Increase of profitability of the enterprises on manufacture of diesel biofuel is directly connected with introduction of modern processes of deep processing grain rape and rapeseed the oils, allowing to receive the whole scale of the demanded accompanying products excluding, in turn, formation and expensive recycling of production wastes. The scheme of processes of complex processing of grain ðàïñà is presented on Illustration 1. Manufactures existing now on processing rape grain are limited basically to processes of preparation of grain to storage and processing, and also pressing of grain with reception crude rapeseed oils and rapeseed cake (oil meal). Crude rapeseed oil is delivered inside of the country for processing in oil refined food and in firm fats at specialized factories, and also appreciably taken out abroad as raw material for diesel biofuel. Thus the oil cake containing up to 40 % of a crude protein, up to 9 %-12 % of oil and up to 12 % of fibre, in the form of fodder additives is fed by an agricultural animal. The technology described above is practically without waste and not causing processsers special efforts in view of an available stable demand for oil and an oil cake. However profitableness of the given scheme of processing is limited to growth of cost of bought grain and low enough cost prices for the crude oil and an oil cake. And with an oil cake 9-12 % of the oil acting with initial grain are lost. Increase of profitableness due to increase in release of the refined food oil as has shown an expert, also is problematic, in view of a saturation of the market traditional food oils. At work in a home market the wholesale price for diesel biofuel, accordingly, should not exceed a level of the existing prices for mineral diesel fuel and to make the order 600 USD for ton that is comparable to a cost price of crude rapeseed oils. Thus cost of process of reception of a biodiesel engine much above cost of process of simple pressing. At mass production of diesel biofuel it is necessary to collide, at least, with three basic problems. First, it is necessary to deduce constantly from a crop rotation one cultures and to replace them by rape. In this case it is necessary to keep a sufficient forage reserve for agricultural animals and a bird. Mass application rapeseed an oil cake is problematic, as because of the high maintenance of fat it badly is stored, oxidized and quickly catches pathogenic microorganisms, is inclined to self-warming and burning at high humidity,incorporates toxic substances and rigid splinters of an environment of grains - husk which cause a toxicosis, the general frustration and damage of a gullet of animals at its strengthened consumption. Besides our researches on hydromechanical processing an oil cake have shown, that in it contains up to 30-32 % of besieged substances (husk, a weed and mineral impurity) which have no nutritional value. Thus, at a mass output of an oil cake its cost price even more will decrease, as manufacturers will be interested in its fastest selling in view of existing problems with storage, and demand will fall, as it not absolutely high-grade mass forage. So in Ukraine now retail demand on rapeseed the oil cake and oil meal practically is absent. Secondly, by manufacture of a biodiesel engine by a method transetherification of rapeseed oils by methanol at presence of the alkaline catalyst the toxic liquid withdrawal - a so-called glyceric phase (a mix of glycerin much methanol and by alkali) which makes up to 20 % from an output of a biodiesel engine is formed. By the legislation of the countries of manufacturers of a biodiesel engine now this withdrawal is not a subject to a usual burial place and burning, and should surrender for the further processing and recycling on special factories, or to be processed on safe products at the enterprise the manufacturer of a biodiesel engine. Necessity of neutralization and complex processing of toxic waste essentially increases the cost price of an end-product - a biodiesel engine, and also raises cost of construction a factory. Thirdly, at an existing price level on rape grain, methanol, alkali and mineral diesel fuel inside of the country, in view of enough expensive process of manufacture, work on a home market on diesel biofuel with sufficient profitability is problematic. One of the ways, allowing to create the highly profitable manufacture of a biodiesel engine working in the present conditions on a home market, application of complex technologies of processing rapeseed oil cake and production wastes of a biodiesel engine with reception of the accompanying products demanded by the market is.
On Illustration 2 and 3 are block diagrams of a factory on manufacture of a biodiesel engine from rapeseed oils and a factory on processing rapeseed oil cake, the realizing developed technologies are resulted. So, the technology of hydromechanical processing of an oil cake allows to return up to 90-92 % of an oil containing in it in a production cycle of reception of a biodiesel engine, extracts and to allocate water-soluble completely acquired fibers (rapeseed an albuminous concentrate (RBC) - 85 % of a protein, 14 % of a-moisture), and also to separate besieged impurity not having to food value – husk.
