A continuous process for the conversion of vegetable oils into methyl esters of fatty acids

An Overview on the Production of Biodiesel Enabled by Continuous Flow Methodologies

Biodiesel was produced via transesterification reaction catalyzed by acids, bases, enzymes or supercritical fluids. The catalysis was homogeneous or heterogeneous and the process could be carried out in batch or using a continuous flow process. Microreactors allowed us to obtain better control of the experimental variables, such as temperature, pressure and flow rate, carrying out the reactions in safe conditions, avoiding exothermic and dangerous processes. The synthetic methodologies in continuous flow, combined with other technologies as microwave irradiation or ultrasounds, led to complete automation of the process with an increase in efficiency, also applicable on an industrial scale.

Bio-plasticizer production by hybrid acetone-butanol-ethanol fermentation with full cell catalysis of Candida sp. 99-125

Hybrid process that integrated fermentation, pervaporation and esterification was established aiming to improve the economic feasibility of the conventional acetone-butanol-ethanol (ABE) fermentation process. Candida sp 99-125 cells were used as full-cell catalyst. The feasibility of batch and fed-batch esterification using the ABE permeate of pervaporation (ranging from 286.9 g/L to 402.9 g/L) as substrate were compared. Valuable butyl oleate was produced along with ethyl oleate. For the batch esterification, due to severe inhibition of substrate to lipase, the yield of butyl oleate and ethyl oleate were only 24.9% and 3.3%, respectively. In contrast, 75% and 11.8% of butyl oleate and ethyl oleate were obtained, respectively, at the end of the fed-batch esterification. The novel integration process provides a promising strategy for in situ upgrading ABE products.

Production of biodiesel from Vietnamese Jatropha curcas oil by a co-solvent method

Biodiesel fuels (BDFs) was successfully produced from Vietnamese Jatropha curcas oil with high content of free fatty acids (FFAs) in two stages. In the first stage, the esterification process was carried out with the optimal conditions as follows; a methanol-to-FFAs molar ratio of 6:1, 1 wt% H2SO4, at a temperature of 65 °C, and using 30% (wt/wt) acetonitrile as co-solvent. This step reduced the concentration of FFAs in the reaction mixture from 15.93 to 2 wt% in 60 min. In the second stage, the transesterification process generated fatty acid methyl esters (FAMEs) with 99% efficiency was performed in 30 min with the optimal conditions as follows; a methanol-to-oil molar ratio of 6:1, 1 wt% KOH, at a temperature of 40 °C, and 20% (wt/wt) acetone as co-solvent. The produced biodiesel quality meets the standards JIS K2390 and EN 14214 regarding FAME yield, FFAs and water contents.

Ultrasound assisted production of fatty acid methyl esters from transesterification of triglycerides with methanol in the presence of KOH catalyst: optimization, mechanism and kinetics

Ultrasound assisted transesterification of triglycerides (TG) with methanol in the presence of KOH catalyst was investigated, where the changes in the reactants and products (diglycerides (DG), monoglycerides (MG), fatty acid methyl esters (FAME) and glycerin (GL)) concentrations were discussed to understand the reaction mechanism and kinetics under ultrasound irradiation. The optimum reaction condition for the FAME production was the concentration of KOH 1.0 wt.%, molar ratio of TG to methanol of 1:6, and irradiation time of 25 min. The rate constants during the TG transesterification with methanol into GL and FAME were estimated by a curve fitting method with simulated curves to the obtained experimental results. The rate constants of [Formula: see text] were estimated to be 0.21, 0.008, 0.23, 0.005, 0.14 and 0.001 L mol(-1)min(-1), respectively. The rate determining step for the TG transesterification with methanol into GL and FAME was the reaction of MG with methanol into GL and FAME.

A Biorefinery

Reducing dependence of any country on imported crude oil is of critical importance for long-term security and continued economic growth. Supplementing petroleum consumption with renewable biomass resources is a first step towards this goal. The realignment of the chemical industry from one of petrochemical refining to a bio-refinery concept is, given time, feasible has become a national goal of many oil-importing countries. However, clearly defined goals are necessary for construction of a biorefinery and the increasing the use of biomass-derived feedstocks in industrial chemical production and it is important to keep the goal in perspective. In this context, the increased use of biofuels should be viewed as one of a range of possible measures for achieving self sufficiency in energy, rather than a panacea (Crocker and Crofcheck, 2006).

A biorefinery is the means by which biomass can be converted to other products - in the current context the other products are biofuels which have the potential to replace certain petroleum-derived fuels.

One aspect of designing a refinery for any feedstocks is the composition of the feedstocks. For example a heavy oil refinery would differ somewhat from a conventional refinery and a refinery for tar sand bitumen would be significantly different to both. Similarly, and because the chemical and physical composition of biomass is variable, there is no obvious simple design panacea for a biorefinery. The variation in the properties of biomass feedstocks dictates that different process options will be necessary in the near-term for converting biomass to biofuels.

This chapter presents the different biomass feedstocks that might be used in a biorefinery and offers descriptions of the various conversion options.

On-line monitoring of the transesterification reaction between triglycerides and ethanol using near infrared spectroscopy combined with gas chromatography

Many analytical procedures have been developed to determine the composition of reaction mixtures during transesterification of vegetable oils with alcohols. However, despite their accuracy, these methods are time consuming and cannot be easily used for on-line monitoring. In this work, a fast analytical method was developed to on-line monitor the transesterification reaction of high oleic sunflower oil with ethanol using Near InfraRed spectroscopy and a multivariate approach. The reactions were monitored through sequential scans of the reaction medium with a probe in a one-liter batch reactor without collecting and preparing samples. To calibrate the NIR analytical method, gas chromatography-flame ionization detection was used as a reference method. The method was validated by studying the kinetics of the EtONa-catalyzed transesterification reaction. Activation energy (51.0 kJ/mol) was also determined by considering a pseudo second order kinetics model.

