A new process for creating biodiesel from low-quality feedstock such as animal fat and waste oil could lead to a proliferation of small scale bio-refineries located closer where the fuel is needed. By eliminating pre- and post-processing steps, biodiesel refineries can be smaller and more economical to operate, according to Rob Tripp, the CEO of Benefuel, which developed the technology.

Standard biodiesel processing uses pre-processing to eliminate impurities and a liquid catalyst that must be removed, Tripp says. This process can use up to 5 gallons of water per gallon of biodiesel produced. Benefuel's process uses an acid-based solid catalyst so water is needed because "you don't have to wash the fuel and remove caustics after the interaction," Tripp says. Ethanol or methanol is also required during the manufacturing process.

Eliminating the two processing steps shrinks the area needed for a 10 million gallon per year biodiesel plant from 10,000 square feet or more to just 600 feet, according to Tripp. Benefuel's refineries are modularized and can be shipped by truck, making it easier to locate refineries near animal renderers or farmers. The smaller footprint and closer proximity to distribution point reduces the amount of fossil fuels required to create biodiesel.

Tripp says the technology has been tested on more than 30 feedstocks including rapeseed and jatropha oil, and that the end product is ASTM-grade biodiesel. He says that the glycerin byproduct is also a higher quality (98 percent pure versus up to 85 percent) than conventional biodiesel production methods.

The first demonstration-scale plant using the technology will be located in Seymour, Indiana, and will be run by Seymour Biofuels.

Other companies developing more energy-efficient biofuel processing technologies include Greenstar USA.