12/09/2013
Biofuel Production & Implementation
Feasibility Study
A Proposal for Calvin College
Presented By: Engineering 333 & Business 380
1
What would it take to operate a biofuel vehicle
using only on-campus resources?
Transportation
Processing
Plant
Feedstock
12/09/2013
Project Objective
Biofuel Vehicle
Application
Waste
2
Technical
Feasibility
•
•
•
•
Fuel Selection
Vehicle Selection
Facilities Selection
Future Planning
Messaging &
Communication
•
•
•
•
•
•
Students
Prospective Students
Faculty/Staff
Alumni/Community
Donors
Decision-Makers
12/09/2013
Project Segmentation
3
Resources
• Prof. Thomas Betts – Business Department
• Mr. Phil Beezhold – Physical Plant Director
12/09/2013
• Prof. Matthew Heun – Engineering Department
• Mr. David LaGrand – Local Biofuel Producer
• Mr. Geoffrey Van Berkel – Physical Plant Grounds
• Mr. Rick Balfor – Dining Services
• Mr. Rich Huisman – Chemistry Department
• Mr. Henry Kingsma– Physical Plant Recycling
4
12/09/2013
Fuel Production and Feedstock
Presented by: Claire Philippi
5
12/09/2013
Fuel?
Processing?
6
Feedstock
Vehicle Application
12/09/2013
Fuel Options
Image source: nationalgeographic.com
Methane
Image Source: biodieselchemist.webs.com
Biodiesel
Image Source: baconsrebellion.com
Ethanol
Image Source: zombiehunters.org/wiki
Vegetable Oil
7
Feedstock
Vehicle Application
12/09/2013
Fuel Quality
Fuel Clarity
Image Source: journeytoforever.org/biodiesel_svo
Acidity
Image Source: titrations.info
Vehicle Application
8
12/09/2013
Filtration Methods
Image Source: filterbag.com
Image Source: threedeadflies.com
Image Source: wvodesigns.com
Vehicle Application
9
Costs
• The Upfront Component Costs:
Total:
$1494
$ 428
$ 50
12/09/2013
• Centrifuge and heating source:
• Settling tanks:
• Filter and screens:
$1972
• Monthly Operating Costs:
• Filters & Screens
• Heat
$ 4
$ 10
10
Vehicle Application
12/09/2013
Facilities & Infrastructure
Presented By: Karl Bratt
11
12/09/2013
Where to Process?
How to Process?
Vehicle Application
12
WVO Processing Location
12/09/2013
Physical Plant Warehouse
Vehicle Application
13
Shelving
12/09/2013
Industrial Racking System
Vehicle Application
14
Heating
12/09/2013
Existing Heater & Heating Tape
Vehicle Application
15
12/09/2013
WVO Storage
Image Source: www.automotivetools.com/Liquidynamics
Image Source: www.disasterstuff.com
Image Source: www.amazon.com
Vehicle Application
16
Process Design
12/09/2013
Rigid, Parallel System
Wait 1
Month…
*120 Sq. Ft
Vehicle Application
17
Raw WVO Transportation
12/09/2013
Recycling Truck
Vehicle Application
18
12/09/2013
Compost
Vehicle Application
19
Costs
• Upfront Component Costs:
Pipes Pipe Connectors:
Calvin Physical Plant labor:
Valves & Actuators:
Electronic Components:
Total:
$ 1,200
$ 600
$ 428
$ 185
12/09/2013
•
•
•
•
$2,413
• Monthly Operating Costs:
• Student Labor (Year 1):
• Student Labor (Year 2):
$ 450
$ 150
Vehicle Application
20
12/09/2013
A Biofuel Vehicle
Presented by: Mike Houtman
21
12/09/2013
What Vehicle?
How to Convert?
Vehicle Application
22
WVO Conversion
Diesel Engine
Image source: Dieseltronics
WVO Purge
5 Microns
Image source: WVO Designs
Image source: Greasecar.com
160°F
12/09/2013
WVO criteria to be met:
Image source: Glow Shift Direct
Vehicle Application
23
Vehicle Yearly Usage (hours)
12/09/2013
2670
1072
200
Lawn
Mower
Leaf
Blower
Front
Loader
100
200
Lift
Tractor
50
20
Dump
Truck
John
Deere
24
12/09/2013
2006 Toro GROUNDSMASTER 4000-D
25
12/09/2013
Previous Experience
26
12/09/2013
Vendors
27
12/09/2013
Kits Available
Image source: Greasecar.com
28
12/09/2013
Image source: Greasecar.com
29
12/09/2013
WVO Tank Location
WVO
Tank
30
Controller
12/09/2013
Image source: Greasecar.com
31
WVO Tank
12/09/2013
Controller Location
32
• The purchased equipment costs of this system derive from:
•
•
•
•
Greasecar WVO kit:
Greasecar “Co-Pilot” controller:
Calvin Physical Plant labor:
Insulating tank cover:
Total:
$1595
$ 300
$ 360
$ 40
12/09/2013
Costs
$2295
33
12/09/2013
Long-Term Planning
Presented by Brandon Koster
34
Possible Expansion?
