Biodiesel is an alternative fuel that can be used for home heating and diesel engines.  Typically derived from vegetable oil, biodiesel burns cleaner than petroleum-derived diesel fuel.  Emissions of pollutants that contribute to smog are reduced, sulfur emissions are eliminated, and fewer carcinogenic agents are emitted. In addition to these human-health benefits, biodiesel also has positive implications for reducing greenhouse gas emissions. For example, it emits almost 80% less carbon dioxide than petroleum diesel. Furthermore, because biodiesel is derived from biomass instead of fossil fuels, it recycles atmospheric carbon rather than releasing stored carbon (National Biodiesel Board).

In May of 2006, the Environmental Steering Committee at Shippensburg University proposed to implement a small scale (35 gallon capacity) biodiesel demonstration project. The project began with a strong interdisciplinary partnership between the Chemistry, Biology and Geography-Earth Science departments. This partnership has now expanded to include the Art Department. Active student involvement remains a cornerstone of the project. Dr. John Richardson (Chemistry), Dr. Todd Hurd (Biology), Dr. Claire Jantz (Geography-Earth Science) and Dr. Ben Culbertson (Art) are coordinating the project in conjunction with Andrew Nair, a Business major and active member of both the Student Environmental Action Coalition and the Environmental Steering Committee. Kyle Shenk, the Geoenvironmental student whose efforts started this project, has since graduated.

Implementation of a biodiesel demonstration project is especially timely. Because biodiesel is viewed as a viable alternative to petroleum diesel that addresses environmental issues as well as issues related to national
fuel security, national production of biodiesel has developed rapidly (Figure 1). Production is expected to increase under new federal programs supporting the development of alternative fuels. Pennsylvania is a leader in commercial-scale biodiesel production. In 2006, two new plants started production: the Agra Biofuels facility in Middletown and the Keystone Biofuels plant in Shiremanstown. With the expansion of the biofuel energy sector—including expanded career opportunities—it is imperative to educate students about this renewable energy technology.

Figure 1: Estimated U.S. biodiesel production. Source: National Biodiesel Board

Synergies

This project will result in multiple educational and research synergies. Because of the interdisciplinary partnership, student involvement with this project is maximized. Faculty in all four departments have expressed a strong interest and anticipate utilizing this project for multiple courses, ranging from introductory, general education courses to advanced courses.  Courses that would utilize the project include Problems of the Environment (BIO 145), Ecology (BIO 242), Conservation of Natural Resources (ESS 108), Land Use (GEO 244), Chemistry, a Cultural Approach (CHM 103), and Organic Chemistry (CHM 221, 222).

In addition to providing content for course curriculum and hands-on learning opportunities, the project can also support a variety of student research projects through the Miklausen-Likar Science Research Fund, the SU Undergraduate and Graduate Research Funds, and potential external funding programs. Relevant student research topics could include the quantification of the effects of washing the fuel, the impacts of oil quality on biodiesel fuel derivatives, or a cost-benefit analysis of using sodium hydroxide or potassium hydroxide in catalyzing the production reaction. These research topics are both appropriate for students and highly relevant for small-scale biodiesel producers.

Ben Culbertson (Art Department) possesses valuable expertise associated with his personal experience with small-scale biodiesel processors. In addition, Dr. Culbertson is pursuing the use of biofuels to fuel the kilns in the ceramics studio.

Finally, this project complements an ongoing effort to establish a Solar Scholars project at Shippensburg University, a program funded by the Sustainable Energy Fund of Central Eastern Pennsylvania. This program provides funding and technical support to establish demonstration solar panel installations at universities in Pennsylvania.  Dr. Tim Hawkins (Geography-Earth Science) is working in conjunction with the Pennsylvania Consortium for Interdisciplinary Environmental Policy to prepare an application for this program. With both solar panel and biodiesel installations, Shippensburg University would be a leader in the Mid-Atlantic region for renewable energy education.

Once in production, our processor will serve as an interdisciplinary educational tool for a number of classes across the disciplines of Geography-Earth Science, Biology, Chemistry, and Art. Additionally, it will be used as an outreach tool to attract talented students to Shippensburg University and will serve as a source of numerous student-faculty research projects.

References and websites

Agra Biofuels. http://www.agrabiofuels.com

B100 Supply. http://www.b100supply.com/

Keystone Biofuels Inc. http://www.keystonebiofuels.com/

National Biodiesel Board. Benefits of Biodiesel. National Biodiesel Board Fact Sheet. Available on-line at http://www.biodiesel.org/resources/fuelfactsheets/.

Methods, Approach and Progress to Date

            Our current project design is outlined in Figure 2 below, and traces the whole production cycle, from the source of the waste oil to biodiesel production to the end products.

Figure 2: SU Biodiesel project overview.

Through the efforts of Dr. Culbertson and Kyle Shenk, we have secured the support of Chartwells Food Service for their supply of used cooking oil. Dr. Culbertson has designed and deployed an oil collection system and Chartwells has consequently cancelled their grease removal contract. Nick Iula, the director of campus dining services, estimates that the elimination of the grease removal services is saving Chartwells approximately $100/month and gives his enthusiastic support to this project. Dr. Culbertson is responsible for oil removal and is currently processing some of this waste oil in a personal small-scale processor, but this waste oil supply will be available for the SU biodiesel project.

