Our process

Masader is a multi-feedstock Biodiesel manufacturer, accordingly we care for pre-treatment of feedstock before processing. feedstock will be treated with unique, highly advanced and automated process units to remove unnecessary contaminants like phosphorus, sulfur and color bodies.
Treated feedstock, based on its type will be mixed with dedicated catalyst (basically homogeneous catalysis), and sent to series of reactors that utilizes different mixing techniques tailored exclusively for our facility, that reduces required reaction time to few seconds only.
During this very short contact time (approximately 5 seconds),an instantaneous conversion of raw materials takes place.
The mix is then sent through a a series of very high speed separators to separate the Biodiesel (light phase) from the Glycerol (heavy phase).
The light phase is then heated, and sent through a flash evaporator, to remove methanol and any present water.
The crude biodiesel is then sent through a lead‐lag system of ion exchange resins towers, to remove any traces of glycerol and other contaminants.
Crude Biodiesel then flows to a high temperature absolute vacuum distillation section which ensures production of low sulfur low freezing point final Biodiesel product that meets European Standard.
The heavy phase is heated to 120°C, and sent through a flash evaporator, to recover methanol.
The crude glycerol is then sent to storage, or to purification at later stage.

Feed Stock Specifications

When sonicating liquids at high intensities, the sound waves that propagate into the liquid media result in alternating high‐pressure (compression) and low‐pressure (rarefaction) cycles, with rates depending on the frequency.
During the low‐pressure cycle, high‐intensity ultrasonic waves create small vacuum bubbles or voids in the liquid. When the bubbles attain a volume at which they can no longer absorb energy, they collapse violently during a high‐pressure cycle.
This phenomenon is called cavitation. During the implosion very high temperatures (approx. 5,000K) and pressures (approx. 2,000atm) are reached locally. The implosion of the cavitation bubble also results in liquid jets of up to 280m/s velocity.
Ultrasound has been proven to generate very homogenous emulsions by the high cavitational shear. As the parameters of ultra sonication are fine‐tuned, particle size and distribution is well adjustable and repeatable.

Feedstock flexibility ‐ ultrasounds achieve the same great results with any feedstock, both high and low FFA feedstock can be used, including blends of different feedstock.
Low power consumption ‐ with a total consumption of approximately 2kWh per ton of Biodiesel produced, our reactors are unmatched for economy.
No moving parts ‐ ultrasonic reactors have no moving parts, meaning that there is virtually no maintenance required, apart from regular cleaning operations.
Consistently High Yields and Quality ‐ by creating micro bubbles, that contract and expand increasingthe surface area where the reaction takes place instantaneously, molecular cavitation emulsifies the feedstock and reagents guaranteeing maximum yields and high quality Biodiesel at all times.
Small plant footprint – due to their energy efficiency, the system has a capacity identical to highly energy intensive mechanical reactors, which are much larger and require a lot more retention time for the reaction to occur.