Innovative Biodiesel Project: Week 2

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Our second week was extremely productive! Ryan started to feel a lot better on Monday thanks to the antibiotics and we organized a work schedule with Tyler’s gardeners, Rigo and Ivan. From Tuesday to Friday, we would start working at 7am and finish at 5 or 5:30pm. Ryan and I have been able to surf at sunset everyday, which is perfect for washing off all the dirt and grime. See our progress throughout this past week by scrolling through the photos. In case you missed the update from Week 1, click here. We picked up more construction materials on Monday and laid out our plans for the week. This is what the project site looked like before we began construction: innovative-biodiesel-project-week-2-(1) On Tuesday, we measured the size of the shelter and began digging the 2 foot deep post holes.

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Me playing in the dirt.

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Ryan cleaning and repurposing the old water heater. We flushed it with water and small amounts of muriatic acid, then we used some of the biodiesel from out little Fanta bottle to finish the job.

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Tyler’s guard dog and our construction site companion, Fiddie.

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We have been collecting fruit scraps from the Casa Tucan and Kaya Sol daily for ethanol fermentation.

Wednesday, Rigo brought all the teak we needed for the shelter, which is sustainably harvested from a local plantation in Nosara (apparently teak grows like a weed here – 2 out of the 3 species of teak are endangered, but not the one we are using). First we had to de-bark all the teak, which is no joke – you smack the bark until it becomes loose and then pull it off. My hands were done at the end of the day:

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Before
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After

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Smack, smack, smack.
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We will let all the bark dry completely and then use it for biochar.

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IMAG0105 After placing the six teak posts in the ground and securing them by compressing dirt and rocks in each hole, Ryan and I went to Kaya Sol to collect 15 gallons of used cooking grease! Thanks Jorge and everyone at Kaya Sol!

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Ryan using a Harbor Freight hand-pump to pump the grease out of Kaya Sol’s 50 gallon drum into a 5 gallon “pechinga.” The restaurants receive their fry oil in these pechingas and we reuse them for WVO collection.

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Pouring WVO through the metal screen filter into our 450 liter collection tank to catch all the crud we don’t want.

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The aftermath… these scraps are used in our compost pile.

innovative-biodiesel-project-week-2-(26) Our little bottle of “Fanta” biodiesel from last week is now completely settled and crystal clear with the glycerine byproduct settled at the bottom (click here or on the image to read Ryan’s DIY instructions for making biodiesel at home). Glycerine has been on my mind a lot lately… let me explain. Seeing local schoolchildren and families smothered by dust when cars zoom by bothers me immensely, and after talking to some of the surf instructors and other locals, I’m not the only one who feels this way. I was reminded of this problem Thursday morning when I saw molasses being poured all over the road (see image below), which is how the town currently keeps the dust to a minimum. However, this process is expensive, smelly and sticky (pieces of it are launched from car tires that drive by – my legs were covered). We want to use glycerine instead because it is hygroscopic, meaning it absorbs moisture from the air. When mixed with water, we can spray it on the roads to keep the dust down without leaving pungent odors and gooey textures. Since glycerine is a natural byproduct of producing biodiesel, its significantly cheaper than molasses. We know this solution is not available right now, but in the near future we want to collect glycerine in mass amounts and use it to solve this health issue for the community.
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Molasses… not for long!

Thursday, we began building the framework for the roof of the shelter and Ryan continued to prepare the water heater for the “greasercycle” pump.
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Securing the tin sheets for our roof to Rigo’s truck.

We were hoping to use the old tin sheets that make up the fence separating the Casa Tucan from this hideous apartment complex that has been sitting unfinished for six years, but the tin is rusty and littered with holes. The group who purchased the Casa Tucan also purchased this space and is tearing down the complex completely (see image below): innovative-biodiesel-project-week-2-(23)
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The beginnings of the roof.

We finished the structure for the roof on Friday and we will install the tin sheets on Monday. innovative-biodiesel-project-week-2-(27)

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Rigo securing the lateral posts with metal wire… he’s 50 and killing it.
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Without him and Ivan, the shelter would have taken another week.

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Ivan will most likely be our trainee for producing biodiesel.

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Almost there…

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Ryan decided that the “Apple Turnover” design would be most appropriate for our water heater because there is too much space between the valve and the bottom of the tank – some of the biodiesel would be stuck at the bottom. Its basically just an inverted Appleseed system. Click here to learn more about the benefits of this system.

