KDV - Diesel Test Run

KDV - Diesel Test Run
The KDV - Demonstration- and Test - Plant in Eppendorf enables diesel test runs
for customers with their own organic material. The Pressureless Chemical
Catalytic Conversion (in German: KDV-Technologie) of all organic materials into a
clean biological fuel of the newest generation is a technical and chemical copy of
the natural process of crude oil forming.
The Pressureless Chemical Catalytic Oiling provides the unique opportunity to produce
biofuels from nearly all kind of organic raw materials. The KDV-Technology allows us to
reduce the dependence of fossil fuels in a social responsible way. This key technology
sets new standards for a low emission mobility and is the basis of an active
environmental protection!
Thanks to its decentralized operation of the plants no other technology is more
appropriate for a climate-friendly production of biofuels from renewable raw materials A revolutionary way!
"Nothing is more powerful than an idea whose time has come"
-
Victor
Hugo
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Pressureless Chemical Catalytic Oiling
KDV-pre-process
This Technology which is developed and
worldwide patented by the inventor Dr.
Christian Koch / Alphakat GmbH is currently
the most efficient and environmental friendly
technology on the market.
A mixing system mixes the well prepared
(shreddered and dried) organic feedstock
with catalyst and calciumcarbonat (as
neutralizer) in a carrier oil (from the KDVmain process). At the same time it will be
heated up to around 150°C with thermal
energy from the power plant which covers
the own energy demand. The water from the
feedstock will be vaporized and distilled in a
first distillation column. Through the catalyst
there is a further extraction of oxygen in form
of CO2 (not H2O as in a thermal processes).
KDV-Main process
The mixed product - a kind of sludge - will be
piped in the KDV-main process. Then it will
be mixed and heated up to around 240270°C in the friction turbine.
It is a technical copy of the natural process
of converting all kind of organic matter (no
food!) like jatropha, palm oil residues, straw,
miscanthus, bagasse, wood, brown coal,
waste oil, plastics, etc. into diesel fuel. The
major difference is the time reduction of the
natural transformation process from 300
million years to 3 minutes by

using 100% crystalline catalysts (Cation
- Aluminum - Silicate) instead of natural
minerals

raising the temperature to 240°C 270°C instead of 14°C – 17°C

mixing and warm up the feedstock with
the catalyst in a carrier oil with a turbine
The catalyst causes a chemical molecule
shortening of the hydrocarbons to the length
of diesel molecules - a cellulose structure
into an alkane structure. Finally the diesel
vaporizes and will be distilled in the second
distillation column.
Wood
Bagasse
Miscanthus
Straw
Palmoil residues
Jatropha
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KDV-Past-Process
Inorganic parts like minerals, sand, stone, glass,
metals, etc. will be separated by the KDV-process
together with some carrier oil in the "Ash-plant" where
the rest of the hydrocarbons will be vaporized either
partly or total - for producing either bitumen for the
asphalt production or a powder which includes all the
inorganic components in the feedstock.
Final product - Diesel fuel conform to EN 590
KDV-150
The use of pure biomass, results in a product of high
quality consisting of saturated hydrocarbons in the
middle distillate range such as diesel.
The Catalytic Chemical Oiling is a pure chemical
reaction and has nothing to do with thermal splitting,
pyrolysis or thermal destruction. Therefore the final
product has a high quality and is (because of the high
destillation column) a very clean product which fullfills
the EU-Norm for mineral diesel EN 590. So the diesel
can be used in cars, power plants, etc.
KDV-1000
Outlook
This Technology has now passed its development
stage and is ready for industrial use. The plants are
very compact and are available in sizes from 150
liters (KDV-150) up to 5000 liters (KDV-5000) per
hour.
With this trendsetting Key-Technology from Alphakat
we can look forward optimistic. As long the sun is
shining - sufficient biomass can be produced even on
Mixing Turbine
a global scale in order to replace fossil fuels with the
climate-friendly biofuels produced using the globally
patented Technology of Chemical Catalytic Oiling!
Central Control Station
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Schedule for a test production of KDV-Diesel in Eppendorf
Monday:
The plant will be prepared and to the customer's requirements (feedstock) by the Alphakat team as
following:

Adaption of the plant especially feeding system


Fill up with carrier oil.
Launch of the plant and complete system check

Addition of lime
Tuesday:
08:00 am
Launch of the plant by the Alphakat team which is at customer's disposal for the entire day
08:30 am
Briefing with customer's team
 schedule of diesel test run
 explanation of the KDV-Technology and the test facility
 reply to all test-related questions
As soon as the process temperature will be reached the feeding of catalyst and customer's
feedstock will be started (expected time: approx. 10:00 am) The catalyst will be substituted
by feeding biomass (through the minerals in the biomass, which conforms to our catalyst) So
there is just a continuous feeding of lime required during process!
11:00 am
The achievement of the first diesel is expected
During around 4 hours diesel fuel will be produced
02:00 pm
Ending of the material entry
04:30 pm
Shutdown of the plant
Wednesday:
08:00 am
Launch of the plant by the Alphakat team which is at customer's disposal for the entire day
08:30 am
Briefing with customer's team
 schedule of diesel test run
 reply to all test-related questions
As soon as the process temperature will be reached the feeding of the customer's feedstock
will be started (expected time: approx. 10:00 am)
11:00 am
The achievement of the first diesel is expected
During around 4 hours diesel fuel will be produced
02:00 pm
Ending of the material entry
Final Team meeting
04:30 pm
Shutdown of the plant
Thursday and Friday:
Emptying and cleaning of the facility
Remarks



