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The overall major constraint for using castor oil as a feedstock for biodiesel is not its physical and chemical properties but the high price paid for castor oil as an industrial and pharmaceutical feedstock. Castor is a member of the Euphorbiaceae family that is found across all the tropical and semi-tropical regions of the world with the major producing countries being India, China and Brazil. Castor seed is typically planted about 1 ? to 2” deep in rows 2 to 6 ft wide depending on plant canopy size and type and harvest method.
Developing new cultivars that have desirable growth habits and canopy structure for mechanical harvesting will allow increased acreage. This work is supported by the USDA National Institute of Food and Agriculture, New Technologies for Ag Extension project.
Currently, one of the most common pretreatment methods is accomplished using steam explosion, but further advances and innovations in other pretreatment methods could diversify pretreatment options. Some of the newest pretreatment innovations involve the use of ionic liquids to break apart biomass into cellulose, hemicellulose and lignin.
Once pretreatment is complete, the temperature is increased, and the heat breaks down the solvent, forming butadiene and sulfur dioxide.
The next step in developing this pretreatment method will focus on optimization experimentation. Halfway across America, the JBEI in California is also developing an ionic liquid pretreatment. While work is being done to improve and research ionic liquid pretreatments, Leaf Energy Ltd.
Explaining how the pretreatment process works, Simmons says crushed bagasse from a sugar processor is churned with the glycerol in a chamber. Other recent developments, Richards notes, include processes to purify the used glycerol for reuse and to maintain lower costs.
Leaf Energy, JBEI and University of Illinois are all using different approaches to create digestible sugars, but all take aim at the same goal. Simmons believes the real challenge in biofuel production lies with inexpensive, sugar production from renewable, lignocellulosic feedstocks.
Advanced biofuel, such as cellulosic ethanol, could play a big role in the pressing carbon debates, says Richards.
When Pacific Biodiesel Technologies’ Big Island Biodiesel refinery came online last year, it was marketed as a state-of-the-art, zero-waste plant.
The 1.5 MMgy Newport Biodiesel in Rhode Island, which collects UCO and refines to biodiesel, has been tagged a zero-waste plant, and Nat Harris, founder and production manager, shares with Biodiesel Magazine how his plant made the journey from paying disposal costs to finding added value in its waste. Waste streams from glycerin refining include salts, which can be used as fertilizer (best) or landfilled (worst), fatty acids that can be esterified to biodiesel and glycerin distillation foots, which can be sold to the feed market (best) or landfilled (worst). While sustainability is powerful, the motivators for zero-waste production are purely economic. Plant optimization is very closely intertwined with the concept of being a zero-waste producer, as both aim to increase margins and decrease wastes. If a batch plant doesn’t want to move to continuous flow ultrasonics, though, Costello says, phase separate out the glycerin multiple times. Many plants have already optimized to become feedstock flexible, but for those that haven’t, strong consideration should be given to do so. Batch plant optimization differs from continuous flow plants by the sheer nature of its operations: repeatedly going full throttle and stopping. Mosali says one critical area where a lot of plants lose value is in lack of methanol recovery.
The tradeoff for better conversion is excess methanol in the reactors versus distillation capacity on the backend.
Ultimately, Costello says, when it comes to plant optimization, most people have done a lot of the obvious; therefore, new opportunities and benefits lie in the unobvious, and for that, many producers should call on the assistance of process technology experts to identify them.


