Design and Performance Test of Biodiesel Reactor Using Helical Screw Agitator and Baffles PDF

IOP Conference Series: Earth and Environmental Science PAPER OPEN ACCESS You may also like - Solar irradiated and meta...

IOP Conference Series: Earth and Environmental Science PAPER OPEN ACCESS You may also like - Solar irradiated and metallurgical waste Design and performance test of biodiesel reactor catalyzed conversion of waste cooking oil to biodiesel using hellical screw agitator and baffles Abdul Majeed Khan, Sana Manzoor, Shazia Kalam et al. - Effect of commercial metals (Al, Cu, To cite this article: D Wulandani and Z A Ibrahim 2022 IOP Conf. Ser.: Earth Environ. Sci. 1038 carbon steel, and Zn) on the oxidation of 012024 soy-biodiesel L Díaz-Ballote, A Castillo-Atoche, L Maldonado et al. - A recyclable solid catalyst of KF/Ca-Mg-Al- O using for biodiesel production from View the article online for updates and enhancements. jatropha seed oil: preparation, characterization, and methanolysis process optimization Qinghong You, Xiulian Yin, Jun Wang et al. This content was downloaded from IP address 106.221.145.56 on 02/05/2024 at 07:55 AESAP-2021 IOP Publishing IOP Conf. Series: Earth and Environmental Science 1038 (2022) 012024 doi:10.1088/1755-1315/1038/1/012024 Design and performance test of biodiesel reactor using hellical screw agitator and baffles D Wulandani1 and Z A Ibrahim2 1 Department of Mechanical and Biosystem Engineering, Faculty of Agricultural Technology, Bogor Agricultural University. Indonesia. 2 PT Fiberhome Technologies Indonesia. Bandung. Indonesia. Abstract. Biodiesel reactor model using hellical screw agitator and baffles have been designed. The hellical screw type is chosen based on the agitation ability on viscous liquid with low energy, while baffles is purposed to generate homogeneous mixing. The objectives of the research was to obtained biodiesel reactor model and determined the best operation of reactor in producing biodiesel. Performance test of biodiesel reactor was done at 10 rotation speed levels of agitator, at range of 100 rpm until 1000 rpm. Biodiesel was produced by catalytical method, with 1.5 % w/w KOH catalyst at temperature ranging from 60 oC to 65 oC, for 60 minutes. The research obtained the model of cylindrical biodiesel reactor with the height of 300 mm and 168 mm diameter. The helical screw agitator has 4 screws and is equipped 4 baffles installed at the reactor wall. Based on the saponification value analysis, the biodiesel contained 99 % w/w methyl ester. The best operation of biodiesel production is resulted at 100 rpm which fulfil the quality standard of biodiesel and has the lowest energy consumption. Keywords: Biodiesel, Hellical, Speed, Reactor, Rotation, Yield 1. Introduction Biodiesel is a biofuel produced from transesterification reaction of oil and methanol. Indonesian country states issues regulation of biodiesel as fuel, where biodiesel have blended with diesel fuel which it namely B20. The largest utilization of diesel fuel in Indonesia is for transportation and industrial sector, which reached to 73 % of total energy demand. However, the availibility of diesel fuel is not enough to fullfill the demand. Biodiesel has opportunity to meet domestic needs. Moreover, biodiesel is environmentally friendly energy due to able to reduce CO and CO2 emission ,. That is mean that biodiesel production is necessary to be carried out and have promissing bussiness opportunity. Catalytical method is the most popular technique of biodiesel technology production. The method is considered more economic than non-catalytical method, although environmental impact of the production waste is still leaving another problem. Due to the immiscibility of oil and methanol, the production of biodiesel through catalytical transesterification reaction of oil and methanol require agitation absolutly. Design of agitator is important to mix briksly oil and methanol and to make sure that reaction occured completely. The propeller and turbin agitator type are commonly used