POR FESR 2007-2013 | OVEST Project: Valorizing Waste Oils through Innovative Plant Design
The OVEST Project was launched with the aim of converting used frying oils and by-products from food oil refining into a renewable, non-food fuel suitable for use in cogenerators powered by pure vegetable oil. This initiative represents one of Spike Renewables’ first experiences in the integrated design of plants dedicated to bioenergy and the valorization of organic residues.
An Optimized Esterification Process
The system is centered on the reaction between fatty acids and glycerol, carried out in custom-designed reactors. Each reactor features an internal thermal oil circuit, sized using advanced thermotechnical calculations to ensure uniform heating of the mixture. An internal agitator ensures thorough mixing of the reactants, while a vertical and horizontal condensation system allows selective recovery of glycerin and process water. The internal coils, each totaling 68 meters, are designed to handle the most critical thermal loads of the cycle.
Modular Design Adapted to the Facility
The initial plan included three independent reactors to be integrated in series. Following technical and economic optimization, two reactors were implemented in the first phase, with provisions and space reserved for a third module. The plant layout underwent multiple optimizations due to both structural constraints of the building and the need to properly accommodate the vertical heat exchangers and main manifolds. Structural checks and iterative layout revisions ensured an efficient and easily scalable configuration.
Energy Recovery and Process Sustainability
A key element of the plant is heat recovery. During execution, a dedicated exchanger was added to preheat incoming fatty acids using the hot esterified oil exiting the process. This device allows the recovery of over 2.6 MW of thermal energy, significantly reducing overall energy consumption and contributing to the economic and environmental sustainability of the process.
An Early Model of Circular Economy
The project demonstrates how technology can enable new circular supply chains for renewable energy production. Converting waste and by-products into a reliable fuel for distributed generation exemplifies advanced resource valorization. Spike Renewables oversaw all phases, from technical design and layout definition to sustainability analyses of the entire system.