Innovative valve technology for sustainable fuel production
Green energy from waste oil and waste materials – safely controlled by SISTO valves from KSB: For modernising its biodiesel plant, TECOSOL GmbH has chosen valves that work reliably even under extreme conditions.
Green energy from waste oil and waste materials – safely controlled by SISTO valves from KSB: For modernising its biodiesel plant, TECOSOL GmbH has chosen valves that work reliably even under extreme conditions.
The project:
Modernising a TECOSOL plant under extreme conditions
In Ochsenfurt, located in Lower Franconia (Bavaria), TECOSOL GmbH is running one of Germany's most modern plants for producing biodiesel – a significant contribution towards the energy transition.
Process reliability, chemical resistance and durability were at the forefront of the company's decision to comprehensively modernise their plant and use KSB's SISTO valves, which are specially designed for demanding applications in the chemical industry.
They ordered numerous diaphragm valves with PTFE lining and TFM diaphragms such as SISTO-20 manually operated and actuated valves in various nominal sizes and SISTO-KB manually operated valves as well as swing check valves with ECTFE-coated bodies and CSM-coated valve discs: Solutions that ensure long-term sealing and reliability also when exposed to temperature fluctuations of up to 135 °C and aggressive cleaning agents.
Experts know the difference: Dr Heiko Kalpen trusts in SISTO valves by KSB.
The customer:
TECOSOL – Fuel innovation from Bavaria
TECOSOL GmbH has been producing biogenous fuels for motors, combined heat and power units and cogeneration plants since 2009, also including biodiesel to DIN standard as well as methyl esters and glycerines of various qualities.
This makes the Ochsenfurt site one of today's most progressive biodiesel production plants in Germany. A particularity of the modern plant is its multi-feedstock design: TECOSOL can process different raw materials, such as waste oils, waste materials and raw vegetable oils. This flexible raw materials mix reduces the share of fresh vegetable oils, enabling CO₂ savings of up to 80 percent. With this approach the company is making an important contribution towards the energy transition and a more sustainable fuel production.
The challenge:
Extreme conditions require maximum resistance
In TECOSOL's biodiesel production, extreme process conditions meet high quality requirements. The valves have be to able to handle aggressive fluids, such as methyl alcohol, potassium hydroxide, strong acids and fatty acid methyl esters (FAME). They also have to cope with temperature differences of up to 135 °C and pH values up to just above zero. With tight takt time schedules this may occur every two hours.
In other words, the valves have to meet quite a few preconditions:
- They have to be chemically resistant under extreme conditions: For reliable sealing, the materials used have to be resistant to the chemicals handled. This is where standard solutions often reach their limits very quickly.
- They have to be safe and reliable: A tight shut-off is decisive for smooth operation without leakage, process faults or even accidents.
- They have to be durable: Given the high load, system components with a long service life are needed. This reduces maintenance costs and prevents a loss of production.
- They have to be energy-efficient and process-optimised: To contribute to a sustainable and efficient system operation the valves used have to reliably reduce the energy input of the pumps.
This means, TECOSOL requires valves that remain tightly sealed, chemically resistant, reliable and efficient – also under the toughest of conditions. And this is exactly what SISTO was able to supply.
TECOSOL's biodiesel plant places the highest of demands on the valves used.
The solution:
SISTO valves from KSB provide maximum safety and efficiency
To satisfy the high demands in biodiesel production also in the long term, TECOSOL opted for valve solutions from KSB that are particularly suitable for handling chemical substances and extreme process conditions.
Compared to alternative solutions, SISTO offers TECOSOL some decisive benefits:
- Hermetic sealing: The unique design of our KSB valves reliably prevents fluid losses and ensures maximum tightness during operation.
- High chemical resistance under extreme conditions: The innovative technology and robust materials of the PTFE lining and TFM diaphragms offer a very high resistance to methyl alcohol, potassium hydroxide, sulphuric acid, methanesulfonic acid and biodiesel. The valves are designed for providing stability and functional reliability in the long term, also in extreme conditions.
- Long service lives and reduced maintenance intervals: The robust design increases the service life, and the modular system makes maintenance easier. This is how costs can be lowered and downtimes minimised.
- Optimised energy efficiency: Precise flow rate control helps optimise the energy consumption required for the pumping process.
- Process reliability through leakage prevention: The use of SISTO valves can clearly increase the operating reliability of the system.
This is noticeable in all process phases.
Even when used on a daily basis, KSB's SISTO valves are resistant to aggressive fluids and high temperature fluctuations.
Reliable valve technology for the entire production process
SISTO valves are used by TECOSOL for all key phases of biodiesel production – from pre-treatment to loading
- Chemical pre-treatment of raw materials
The plant processes waste oils, waste materials and vegetable oils that have first been pre-treated with aggressive cleaning agents such as acids and lyes. SISTO-20 manually operated and actuated valves provide hermetic sealing. - Transesterification and esterification
In the main reaction of biodiesel production, greases and oils or fatty acids are converted into biodiesel and glycerine by adding methyl alcohol and catalysts (e.g. potassium hydroxide or acids). These fluids are highly reactive and require reliable shut-off technologies. The PTFE-lined SISTO valves with hermetic sealing ensure maximum process reliability. - Separation and cleaning
For the subsequent separation and further processing of biodiesel and glycerine, strong washing liquids and chemical neutralisation agents are used. SISTO valves provide an absolutely tight shut-off, also for acids, lyes and solvents. - Final storage and loading
The finished biodiesel has to be stored safely and pumped into transport containers without any residues or contamination. Our valves provide the highest purity and safety during storage.
Figures I Data I Facts
Location: Ochsenfurt (D), Wittenberge (D) and Otrokovice (CZ)
Customer: TECOSOL
Application: Biodiesel plant
Products used
SISTO-20
Weir-type diaphragm valve to DIN/EN with flanged ends, threaded socket ends or socket weld ends, in straight-way pattern; shut-off and sealing to atmosphere by supported and confined diaphragm; body with coating or lining, position indicator with integrated stem protection. All moving parts are separated from the fluid by the diaphragm. Maintenance-free.
SISTO-KB
Diaphragm valve to DIN/EN with flanged ends, in straight-way pattern; shut-off and sealing to atmosphere by diaphragm; hydraulically favourable full bore body with coating or lining, position indicator with integrated stem protection. From DN 125 with threaded bush. All moving parts are separated from the fluid by the diaphragm. Maintenance-free.
SISTO-RSKS
Swing check valve to DIN/EN with flanged ends, short face-to-face length, straight-way pattern, full bore, body with coating or lining, slanted-seat design, static sealing to atmosphere; with soft rubber encapsulated pre-loaded valve disc featuring short travel to closure.