for chemical reactor. Both of types often be applied for low viscosity liquid and needed high or medium energy. Dickey et al declared that hellical screw agitator often be used for high viscosity liquid with low energy. Ameur et al. obtained better performance for implementation of hellical screw Content from this work may be used under the terms of the Creative Commons Attribution 3.0 licence. Any further distribution of this work must maintain attribution to the author(s) and the title of the work, journal citation and DOI. Published under licence by IOP Publishing Ltd 1 AESAP-2021 IOP Publishing IOP Conf. Series: Earth and Environmental Science 1038 (2022) 012024 doi:10.1088/1755-1315/1038/1/012024 type agitator than hellical ribbon type agitator. Wulandani et al reported that turbulence and contact between oil and methanol was very important factor to speed up the rate of transesterification reaction. The turbulence could be increased by fixing baffles inside the reactor which is useful for breaking the flow and intesify the vertical velocity. Based on above statements, to accelerate the reaction rate of biodiesel and to save energy consumption of agitation, hence the hellical screw agitator and adding the baffles were used in the biodiesel reactor. The research aimed to design and to test the performance of hellical screw agitator and baffles applied within the model of biodiesel reactor. 2. Methodology 2.1. Material and apparatus Materials and apparatus used in the research is devided by two categories, first is for design and second is for performance test of reactor. 2.1.1. Design. The materials and apparatus needed were stainlessteel plate, holow iron, electric welding machine, grindstone, drilling machine, lathe, meter, vernier calipers, tachometer, thermostat, thecmocouple, thermorecorder, tool kits, electrical heater, electrical motor, etc. 2.1.2. Test Performance. Palm oil, methanol, KOH, indicator phenolphtalein (PP), isoprophyl alcohol, chemical glass apparatus, electrical balance, Ph indicator, stopwatch, etc. 2.2. Research flow diagram. The step of research follows the flow diagram (Figure 1). Design concept, functional analysis, structural analysis, and drawing the design Manufacturing Performance test (10 stage of RPM) Biodiesel Quality test (yield and methyl ester content) Recommendation Figure 1. Flow diagram of research 2.3. Functional Analysis The analysis is important to obtain that the components of reactor designed should have a function properly. The analysis is presented in Table 1. 2 AESAP-2021 IOP Publishing IOP Conf. Series: Earth and Environmental Science 1038 (2022) 012024 doi:10.1088/1755-1315/1038/1/012024 Table 1. Functional analysis NO The function expected Components 1 Container of the liquid Cyllindrical reactor 2 To mix and the liquid Hellical screw agitator 3 Conditioning turbulent flow Baffles 4 To provide power for stirrer Motor 5 Heating liquid Heater 6 Controlling temperature Thermostat 7 Controlling motor rotation speed Dimmer 8 To support of reactor Cantilever/frame 2.4. Structural Analysis The structural analysis is required to specify the dimension of reactor, agitator, strength of frame/cantilever of reactor, and power of motor. The analysis based on the equation (1) to (12). Wall thickness: 𝑦𝑝 𝑃𝑎 𝑟 𝜎𝑐 = = (1) 𝑆𝑓 ℎ where: c = allowable stress value (kg/mm2) yp = maximum stress value for stainless steel (Pa) Sf = safety factor Pa = Atmospheric pressure (Pa) r = radius of reactor (mm) h = wall thickness of reactor (mm) Dimension of hellical screw blade and the baffles follow the design depicted in Figure 2 which has developed by Aubin et al,. Dimension of hellical screw blade: lt/d = 1.45 (2) ct/d = ct’/d = 0.13 (3) dt/d = 1.1 (4) da/D = 0.18 (5) d/D = 0.64 (6) s/d = 1 (7) c/d = 0.06 (8) Note: D = diameter of cyllindrical reactor (m) d = diameter of blade (m) s = length of pitch (m) da = axis diameter (m) Dimension of baffles width (b): b = 1/3 d (9) 3 AESAP-2021 IOP Publishing IOP Conf. Series: Earth and Environmental Science 1038 (2022) 012024 