CERF Involvement?
12/09/2013
Mower Maintenance?
Educational Outcomes?
35
12/09/2013
Fuel Injector Maintenance
Image Source: www.standardbrand.com
Image Source ecx.images-amazon.com
36
12/09/2013
Fuel Filter Maintenance
Image Source: www.vw-resource.com
37
12/09/2013
Engine Oil Analysis
Image Source: www.rockingsconsulting.com
38
12/09/2013
Testing Period
Image Source : bestclipartblog.com
39
Campus Safety Vehicle
Transportation Van
12/09/2013
Additional Vehicle Options
Image Source: vimeo.com
40
New Vehicle Selection
12/09/2013
2002-2006 Dodge Sprinter Van
http://mbgtown.files.wordpress.com/2010/10/2008-sprinter-passenger-van-0061.jpg
http://www.moibibiki.com/images/dodge-sprinter-4.jpg
41
12/09/2013
New Feedstock Sources
http://1.bp.blogspot.com/
http://farm4.static.flickr.com/3201/2409592844_f382ca64a7_o.jpg
42
12/09/2013
CERF Integration: Capital Funding
43
12/09/2013
CERF Integration: Internship Program
http://www.chamaschools.org/wp-content/uploads/CLIPART_OF_32162_SMJPG_2.jpg
44
Engineering
101
Fridays at
Calvin
Annual
Seminars
Prelude
12/09/2013
Educational Integration
45
12/09/2013
Possible Senior Design Project:
Automating the Production System
Two Electrical
Concentrations
One
Mechanical
Concentration
One Chemical
Concentration
46
• The monthly ongoing maintenance costs:
•
•
•
•
1 hour Physical Plant Mechanic Time:
Fuel Injector Additive:
Fuel Filter:
CERF Intern
Total:
$
$
$
$
45
16
15
180
12/09/2013
Costs
$221/month
47
• Fuel Processing Costs:
• Vehicle Conversion Costs:
• Infrastructure Costs:
Total:
$ 1,972
$ 2,295
$ 2,413
12/09/2013
Upfront Capital Costs
$6,680
48
• Fuel Processing Costs:
• Vehicle Conversion Costs:
• Infrastructure Costs:
Total:
$
$
$
14
221
150
12/09/2013
Monthly Operating Costs
$ 385
49
Total Cost Analysis
Breakeven (w/ Student Labor)
Diesel vs. WVO
$40,000
12/09/2013
$35,000
$30,000
Cost
$25,000
$20,000
$15,000
Diesel
$10,000
$5,000
WVO (Centrifuge)
$-
1
2
3
Year
4
5
6
50
12/09/2013
Proposed Timeline
Fall 2014
Summer
2014
Construction
Senior
Design
Automation
& WVO
Collection
Winter
2014/15
Spring 2015
Mower
Conversion
Begin
Operation
51
• Practically Feasible?
• Economically Feasibility?
• Environmentally Feasibility?
YES
YES
YES
12/09/2013
Feasibility
52
12/09/2013
We recommend that Calvin operate one
mower on WVO beginning April 2015.
53
Thank you for your time…
12/09/2013
Questions?
