Biodiesel Production Course

Lesson 1 • Biodiesel Product Specifications

Defines key quality parameters such as ester content, viscosity, and flash point. Establishes the quality targets that guide all production decisions.

Lesson 2 • Alcohol Selection and Properties

Compares methanol and ethanol as transesterification agents. Guides feedstock-alcohol pairing decisions throughout the course.

Lesson 3 • Fats, Oils, and Fatty Acids

Covers triglyceride structure, fatty acid chain length, and saturation levels. Builds the molecular foundation needed for all downstream processing decisions.

Lesson 4 • Transesterification Reaction Basics

Explains the core chemical exchange between triglycerides and alcohol. Connects reaction stoichiometry to yield optimisation in later chapters.

Lesson 1 • Virgin Vegetable Oil Feedstocks

Examines soybean, canola, palm, and sunflower oils as primary feedstocks. Connects oil composition to expected reaction performance and fuel quality.

Lesson 2 • Algae and Non-Food Feedstocks

Introduces microalgae, jatropha, and camelina as emerging biodiesel feedstocks. Positions these alternatives within a sustainable production strategy.

Lesson 3 • Feedstock Quality Testing Methods

Teaches laboratory methods to measure free fatty acid content, moisture, and impurities. Directly informs pretreatment and catalyst selection decisions.

Lesson 4 • Waste and Recycled Oil Feedstocks

Covers used cooking oil, animal fats, and trap grease as low-cost feedstocks. Highlights contamination challenges that require pretreatment before processing.

Lesson 1 • Moisture Removal and Drying

Addresses water content reduction through heating and vacuum drying methods. Prevents soap formation and catalyst deactivation during transesterification.

Lesson 2 • Degumming and Phospholipid Removal

Covers water and acid degumming to remove phospholipids from crude oils. Prevents catalyst poisoning and emulsion formation in downstream processing.

Lesson 3 • Acid Esterification of High-FFA Feedstocks

Teaches acid-catalysed pre-esterification to reduce free fatty acid content below 1%. Enables high-FFA feedstocks to proceed through alkaline transesterification.

Lesson 4 • Pretreatment Process Integration

Combines individual pretreatment steps into a coherent sequence for mixed feedstocks. Prepares learners to design complete pretreatment trains for real power stations.

Lesson 1 • Reaction Temperature and Pressure

Examines how temperature and pressure affect reaction rate and methanol recovery. Guides parameter selection for different catalyst and feedstock combinations.

Lesson 2 • Batch Reactor Systems

Covers batch reactor configuration, mixing requirements, and cycle management. Establishes the baseline production model before introducing continuous systems.

Lesson 3 • Reactor Monitoring and Control

Teaches instrumentation and control loops for real-time reactor management. Connects sensor data to process adjustments that maintain product quality.

Lesson 4 • Catalyst Dosing and Mixing

Covers catalyst preparation, dissolution, and injection into the reactor feed. Ensures uniform catalyst distribution for consistent conversion across the reactor.

Lesson 1 • Biodiesel Washing Methods

Teaches water washing and dry washing to remove residual soap, catalyst, and glycerol. Directly impacts final product acid number and ash content.

Lesson 2 • Gravity Separation of Glycerol

Covers density-driven phase separation of biodiesel and crude glycerol layers. Establishes the primary separation step before washing and refining.

Lesson 3 • Glycerol Refining Basics

Introduces crude glycerol purification through acidulation, neutralisation, and evaporation. Positions glycerol as a co-product that adds revenue to the operation.

Lesson 4 • Methanol Recovery and Recycling

Covers flash evaporation and distillation to recover excess methanol from both phases. Reduces raw material cost and prevents methanol in the finished fuel.

Lesson 1 • Core Biodiesel Quality Parameters

Reviews ester content, acid number, water content, and methanol limits as primary quality indicators. Ties each parameter to its effect on engine performance.

Lesson 2 • Cold Flow and Thermal Properties

Covers cloud point, pour point, and cold filter plugging point testing for cold-weather performance. Guides blending and additive decisions for seasonal markets.

Lesson 3 • Statistical Process Control in QC

Applies control charts and sampling plans to monitor production quality trends. Enables early detection of process drift before specification failures occur.

Lesson 4 • Oxidative Stability Testing

Teaches Rancimat and pressure vessel oxidation stability methods. Connects antioxidant treatment to storage life and fuel system compatibility.

Lesson 1 • Emergency Response Planning

Covers emergency action plans, evacuation routes, and incident reporting systems. Prepares operators to respond effectively to fires, spills, and injuries.

Lesson 2 • Standard Operating Procedures

Teaches SOP development, review, and enforcement for routine and non-routine tasks. Ensures consistent, safe execution of all plant operations.

Lesson 3 • Chemical Hazard Identification

Covers hazard properties of methanol, sodium hydroxide, sulfuric acid, and biodiesel. Establishes the hazard awareness foundation for all safety procedures.

Lesson 4 • Personal Protective Equipment

Specifies PPE requirements for each production area and chemical exposure scenario. Connects correct PPE selection to injury prevention outcomes.

Lesson 1 • Profitability and Feasibility Assessment

Applies net present value, payback period, and break-even analysis to biodiesel projects. Enables data-driven go/no-go investment decisions.

Lesson 2 • Equipment Sizing and Selection

Covers sizing reactors, separators, pumps, and heat exchangers for target production capacity. Connects equipment specifications to capital cost estimates.

Lesson 3 • Capital and Operating Cost Analysis

Builds capital expenditure and operating cost models for a biodiesel plant. Provides the financial framework for investment and pricing decisions.

Lesson 4 • Process Flow Diagram Development

Teaches construction of process flow diagrams and piping and instrumentation diagrams. Translates unit operations into engineering documents used for plant design.