doi:10.1088/1755-1315/1038/1/012024 Figure 2. Dimension of blade of hellical screw and baffles in the reactor Power of motor: Pm = S  N3 d 5 (10) Pm = power of motor (W) S = coefficient of power  = density of liquid (kg/m3) N = rotation speed (rpm) Power of heater: Q = m Cp (T2 – T1) (11) Ph = Q/ (12) Q = Energy of heater (J) Ph = Power of heater (W) m = mass of liquid (kg) Cp = Specific heat of liquid (J/kgoC) T1 = initial liquid temperature (oC) T2 = final liquid temperature (oC)  = time of reaction (s) 2.5. Experimental set up The biodiesel reactor was test by using 3 L of palm oil with mole ratio of oil and methanol = 1:6. Potassium hydroxide was added as catalyst which dissolved into methanol. Temperature of liquid was maintained at 60 oC to 65 oC. The experiment of biodiesel production was carried out in 10 value of agitation rotation, i.e. 100 rpm, 200 rpm, 300 rpm, 400 rpm, 500 rpm, 600 rpm, 700 rpm, 800 rpm, 900 rpm and 1000 rpm. Transeterification reaction is assumed to be completed at 60 minutes. Biodiesel produced from the transesterification reaction was separated from glycerol by sedimentation process. The catalyst remains within the biodiesel was purified using wet washing method by added warm water (60 oC) into biodiesel. To ensure that no catalyst left within the biodiesel, it is indicated by measuring that the waste water should have Ph value of 7 (neutral). Then the remain water within the biodiesel was evaporated. Quality test of biodiesel was perform by measuring saponification number, glycerol total, acid value, yield and methyl ester content. Methyl ester content was measured by using saponification value analysis. 4 AESAP-2021 IOP Publishing IOP Conf. Series: Earth and Environmental Science 1038 (2022) 012024 doi:10.1088/1755-1315/1038/1/012024 3. Discussion 3.1. Design of reactor Reactor biodiesel have designed and consisted the main components as follow, i.e., Cyllindrical reactor, hellical screw agitator, four baffles, electric heater, motor, temperature controller, motor rotation controller, and cantilever/frame of reactor. Base on equation (1) to (12), we found the dimension of reactor and it’s components. Biodiesel reactor tank capacity is 5 L of liquid, has diameter of 168 mm and height of 300 mm. Reactor rest on the hollow iron frame with dimension of 300 mm x 300 mm x 600 mm. Four baffles are installed vertically inside the reactor and fastened with bolt. A hellical screw agitator is assembled with axis in the center of cyllinder which powered by electrical motor. Considering to height of reactor, it can be designed 4 screws (2 peak of amplitudes) of blade along the axis. Electrical heater is located below the agitator. The specification of design is shown in Table 2. Table 2. The specification of reactor designed No Components Specification Materials 1 Cyllindrical reactor Diameter of 168 mm, Stainlessteel Height of 300 mm 2 Hellical screw agitator Diameter of blade 108 mm, Stainlessteel diameter of axis 30 mm, length of 190 mm 3 Baffles 4 pieces Stainlessteel Height of 160 mm, Weight of 12 mm, baffles aperture 5.4 mm 4 Motor 200 W 5 Heater 1000 W 6 Thermostat 7 Frame L= 300 mm; W=300 mm; H=600 Hollow iron mm The design has fulfilled the required criterias, where the reactor is designed for laboratorium scale. Reactor applied batch system. Reactans materials (oil, methanol and catalyst) are entered into reactor, and then reaction occurs. After the reaction completed, all of biodiesel could be taken out through the outlet valve on bottom of reactor. Reactor is designed with knockdown agitator system for ease replacement and maintenance of agitator. Feeding system utilizes inlet on the top reactor, whereas outlet of biodiesel system uses valve on the bottom of cone-shaped reactor, so biodiesel can flowing out easily and completely. Operation target of biodiesel production has been achieved, that is reactor could containing 5 L liquid with temperature controlled of 60 oC – 65 oC. Heating of liquid is supplied by 1 kW electrical heater and be controlled by thermostat. The