Continuous biodiesel production in a cascade of flow ideally stirred reactors

The continuous methanolysis of rapeseed oil catalyzed by KOH in a cascade of 4 flow stirred reactors at a steady state of 60 degrees C was studied. By comparing of the determined steady state concentrations of rapeseed oil, biodiesel and KOH in the reactors (under various initial concentrations of these components and feeding) with the assumed kinetic model the rate constants of the relevant differential rate equations for rapeseed oil consumption and biodiesel production were calculated.

Production of biodiesel using a continuous gas-liquid reactor

A novel continuous reactor process has been developed for the production of biodiesel from fats and oils. The key feature of the process is its ability to operate continuously with a high reaction rate, potentially requiring less post reaction cleaning and product/reactant separation than currently established processes. This was achieved by atomising the heated oil/fat and then spraying it into a reaction chamber filled with methanol vapor in a counter current flow arrangement. This allows the continuous separation of product and the excess methanol stream in the reactor. The overall conversion based on a single cycle of this process has been between 50% and 96% of the feed stock materials. Conversions of 94-96% were achieved while operating with 5-7 g of sodium methoxide/L of methanol at methanol flow rate of 17.2 L/h and oil flow rate of 10 L/h. Additional variations in the reactant stoichiometry (i.e. reactant flow rates), catalyst type/concentration, and reaction temperature on the overall product conversion were investigated.

Catalytic applications in the production of biodiesel from vegetable oils

The predicted shortage of fossil fuels and related environmental concerns have recently attracted significant attention to scientific and technological issues concerning the conversion of biomass into fuels. First-generation biodiesel, obtained from vegetable oils and animal fats by transesterification, relies on commercial technology and rich scientific background, though continuous progress in this field offers opportunities for improvement. This review focuses on new catalytic systems for the transesterification of oils to the corresponding ethyl/methyl esters of fatty acids. It also addresses some innovative/emerging technologies for the production of biodiesel, such as the catalytic hydrocracking of vegetable oils to hydrocarbons. The special role of the catalyst as a key to efficient technology is outlined, together with the other important factors that affect the yield and quality of the product, including feedstock-related properties and various system conditions.

Performance test of a 6-stage continuous reactor for palm methyl ester production

Effects of residence time (3-12 min), stirrer speed (0-800 rpm), and NaOH concentration (0.25-1.0 wt% of oil) on the production performance of the designed 6-stage continuous reactor (2.272 l) for transesterification of palm oil were investigated at molar ratio of methanol to oil of 6:1 and temperature of 60 degrees C. Higher stirrer speed increased the reaction rate up to an appropriate speed but excessive stirrer speed decreased the reaction rate. Inappropriate stirrer speed runs dramatically decreased the production capacity of the reactor. Higher NaOH concentration significantly increased reaction rate and production capacity of the reactor. The reactor had a residence time distribution equivalent to 5.98 ideal CSTRs in series and a production performance equivalent to a plug flow reactor. At NaOH of 1.0 wt% of oil, the reactor could produce saleable biodiesel within residence time of 6 min in which a production capacity was 17.3 l/h and a power consumption of stirrer was 0.6 kW/m(3).

Ultrasonically driven continuous process for vegetable oil transesterification

A bench scale continuous process for the manufacture of biodiesel from neat vegetable oils under high power low frequency ultrasonic irradiation was investigated. The experimental studies explored variations in alcohol-oil stoichiometry and type of oil. Important parameters such as residence time and reaction volume were considered. The highest conversion was achieved when short residence time was employed. The transesterification under ultrasonic irradiation is mainly influenced by the residence time in the reactor and alcohol-oil molar ratio.

Fatty acids methyl esters from vegetable oil by means of ultrasonic energy

The transesterification of vegetable oil with short-chain alcohols, in the presence of base-catalyst, by means of low frequency ultrasound (28 and 40 kHz) in order to obtain biodiesel fuel was studied. By using ultrasounds the reaction time is much shorter (10-40 min) than for mechanical stirring. The quantity of required catalyst is 2 or 3 times lower. The molar ratio of alcohol/oil used is only 6:1. Normal chain alcohols react fast, while secondary and tertiary alcohols show some or no conversion after 60 min of reaction. Surprisingly, 40 kHz ultrasounds are much more effective in the reduction of the reaction time (10-20 min). Twenty eight kilohertz give slightly better yields (98-99%), but longer reaction time, while higher frequencies are not useful at all for the transesterification of fatty acids.

Integrated biodiesel production: a comparison of different homogeneous catalysts systems

The most common catalysts for biodiesel production are homogeneous basic catalysts. In the present paper, a comparison is made of different basic catalysts (sodium methoxide, potassium methoxide, sodium hydroxide and potassium hydroxide) for methanolysis of sunflower oil. All the reactions were carried out under the same experimental conditions in a batch stirred reactor and the subsequent separation and purification stages in a decanter. The analytical methods included gas chromatography and the determination of fat and oil conventional parameters. The biodiesel purity was near 100 wt.% for all catalysts. However, near 100 wt.% biodiesel yields were only obtained with the methoxide catalysts. According to the material balance of the process, yield losses were due to triglyceride saponification and methyl ester dissolution in glycerol. Obtained biodiesel met the measured specifications, except for the iodine value, according to the German and EU draft standards. Although all the transesterification reactions were quite rapid and the biodiesel layers achieved nearly 100% methyl ester concentrations, the reactions using sodium hydroxide turned out the fastest.