow from the processor into the wash tank.  Turn on the pump to once the flow slows into the wash tank.  If there is no biodiesel above the top of the standpipe you might shot biodiesel out the top of the wash tank.

Fill wash tank with water.

1. Once the wash tank is filled with biodiesel, make sure to fill the wash tank with water up to the line on the side of the barrel.  If there is too much water that is OK.
2. To fill the wash tank connect the hose to the laundry faucet in the bathroom.
3. Close the valve on the hose to stop the water and turn the faucet on.
4. At the wash tank gently fill the wash tank to the appropriate height.

Start the bubbling 

Set the timer for 6 hours with the air bleed valve mostly open (gentle bubbling)

After wash tank timer has stopped and the biodiesel has had at least 30 minutes to settle, drain the water from the wash tank.  Fill the wash tank with water to the indicator line and start the process again.

First wash – 6 hours

Second wash – 4 hours

Third and forth was – 3 – 4 hours

Let final wash settle for at least 6 hours (to dry the fuel), then drain into finished tank.

Start the process again!