thermostat is connected serial with heater. Heater could producing maximum temperature of 120 oC. Motor for agitator have power of 200W and supported by controller of rotation, hence the agitator rotation could be set from 100 rpm to 1800 rpm. The material of reactor, agitator and baffles are made of stainless steel, which is resistant to chemical reaction with strong base (KOH or Na OH). Reactor is placed on sturdy frame and could withstand the load (reactor and liquid) and vibration of motor shaft rotation. The reactor is support with AC electricity motor. The reactor designed is operated and maintained easily and savely. The biodiesel reactor and hellical screw agitator designed are shown in Figure 3 dan 4. 5 AESAP-2021 IOP Publishing IOP Conf. Series: Earth and Environmental Science 1038 (2022) 012024 doi:10.1088/1755-1315/1038/1/012024 Motor Inlet of liquid Controller Cyllindrical reactor Frame Outlet of liquid reactor Figure 3. Reactor of biodiesel Figure 4. Hellical screw agitator 3.2. Performance test and quality test 3.2.1. Liquid temperature distribution within the reactor. Temperature is the important factor influenced of reaction rate of biodiesel production. The optimal temperature is 60 oC to 65 oC, where methanol hasn’t reached yet its boilling point. Homogen temperature should be achieved to make sure that the reaction takes place completely throuhgout the liquid. Measurement of temperature was carried out at three position; top, middle and bottom of reactor at several stages of RPM agitation. Figure 5 shows the standard deviation value of temperature at all treatments. The standard deviation value of temperature very small with variation of 0 oC to 0.25 o C. Based on the result, the rotation of 100 rpm and 200 rpm indicates the homogeneous terperature (Figure 5 and 6). Agitation and baffles have important role to make the homogenity of temperature. The result meet with the statement of Kamla et al , that baffles insertion could getting more heat transfer area in large scale reactor tanks. Godlewska and Karcz have resulted that baffles generate radially axial circullation of liquid in the reactor. The statement agrees with Nelwan et al. as written above. This phenomena give result to uniformity of temperature. 6 AESAP-2021 IOP Publishing IOP Conf. Series: Earth and Environmental Science 1038 (2022) 012024 doi:10.1088/1755-1315/1038/1/012024 0.30 Standard of Deviaton 0.25 0.20 0.15 0.10 0.05 0.00 0 100 200 300 400 500 600 700 800 900 1000 RPM Figure 5. Standard deviation of liquid temperature at several stages of agitation 64 Temperature (C) 62 60 58 56 0 20 40 60 80 Time of reaction (minutes) top midle bottom Figure 6. Temperature distribution of liquid within the ractor at 100 rpm. 3.2.2. Biodiesel Quality. Biodiesel is produced by transesterification reaction of oil and methanol at the optimal temperature and agitation. Biodiesel quality standard refers to the Indonesian National Standard (SNI 7182:2015),. Quality parameters analyzed were yield of biodiesel and methyl ester content, acid number, total glycerol and saponification number. All of treatments have total glycerol of 0.28 %. This value isn’t match with standard of biodiesel (< 0.24 %), except of total glycerol of treatment 100 rpm has required standard of biodiesel of 0.12%. Acid value of biodiesel have qualified (< 0.4 mg KOH/g) i.e., 0.06 mg KOH/g to 0.12 mg KOH/g for all treatments, except at 1000 rpm obtained 0.9 mg KOH/g. 3.2.3. Yield of biodiesel and methyl ester content of biodiesel. Base on the experiment result, the yield of biodiesel is in the range of 80% (at 1000 rpm) until 92% (at 200 rpm) as depicted on Figure 7. No special pattern of yield graph obtained in all experiments. The result appropriate with another researchers, that for certain type of agitator and combination of treatments, there was an optimal rotation; Hasan et al. has obtained 600 rpm; Miskah et al. got the best agitation of 750 rpm for propeller type of agitator. However, for spinning disc reactor, Wen and Petera found at agitation of 2000 rpm gave the best result of biodiesel quality. This can be explained that spinning disc have an agitation only at the bottom of tank, so fast rotational speed is needed to enhances mixing among reagents by generating high shear forces, then eliminates transport resistance. 