54
12/09/2013
Appendix
55
Operating Procedure
• The system must be started on diesel and the “Co-Pilot” will assist
the operator in the fuel switch over
• Process takes approximately 5 minutes
• System flush
12/09/2013
• WVO temperature
• System must be flushed with diesel before final shut-down
• Process takes less than 1 minute
• Fuel Usage
•
•
•
•
The tank must be routinely at capacity to prevent air in the lines
The tank must not be stored with WVO throughout winter
The tank must be cleaned and inspected to prevent polymerization
The fuel must be treated with additives to prevent bacterial growth
56
Total Cost Analysis
Breakeven (w/ CERF Grant)
CERF Grant vs. No CERF Grant
$40,000
12/09/2013
$35,000
$30,000
Cost
$25,000
$20,000
$15,000
$10,000
Diesel
No CERF Grant
CERF Granr
Grant
Breakeven Point: August 2015
$5,000
$-
1
2
3
4
5
Year
57
12/09/2013
Tank Insulation
58
• Fuel savings
• 1300 gallons of
diesel
12/09/2013
Yearly Savings
• Cost savings
• $4,000 of
purchased diesel
59
12/09/2013
Hardware Locations
Image source: Greasecar.com
60
12/09/2013
Temperature Concern
WVO
Tank
Vehicle Application
61
Yearly Lawnmower Usage
(hours/model)
630
360
Mower 1 (4700D)
Mowers 2&3 (4000D)
12/09/2013
1680
Mower 4 (3280D)
62
12/09/2013
Temperature Solution
Image source: Zoro Tools
63
12/09/2013
Controller Location
64
Presentation Outline
Transportation
Fuel
Source
After:
Processing
Plant
Biofuel Vehicle
Vehicle
Application
12/09/2013
Before:
Waste
65
Process Design
12/09/2013
Rigid, Parallel System
66
Tank Dispense
12/09/2013
Two Outlet, Float Dispense
Image Source: www.vegoilcar.co.uk
67
Total Upfront Costs = $6,850
Cost
Quantity
Total Cost
Greasecar
Calvin Physical Plant
$
$
1,895.00
60.00
1
8
$
$
$
1,895.00
480.00
2,375.00
Facilities & Infrastructure Team
Raw Power Centrifuge
Centrifuge Bolt-on Heater
275 gallon IBC Tote
Duda 110 Gallon Cone Tank
25gpm Industrial Oil Transfer Pump
2" PVC Piping (per foot)
PVC Schedule 40; 2" Ball Valves
Ball Valve Actuator
Male/ Female Connectors
PVC 90 Degree Joints
600 Micron EZ Strainer - 55 Gal
Heating Tape ($/ft)
Uniseal for 2" Pipe
Installation Time
Floats
Tubing (33ft)
Manual Trigger Nozzle
Light switches
250 ft Wire
Plug
AC to DC converter
1/4" Ready Fuel Hose ($/ft)
Facilities & Infrastructure TOTAL
WVO Designs
WVO Designs
Craigslist
DudaDiesel
WVO Designs
Lowes
Lowes
MegaHobby
Lowes
Lowes
Amazon
ACE Hardware
Tank Depot
Calvin Physical Plant
Walmart
WVO Designs
AdBlueOnline
Lowes
Lowes
Lowes
Lowes
Delcity
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
1,197.00
297.00
30.00
188.00
350.00
2.04
14.85
15.50
2.60
15.00
50.00
1.67
5.00
30.00
12.60
60.00
44.00
0.69
63.24
4.34
31.90
1.08
1
1
8
1
2
150
13
11
7
12
1
24
4
20
4
1
1
8
1
1
1
15
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
1,197.00
297.00
240.00
188.00
700.00
306.00
193.05
170.50
18.20
180.00
50.00
40.00
20.00
600.00
50.40
60.00
44.00
5.52
63.24
4.34
31.90
16.20
4,359.67
$
6,850.35
Total Upfront Cost:
12/09/2013
Vendor
Vehicle Team
Lawn Mower Kit
Installation Time
Vehicle TOTAL
68
Student Worker Wages
Additional Preventive Maintenance Labor
Fuel Filters
Fuel Injector Cleaner
Cost of Industrial Space
Energy
Calvin College
Calvin Physical Plant
Greasecar
Ryder Fleet Products
Calvin College
Consumers Electricity
$
$
$
$
$
$
10.00
60.00
15.00
8.00
4.00
5.00
14
1
1
2
120
1
$
$
$
$
$
$
140.00
60.00
15.00
16.00
480.00
5.00
Total Operating Cost:
Total Operating Cost Less Sunk Costs
$
716.00
$
236.00
Total First Year Costs
Total First Year Costs Less Sunk Costs
$
15,442.35
$
9,682.35
12/09/2013
Operating Costs = $236/month
69
Valve Design
12/09/2013
Actuator Controlled Valves
Image Source: www.praher-valves.com
70
Valve Design
12/09/2013
Actuator Controlled Valves
71
Transportation Van Cost Analysis
12/09/2013
Result: 1.5 year payback time
Thousands
Transportation Van Payback
$10.00
$9.00
$8.00
Dollars Spent
$7.00
$6.00
Diesel Cost
$5.00
WVO Cost
$4.00
$3.00
$2.00
$1.00
$May-13
Nov-13
Jun-14
Dec-14
Jul-15
Jan-16
Aug-16
Mar-17
72