Further use of process of hydrolysis of vegetative raw material (straw) with the condensed albuminous whey and remained albuminose-oil cake paste, carrying out separation of fibers and homogenization of the received product allows to receive with a good output the standardized albuminose-vegetative forage (AVF)-12 % of a protein, 38 % fibers), fortified of calcium, assimilable phosphorus and magnesium. From 1 ton rapeseed oil cake probably to receive up to 80 kg of oil, 200-250 kg rapeseed albuminous concentrate, and also in a mix about 2700 kg of straw to make up to 3000 kg of albuminouse-vegetative mixed fodder.
The remained withdrawal – a powder of husk and the weed impurity, containing up to 20 % of a moisture, in quantity of 300-360 kg is used in a mix with straw and wood sawdust of coniferous breeds for manufacture of fuel granules (FG). The developed new technology of continuous process tranetherification of rapeseed oils methyl spirit at presence of the alkaline catalyst with functional blocking return reaction (FBRR process and FBRR-N process) guarantees a degree of transformation triglycerids the oils, 99.8 % equal not less, and also guarantees quality of the received methyl ether (RME) – a biodiesel engine, corresponding all parameters of European standard DIN EN 14214:2003. The samples of diesel biofuel made with application of our technologies and the equipment, have passed laboratory inspection on 22-nd parameters in laboratory of the Ukrainian scientific research institute of a petroleum-refining industry «MASMA» (Illustration 4), Official acknowledgement (all more than 10) are received, that the presented samples of methyl ethers rapeseed oils (RME) on all parameters correspond to requirements of the European specifications of standard EN 14214:2003. Motor tests of the diesel biofuel received by us for special installation in Research institute of technology ChNTU of an agriculture have been in addition in name of Vasilenko. Tests of work of the diesel engine in various extreme and critical modes have been lead. In the report, in section "Conclusions", it is noted: «Thus, bio-diesel, which is producing by "Technosoyuz Ltd" installation, have not shown any fluctuation or other ghost effects in oeration of engine. Values correspond to standards of bio-fuels, received from natural oil. This production may use as fuel for diesel engines.»
Studies have shown that one of the factors determining the quality of biofuels derived diesel, a preliminary deep cleaning oil hydration and special chemical refining. Designed oil cleaning process for the production of biodiesel (PROCESS 5-0), in conjunction with the main production technologies enables output methyl esters corresponding indices of modern foreign productions, that is, not less than 950 kg of biodiesel from 1000 kg of purified oil. This is a complex processing allocated fatty acids in the pre-eitherification methyl esters returning in the last production cycle, and the waste separation processes soap, pre-etherification and phase separation glycerine processed, emitting crystal monophosphate potassium and office crude 86-95% - of glycerol . Wet glycerin (WG), in the future, apply for the production of distilled glycerol (DG). Monofosfat potassium used for the production of integrated liquid mineral fertilizers (LMF). In the process of hydration crude oil press, in consultation with the customer may receive phosphatide emulsion on technical conditions of manufacturer or Rape phosphatide concentrate (RFC) Standard of Ukraine for 4526-2006. At Fig.5 submitted material balance diesel production of biofuels from raw pressed rapeseed oil with a comprehensive treatment of waste production.
Currently, different technologies and tested recipe rapeseed protein concentrate VEGAMIN ™ for food and feed purposes, as well as vegetable-protein fodder VEGAFIL ™ waste from the production of rapeseed protein concentrates for farm animals and poultry. A legal and technical documentation in the form of a compendium of recipes and technical conditions (17 recipes) for the root and leaf feeding on plants, liquid fertilizer complex ORGVITOL ™ monophosphate of potassium and wastes water - waste production of biodiesel. Clean and safe cooling agents HVG ™ for refrigeration and antifreeze new generation of cooling systems of internal combustion engines GLIKOSOL ™ made from glycerine and distilled Chemical Reactives edible use. They do not require special disposal after deep and can be used for cultivation in water 50-100 times even in the form of organo-mineral feeding and protective equipment – immunocyte-ophyt for plants. The draft in this regard is implementing the concept of road transport future - when the diesel engine using cleaner fuel Renewable biodegradable - rapeseed oil methyl ester, clean automobile antifreeze in the cooling system and clean braking fluid on the basis of distilled mixture of glycerol and poliglikols and depressor additives.
When the supply of technology and equipment provided to the customer at the same normative and technical documentation and formulas on the developed products, and also is allowed the right to release this production under the given above registered trade marks. In Illustration 6 is represented the version of the calculation of the annual turnover of the production of diesel biofuel and associated products from the grain of rape for the conditions of the domestic market of the Ukraine. When the claimed market for protein products is present, is ensured the high profitability of enterprise and the acceptable return on the capital expenditures with the wholesale selling price for biodizel from 600 usd for the ton.