In special cases the schedule of the program will be adapted!
Customer's feedstock will be mixed with additional biomass from Alphakat if the process is not running well.
During this test run customer's Team of max. 5 persons can join the whole day on the facility, take notes, take
diesel samples and make pictures.
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General terms and conditions for the test run
Task of Customer's Technicians and Engineers
The task of the customer's technicians is to supervise and control the performance of the test, picking all
the information and samples required by them.
The technicians of the customer will be helping the Alphakat plant operators if required by all the
operational procedures, and specially by preparing and handling of the feedstock and assessing it (if
required) before it will be feed in the system.
The technicians of the customer have strictly to follow the instructions of the Alphakat plant operators in
order to preserve the save operation of the plant.
The technicians of the customer will bring with them all the tools they consider are needed to develop
their task of monitoring and supervising of the test results (including laptops). We suggest them to bring
work gloves, and safety equipment (eye glasses, footwear, dust mask respirators, first aid supplies,
protective clothing, rainwear, tool bags ...).
KDV - Demonstration and Test Plant
The KDV-Facility in Eppendorf is a Demonstration and Test Plant for producing diesel out of different
feedstocks (biogenic / organic residues) with the process of the catalytic and pressure less conversion.
Data Logging
A special board panel monitors the operation of the KDV plant. (see our
beside pictures). On the board panel the operators can overview all
important parameters for operating the plant.
In the commercial KDV systems all parameters and data are collected by
a stored program control (SPC) from Siemens but on the KDVDemonstration- and Test Plant in Eppendorf, whole system is very simple
and controlled by hand.
The board shows all the required parameters and this data can be stored
manually by the a person of the customer if it is required.
Feedstock
For the test run we need around 500 kg of input material in a prepared form: that means a size of less
than 5 mm (as smaller as better), a moisture content between 5% and 15% (it has to be dried soft - that
means not more than with 150°C!!!) and an inorganic content of less than 4% (no glass and ceramic!). If
the feedstock won´t fulfill these requirements it could be that we cannot run this test!
The material should be delivered to Eppendorf at least 5 days before the test in the required quality and
quantity to the following address:
Alphakat GmbH
Zweigstelle Eppendorf,
Freibergerstrasse 222
09575 Eppendorf
Germany
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Furthermore the Customer have to make a chemical analysis of the feedstock in a laboratory and send a
copy at least 5 days before the test to Alphakat GmbH (see address above).
The feedstock materials have to be analyzed according to the following parameters:






Moisture content
Calorific value
Hydrogen, Carbon, Nitrogen, Oxygen
Sulphur
Chlorine
Ash content
Test Objective
The Main objectives of the KDV-Diesel test run is to prove the function of the KDV-process with the
feedstock defined and delivered by the customer.
After the test run, we can differentiated assess the suitability of the feed material for the production of
synthetic diesel fuel. Especially, we can assess which process-related adjustments must eventually be
made to ensure that the produced diesel meets the requirements of the target market and the country
specific legislation.
The diesel from the demonstration and test plant is nearly diesel which conforms EN 590 - dependent on
the feedstock most probably the sulfur and water content is too high - that is because of the small
distillation column. Furthermore it could be that we have some light fraction in the final diesel because of
starting the plant with low temperatures - that results in a lower flash point.
The global objectives of the test run can be also detailed as follows:



Confirmation of the feasibility of converting of the Feedstock to synthetic diesel fuel.
Analysis of the main product and byproducts which are produced in the test facility.
Confirmation of the final product's quality (synthetic diesel) and specifications (done by a test
laboratory by the customer). A copy of the laboratory analysis will also be sent to Alphakat GmbH.
Test Coordination
The Test Coordination will be jointly done by Uwe Feller and Sebastian Fehrenbach.
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ANNEX A: Pictures - KDV150 TEST PLANT
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ANNEX B: FEEDSTOCK PICTURES
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Accommodation
We suggest you to stay with your team in the "Hotel Trakehnerhof" which is very close to the
Alphakat Facilities.
Trakehnerhof Gaststätte und Hotel
Mittelsaidaer Straße 25
9575 Eppendorf,
Germany
Phone 0049-37293-329
http://www.trakehnerhof.de
Alphakat GmbH
Schulstrasse 8
96155 Buttenheim
Germany
Phone: 0049 - (0)9545 - 208
mail@alphakat.de
www.alphakat.de
Alphakat GmbH Zweigstelle Eppendorf
Freibergerstrasse 222
09575 Eppendorf
Germany
Phone: 0049-37293-799 136
Coordination Diesel Test
Uwe Feller
Phone: 0049-37293 - 799 136
Mobile: 0049-152-227 376 96
u.feller@alphakat-eppendorf.de
Sebastian Fehrenbach
Phone: 0041-44-585 35 99
Mobile: 0049-174-150 81 98
sebastian.fehrenbach@alphakat.ch
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