            We continue to work on the design of our biodiesel system and design safety and safe siting of the processor are our main concerns at this time. We have purchased an “Appleseed” biodiesel processing system from B100 supplies (see Figure 3 below). This is a complete system except for a steel hot water tank within which processing occurs. Tony Gardner, the Assistant Director for Utilities and Energy Management at SU, secured a commitment from Adams Electric to donate a hot water tank for this project. This system will produce biodiesel that meets ASTM specifications and, according to B100 Supply, is in use by thousands of individuals and institutions across the country. This system is very similar to the original system installed at nearby Dickinson College (see photos in Figure 4).

The SU Appleseed processor will consist of a 50 gallon water heater, which has the capacity of producing approximately 35 gallons of biodiesel per batch.  Safety is always a concern and must be taken into account at all times when handling the chemicals and in the process of making biodiesel.  The Appleseed processor is designed as a sealed unit, which keeps all hazardous fumes contained within the unit. 
            To produce biodiesel, heated (120 F - 50 C) waste grease is initially mixed with methanol (or possibly ethanol). In the presence of a simple catalyst (either sodium or potassium hydroxide) the alcohol will transfer fatty acids from the grease, producing a layer of fuel floating above a layer of glycerin. Titration of the oil is performed to determine how much of the catalyst will be needed to complete the reaction—the exact amount varies depending on the quality of the oil.  The catalyst is then added to the methanol to form methoxide. The methanol is generally 20% by volume, so a 35 gallon batch will require approximately 7 gallons.  The methoxide solution is then slowly mixed within the processing unit by means of an electric pump.  The mixing takes place for approximately an hour and then the oil is allowed time to separate.  Glycerin, the byproduct is formed on the bottom and unwashed biodiesel is formed on the top.  The glycerin is pumped from the bottom and separated from the biodiesel fuel. 
The biodiesel is then pumped to the washing tank (the black 55 gallon drum pictured in Figure 3) where it will undergo a series of washes to remove excess glycerin and other impurities.  This crucial step will ensure that the fuel is free from contaminants that could degrade a diesel fuel injection system. The wash water is then pumped from the bottom and disposed of properly.  Once the biodiesel is washed, it is pumped to a storage container where is will settle and then dried.  This is achieved by exposing the fuel to the air through means of pumping it through a showerhead, or similar device.  Finally the fuel is pumped to a final storage drum where it will receive filtration and tests to ensure quality standards.
            Siting of the processor represents a significant challenge for this project and we continue to work closely with Dave Wozniak and Lance Bryson to find a suitable location. We have confirmed with the Pennsylvania Department of Environment that a processor of this scale is not subject to any environmental regulations. We are presently working with Dave Wozniak to clarify the insurance requirements for the system, and are strongly considering siting the unit in a designated shed in a more remote area of campus. To gain a better understanding of siting and safety requirements, a group of interested faculty, staff and students visited the biodiesel installation at Dickinson College in January of 2007 (see photos in Figure 4 below).

Based on our experience at Dickinson College, we now have a much clearer vision of the requirements for siting the processor. We will require a site that is well-ventilated, has access to electricity and water, is in a low-traffic area, and can be secured. We must also be able to safely store quantities of waste grease, biodiesel fuel and reagents. Input, support and approval by Dave Wozniak and Tony Gardner have been critical for the planning of this project, and their continued input will be equally important for its success.
            Randall Nenniger, the facilities manager at Dickinson College, also explained that they have been using various concentrations of biodiesel fuel in their grounds equipment and other machines for roughly one year. To date, they have not experienced any problems. We anticipate providing fuel for the grounds equipment here at SU.
            An important outcome of our visit to Dickinson College is that we were able to build a stronger relationship with the biodiesel project coordinator, Matt Steinman. Prior to Dickinson College, Mr. Steinman started a biodiesel program at Wilson College. He has many years of expertise in small-scale biodiesel systems and is currently working closely with the DEP to develop safety guidelines for small-scale processors.  We anticipate working closely with Mr. Steinman as we develop our system, and he has agreed to provide his expertise when needed.  In particular, Mr. Steinman will be invited to inspect our system’s site and design for safety.
Glycerin is the primary byproduct from processing biodiesel. For each 35 gallon batch of biodiesel, roughly 7 gallons of glycerin is produced and we anticipate producing 35-105 gallons of biodiesel each semester. There are several potential uses for glycerin. Initially, faculty and students can use the glycerin to produce soap. Dr. Culbertson is currently pursuing the use of biofuels, including glycerin, for the kilns in the art department. Glycerin can also be composted, perhaps in collaboration with municipal or private composting of wood mulch (avenues that we are currently pursuing).
Future plans to expand the project will entail powering the heating element with a solar or solar/wind hybrid battery system (if feasible) or with an electric heating element powered by a biodiesel generator. We also eventually would like to mount the processor on a trailer for transport to other locations.  Once the production process is perfected, the university could consider designating at least one fleet vehicle to run on the produced biodiesel fuel.

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