Castor’s use is limited to some extent because the unprocessed seed contains a highly toxic protein—ricin.
There are two main types of castor plants-- giant (tree-like) and dwarf (tall shrubs), although crossing and breeding have resulted in a wide range of sizes and types (Figure 1).  Leaves are normally large, lobed and palmately arranged (Figure 2). Plant populations can range from less than 5000 to more than 25,000 plants per acre for large or dwarf types, respectively. Breeding ricin-free cultivars along with modified oil profile characteristics to enhance processing and use will overcome current limitations. In recent months, several breakthroughs and new approaches have been announced, one of which is organic solvent pretreatments with butadiene sulfone. Ionic liquids, or liquid salts, are being researched at both the University of Illinois at Urbana-Champaign and the U.S. De Frias says the most important advantage of this method is that the solvent’s recovery process is industrially available at mild to higher temperatures.
Unlike the University of Illinois’ butadiene sulfone method, the institute is utilizing imidazolium chloride with mixed feedstocks. What the researchers unexpectedly discovered was the mixtures performed better in pretreatment than single feedstocks.
Simmons hopes sugars produced from ionic liquids will be marketable within three to five years. Dissolved lignin and glycerol are then pressed out, leaving the cellulose and hemicellulose.
EPA certification to generate D3 renewable identification numbers (RINs) for cellulosic ethanol produced with Cellerate process technology. If the plant is processing used cooking oil (UCO), there are wastewater and solids to contend with.
The best avenue for wet methanol would be in-house rectification and reuse, followed by marketing to an external refinery or, as a last resort, disposal as hazardous waste.
He says typical return on investment  from biodiesel and glycerin methanol recovery is six to eight months.
However, the high viscosity may limit its use to lower percentages in biodiesel blends or to warm climates.
Castor is a perennial dicot plant that is monoecious (has separate male flowers and female flowers interspersed on a raceme-Figure 3). What the researchers discovered was the biomass did not solubilize, but instead developed similar physical characteristics of pretreated material.
During pretreatment, he explains, the solvent decomposes into 1,3-butadiene and sulfur dioxide at 90 to 110 degrees Celsius (194 to 230 degrees Fahrenheit). With its pretreatment technology, the institute is able to liberate 95 percent sugar yields from biomass in less than 24 hours, recovering roughly 95 percent of the ionic liquid. The biggest steps that need to be taken, he says, are more process engineering and scaling to minimize risks. The most favorable use of wastewater and solids from pretreatment of UCO, according to Smith, is anaerobic digestion, followed by composting and landfilling. But a fairly recent development in the past year or so has allowed Newport Biodiesel to turn that disposal cost into added value by selling its high BOD (biochemical oxygen demand) wastewater and food scraps from UCO pretreatment to an anaerobic digester in Maine. In-house recovery of unrefined glycerin to refiner’s crude grade is optimal, Smith says, followed by marketing it to a refiner, then anaerobic digestion, and finally disposal as a hazardous waste.
At Big Island Biodiesel, and the plants Pacific Biodiesel has built on the mainland, they produce glycerin that’s 85 percent pure.
I think the small producers are figuring out that they have small amounts of waste and it’s a good idea to do something with it, whereas on a large scale, those problems were already solved because they were such big problems that they have done something about it already.
The fruit is a globular spiny capsule with three multicolor (cream, brown, black, red) variegated seeds (Figures 4).


Conversion to biodiesel requires some modification of the standard transesterification process used for soybeans.
Improving the quality of the meal residue could make it useful as a livestock feed and enhance the economic value of the crop. Gums and foots are a side stream of oil degumming practices, and lecithin upgrading is preferred over selling direct to the feed market or, lastly, landfilling.
For saltwater and methanol from esterification, the best route, again, is in-house recovery and reuse or, as a second option, selling to an external refinery.
We think that’s the wrong thing to do because then you have a poor-quality crude glycerin.
What happens is, if you go with yellow grease versus corn oil from ethanol plants and animal fats, there’s a big fluctuation in the amounts of moisture and sediments that come in. In addition to the approximate 50% oil content, the seed also contains the toxic protein ricin, which must be removed. To Will Smith, engineering manager at Pacific Biodiesel responsible for process technology design and implementation at Big Island Biodiesel, being a zero-waste plant is not necessarily about being green or sustainable—although those attributes come as a nice added benefit.
Also, soapstock from caustic refining, spent bleaching clay and deodorizer distillate are more potential wastes generated from feedstock refining or pretreatment.
For water-wash plants, spent water can be recycled and reused in-house, anaerobically digested or, at least value, disposed via the sewer system.
He starts with the transesterification unit and works out from there, from the front to back. The best route for soapstock would be to split to acid oil and esterify to biodiesel; second is direct sale of acid oil to feed markets.
Once all that data is in-hand, plus knowing what feedstocks the plant will consume, they go one step at a time and develop a series of procedures required to optimize to perform at the specified volume. Spent ion exchange resins can be returned to the manufacturer for regeneration or landfilled, according to Smith, but Newport Biodiesel and its supplier have found another value-added use for spent resins. And depending on the feedstock utilized at a particular plant, there can be a multitude of varying waste streams generated from virtually every stage of the process. Lastly, the best option for deodorizer distillate is selling for vitamin E recovery, or sold directly to feed markets.
More methanol means better conversion, but more methanol means more energy to strip the methanol out of the biodiesel distillation column downstream.
Smith documented all possible waste streams from biodiesel processing and has developed a matrix he shared with Biodiesel Magazine identifying uses of those side stream waste products, from most to least favorable. When the resin is spent, the supplier takes the old resin and sells it to oil and gas drilling companies as hydraulic fracturing lubricant for wells. Pumps can decrease throughput for various reasons—additional piping or tees, or too much sediment in feedstock. Finally, still bottoms from the distillation columns can be used in-house as fuel for process heat and steam, or sold as heater fuel to outside companies.
QCCP expects to produce 1 million gallons of cellulosic ethanol in 2014 and 2 million gallons in 2015. Pacific Biodiesel’s Big Island plant employs distillation and uses its still bottoms to generate process heat and steam, helping offset the higher energy consumption of distillation.



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