Additionally, we are testing a smaller, cheaper and easier to use pump (see image below) than the traditional 1.5 horsepower electric water pump ($90) that you connect to a bicycle to mix the chemicals and grease to make biodiesel. Ryan installed a drill chuck on to a heavy duty drill bit pump (Harbor Freight – $15) that we can hook up to Tyler’s beach cruiser (we’ll test our new design Monday or Tuesday).
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New pump with drill chuck attached.

See what other cool things people are doing with bicycle pumps all over the world (click closed captioning “CC” for subtitles):

I had sent out an email earlier in the week to all the restaurants in Nosara explaining our project and that we would like to start collecting their grease and fruit scraps. Beach Dog Cafe and Cafe de Paris have joined the program and it looks like we’ll have Rancho Tico as well. On Saturday, I went to collect grease and fruit from Beach Dog Cafe and the owner, Mike, was really helpful. Fabian from Cafe de Paris, will notify us when he has more grease because he currently has less than a liter. Thanks for the support! The methanol and lye arrived on Saturday as well. After collecting all the fruit from the past week, we will be ready to start ethanol fermentation on Monday. Once the 120 gallon drum is half full with fruit, we fill it with water to 3/4 full and add yeast – let it sit for two weeks and then we’ll have ethanol! We should have the roof finished tomorrow as well as the other parts to the biodiesel system… we will be ready for production by mid-week! Ryan and I are presenting at Nosara Sostenible’s weekly meeting tomorrow to talk about our project and hopefully rally more support from the local businesses who are passionate about sustainability. See you next week!
Jump to “Week 3.”

Innovative Biodiesel Project: Ryan’s DIY Kit

If you’re interested in learning how to make your own biodiesel the first steps are simple and easy; don’t jump right into building a processor, titrating waste oil, processing big batches, and risking producing poor quality biodiesel. Start out with a 1 liter “test batch” using new vegetable oil to learn the basic chemistry – there’s little risk and you’re almost certain to end up with good results! Familiarize yourself with this tutorial so when we publish our designs and instructions for the “Innovative Biodiesel Project,” you’ll be good to go! – Ryan King.

Safety first:

Your 2 primary reagents are lye and methanol – learn how to store, handle, and work with these chemicals in small amounts before moving on to large quantities.
KOH and NaOH (both referred to as lye) are caustic and must be handled with gloves. Breathing masks are recommended when handling large amounts of lye – if the dust is inhaled, it can burn the nasal passageway and respiratory system. Lye reacts with aluminum, tin and zinc. Use HDPE (High-Density Polyethylene) or #2 plastic, glass, enamel or stainless steel containers for lye and methoxide. Lye is also hygroscopic, meaning it absorbs moisture from the air. Care must be maintained during storage and weighing to avoid prolonged exposure to open air. Lye containers must be airtight, and weighing should be performed quickly in a dry, safe location.
Methanol is also hygroscopic and must be stored in air tight containers. Methanol has a high toxicity in humans. If as little as 10 mL of pure methanol is ingested it can break down into formic acid, which can cause permanent blindness. As little as 30 ml of ingested methanol is potentially fatal. The initial symptoms of methanol intoxication include: central nervous system depression, headache, dizziness, nausea, lack of coordination, and confusion. Sufficiently large doses can cause unconsciousness and death. The initial symptoms of methanol exposure are usually less severe than the symptoms resulting from the ingestion of a similar quantity of ethanol. Once the initial symptoms have passed, a second set of symptoms arises, 10 to as many as 30 hours after the initial exposure to methanol, including blurring or complete loss of vision. Methanol ingestion, absorption through the skin or inhalation of fumes can be treated with ethanol, which acts as a competitive inhibitor of the hepatic enzyme alcohol dehydrogenase, preventing methanol’s conversion to toxic by-products.

Getting started:

Buy about a liter of new vegetable oil (canola, soy, sunflower or corn oil) at the grocery store. New, unused oil will not need to be dewatered or filtered. Pick up a few hundred milliliters of 99% or higher purity methanol (most automotive stores sell HEET brand antifreeze – the yellow container is pure enough for biodiesel production), and pick up some lye from a grocery or hardware store (make sure to get pure lye without coloring or added drain cleaners).

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New Vegetable Oil
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Heet – methanol
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Store bought lye

Making Biodiesel!