7 AESAP-2021 IOP Publishing IOP Conf. Series: Earth and Environmental Science 1038 (2022) 012024 doi:10.1088/1755-1315/1038/1/012024 94.0 92.0 90.0 88.0 Yield (%) 86.0 84.0 82.0 80.0 78.0 76.0 74.0 100 200 300 400 500 600 700 800 900 1000 RPM Figure 7. Yield of Biodiesel of all experiments According to biodiesel standard in Indonesia , methyl ester content should be more than 96.5 % (SNI 7182:2015). All experiments obtained methyl ester content of 99%, which have macthed with the SNI requirement. By considering of quality of biodiesel, the best of rotation speed for helical screw agitator was 100 rpm. The biodiesel produced at 100 rpm have qualified to SNI, especially of content of total glycerol. Another rotation speed not fulfil the SNI requirement. The presence of glycerol in the biodiesel isn’t expected due to influence to engine performance when biodiesel applied. Furthermore, the implementation of rotation speed 100 rpm, could save energy consumption instead of high rotation speed. 4. Conclusion Design of biodiesel reactor using helical screw and baffles have been conducted as well as experiment of its performance test. Reactor consists of cylindrical tank, helical screw agitator, 4 vertical baffles which installed on the inside wall of reactor. Reactor is equipped with motor (200 W), heater (1000 W) and controller. The tank is supported on the sturdy frame. The capacity of reactor is 5 L, and it have overall dimension of 300 mm length, 300 mm width and 600 mm height. The agitation and heating controlling system have managed the temperature of liquid within the reactor homogenly and keep at constant value. All experiments have reached the desired target of methyl ester content of 99%. The best operation of agitation rotation is 100 rpm which meet with SNI requirement of methyl ester content (99%), total glycerol of 0.12%, acid value of 0.09 mg KOH/g and yield of biodiesel of 89% 5. 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Nelwan O L, Wulandani D, Hartulistiyoso E, and Purwanti N. 2015 Dasar Teknik Proses Biosistem. (Bogor (ID) : Departemen TMB-IPB) Aubin J, Naude I, Bertrand J, Xuereb C 2000 Blending of Newtonian and Shear-Thinning Fluids in a Tank Stirred With a Blade helical screw. Institution of Chemical Engineers: Trans I Chem E, 78, Part A Kamla Y, Bouzit M, Arab M I, and Hadjeb A 2017 Effect of the Inclination of Baffles on the Power Consumption and Fluid Flows in a Vessel Stirred by a Rushton Turbine Chinese J. of Mechanical Engineering 30 pp 1008-16 Godlewska M M and Karcz J 2018 An effect of the tubular baffles configuration in an agitated vessel with a high-speed impeller on the power consumption. Chemical Papers (Cross Mark. Springer ) 72 pp 2933–43 Anonymous 2012 BSN-Badan Standardisasi Nasional Standar Nasional Indonesia (SNI) Nomor: 04-7182:2012 tentang Biodiesel. (BSN. Jakarta) Hasan A A M, Mashkour M A and Mohammed A A 2017 Impact of mixing speed and reaction time on biodiesel production from sunflower oil Journal of Engineering Sciences 3, 24 pp 127- 134 Miskah S, Apriani R and Miranda D 2017 Pengaruh Waktu Reaksi Dan Kecepatan Pengadukan Terhadap Konversi Biodiesel Dari Lemak Ayam Dengan Proses Transesterifikasi Jurnal Teknik Kimia 1, 23, Januari 2017 pp 57-66 Wen Z and Petera J 2015 CFD numerical simulation of biodiesel synthesis in a spinning disc reactor Chemical and Process Engineering 36 (1) pp 21-37 Sahirman, Suryani A, Mangunwidjaja, Sukardi, Sudradjat R 2008 Pengujian Sifat Fisiko-Kimia, Kinerja dan Pengaruh pada Mesin terhadap Biodiesel dari Minyak Biji Bintangur (Cailophylum inopylum). Seminar Nasional Hasil Penelitian. (Bogor, 19-20 Agustus 2008) Acknowledgments Authors would kind to present appreciation to student and technicians for assistance and support in the research. 9