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Finished product.

Start warming up your new vegetable oil on an electric stove or with passive solar (no open flames!) to a temperature of around 120-132 degrees Fahrenheit. If the oil is too hot, the methanol will start evaporating and the reaction won’t perform as well. The average amount of lye needed to fully convert 1 liter of new oil is about 3.5 grams of NaOH or about 4.9 grams of KOH. In a separate container, mix either 3.5 grams of NaOH or 4.9 grams of KOH into 200 ml of methanol until fully dissolved – use a safe container made of HDPE plastic. This is the methoxide mix – the combination of the reagent and catalyst that will break the triglycerides of the vegetable oil into individual fatty acid methyl esters (also known as “biodiesel) and a layer of settled out byproduct consisting mostly of glycerin (which you can use to make soap!). When the oil is up to temperature, carefully pour in the methoxide, close the container and shake vigorously for about 3-5 minutes. You will notice a color change, indicating the reaction is occurring. After shaking, allow the byproduct to settle out – it usually takes about 10 to 20 minutes to start noticing the separation, then a few hours for substantial byproduct to precipitate.
 
Here’s a short video that Make Magazine put together for a DIY biodiesel project:

Check out http://journeytoforever.org/biodiesel_make.html for more details on biodiesel test batches, and let us know if you have questions!

Innovative Biodiesel Project: Week 1

The “Innovative Biodiesel Project” has begun!

Welcome, I am Safari Surf’s Sustainability Director, Carl Kish, and together with biodiesel expert, Ryan King, we will be posting updates on our progress every week during the 4 weeks that we are here in beautiful Nosara, Costa Rica. Follow our progress as we create the world’s first small-scale biodiesel production system that is closed-loop (zero waste), energy independent (off-grid), and carbon negative. Our project was successfully funded on Feb 6th on the crowdfunding website, Indiegogo – view our campaign page for more information: http://www.indiegogo.com/nosara-biodiesel.
We are eternally grateful to the following people (and to those who wish to remain anonymous) who made this possible:


Maegan Badham
Tim Marsh
Alexander Vinson
Stephen Kish
Jayne Kerry- Chandler
David Thibeault
Steve Scagliotti
John Anderson
Carl Graziani
Janet Davidson
Dominic Graziani
David Mahony
Peter McConnell
Marian Lim
Linus Eriksson
Hilda Hardy
Keith Mello
Courtney Keller
Sam Evans
John Dobleman
Andrius- Kavaliunas
Andrew Oliveira
Bob Balch
Prudence and Marianne Carter
Debra Takami
Jess Ponting
Alfred Padula
Marcy Siskind
Rosie Roberts
Harry Luce
Deborah Dobbins
Cara Hoffman
Sarah Lowry
Aaron Wong
Sarah Bexell
Rhett Butler
Kevin Mello
Jenny Mei
James Hake
Nick Glasco
Leah Bremer
Justine Schmidt
Vernon Badham
Hector Bertrand
Joyce McAfee
Dylan Fish
David Perault
Jennifer Willcott
Olivier Lejade
Diane Tran
Travis Heacock
Rebecca Needens
Dawn Kinney
Fredrico
Vincent Graham
James Ebrahimi
Matt Carlucci
Kevin Davidson
John Bowling
Jennifer- Stojanovich
Joseph Walsh
Kathleen Kish
Sherry Smith-Witcraft
Amelia Scott
Megan Brown
Jenna Black
Tobias Haller

Week 1

Ryan and I landed in San Jose Tuesday morning, and our driver Miguel was there to shuttle us 250 km back to Nosara.

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My new Tico name.

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Costa Rican Countryside

We stopped at a few places in Nicoya to pick up materials and get prices for the larger pieces of our system so we could budget our funds accordingly. Six hours later, we arrived at the Hotel Casa Tucan in Playa Guiones at four in the afternoon, hungry and jetlagged.

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Gnarliest bull in Nosara – apparently its killed two matador’s already.
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I missed this… nachos con pollo y Segua (Costa Rica Craft Brewing Co)

Exhausted from all the travelling, we dropped off our bags, and then went to relax on the beach. We walked to the north end of Guiones to see the defunct palace that has been empty for years… still a cool place with a nice view:

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“Mis Amores” Horseback Tours

That night we calculated our expenses and laid out the entire project budget for the next four weeks… then we passed out.
Next day (Wednesday), Ryan woke up with some sort of bug and he still hasn’t shaken it off (its now Sunday). He’s been a trooper though – still working all day with a few breaks here and there, but hopefully he fully recovers before we begin construction tomorrow.
We placed an order for methanol and lye with Arvi Chemicals in Cartago, which was more difficult than I had expected because we needed to find our own transportation to bring it to Nosara (driving with flammable chemicals… most of our contacts weren’t willing), but we eventually found someone and they will be here Wednesday. Now some of you may be thinking “Wait, I thought you guys were using homemade ethanol instead of methanol?!” Well unfortunately, we have to use some methanol for the first batch of biodiesel because it is the control variable against which we test all other variables. This includes testing the purity of our homemade ethanol. Therefore, if we encounter any problems as we add our unique aspects to the traditional Appleseed Biodiesel System, we will be able to identify which variable caused the issue and fix it. Once all the testing is done, we will use our homemade ethanol for biodiesel production instead of methanol.
We are collecting fruit scraps from the Casa Tucan kitchen as well as a local restaurant/hotel, Kaya Sol, who have been generous enough to provide us with their fruit scraps daily! The sugar from the fruit, mixed with yeast and water, will produce ethanol in 2 to 3 weeks. We have a small test batch of ethanol in a 5 gallon bucket while Ryan and I are here, but we are collecting fruit scraps to fill our 120 gallon tank so that by the time we leave, we can begin the fermentation process on a larger scale.  It is ideal to produce as much ethanol as possible because by the time we collect enough waste oil to make a batch of biodiesel, the ethanol fermentation tank will be full and will last for several batches (giving us enough time to fill the 120 gallon drum with fruit again). Just to give you an idea – the amount of ethanol used in each batch of biodiesel averages to about 30% of the volume of waste oil.

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Ryan and I went to the landfill on Thursday to see if we could repurpose any of the trash, luckily we were able to find one plastic jug that was still clean and wasn’t cracked. This will be our methoxide tank (methanol and potassium hydroxide), which we mix with the grease to make biodiesel. We also were very lucky to find an old 50 gallon water heater behind the Hotel Casa Tucan, which is in working order (we just need to clean it up a bit). That will save us about $500!
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I really wanted to see the new Recycling Center the town is building, which is part of the landfill. I have been following their progress on this blog: http://www.nosara.hollerarchitecture.com/ and I was stoked to see in person how large it is and how far they have come – its truly impressive:

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Now, there has been a sudden development, and the Hotel Casa Tucan has been purchased. While unfortunate, this does not affect our program, it actually enhances it because we are designing the system to be portable – all the parts can be disassembled and reassembled at their new location. Just because the location changed, does not mean our goal is any different – we are still creating a sustainable method for small-scale fuel production and sharing the designs online for free. This was just a minor setback and Safari Surf School will be moving out of the Hotel Casa Tucan this September when their lease is up. As a result, Tyler Marsh (co-owner of Safari Surf), has been so kind as to let us build the system on his property temporarily, until we are ready to transfer the system to Safari Surf’s new headquarters (yet to be determined). We surveyed Tyler’s property on Friday and picked a perfect location for the time being. Tyler’s gardener is also going to help us construct the shelter, which is a huge bonus. We are going to the Ferreteria in Nosara (hardware store) Monday morning to purchase all the necessary supplies.

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New Project Site

One of Safari Surf’s surf instructors, Enrique, had 5 gallons of methanol left over from when Ryan was in Nosara three years ago! Ryan tested the methanol to make sure it was still in tact – we bought some cooking oil from the market and made a small test batch of biodiesel in a Fanta bottle so I could be more familiar with the whole process (its really easy!):
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Fanta’s new flavor. [Orange stuff settled at the bottom is glycerine, which we use to make soap]
Tomorrow is a big day – we will purchase all the construction materials for the shelter and then we will break ground. Tonight is Karaoke night at the Casa Tucan, should be fun! Thanks for reading! Pura vida!
Jump to “Week 2.”
 

Innovative Biodiesel Project

I launched our fundraising campaign for the Innovative Biodiesel Project on IndieGogo last week and we have already raised 56% of our $5,000 goal!
Please watch the video below and if you believe in the project, surf over to our campaign page to make a pledge and share it with your friends, family and coworkers using the sharing tools right below the video: http://igg.me/p/287334/x/1838244

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