A new process for catalyst-free production of biodiesel using supercritical methyl acetate

Production of glycerol is unavoidable in the conventional processes for biodiesel fuel (BDF) production. In this research, therefore, we investigated conversion of rapeseed oil to fatty acid methyl esters (FAME) and triacetin (TA) by processing of supercritical methyl acetate. As a result, it was discovered that the trans-esterification reaction of triglycerides with methyl acetate can proceed without catalyst under supercritical conditions, generating FAME and triacetin. In order to study the effect of the triacetin addition to FAME, its effect was investigated on various fuel characteristics. It was, consequently, discovered that there were no adverse effects on the main fuel characteristics when the molar ratio of methyl oleate to triacetin was 3:1, corresponding to the theoretically derived mole ratio from the trans-esterification reaction of rapeseed oil with methyl acetate. Moreover, the addition of triacetin to methyl oleate improved the pour point and triacetin has high oxidation stability. Therefore, by defining BDF as a mixture of methyl oleate with triacetin, we can obtain an improved yield of 105% of BDF by the supercritical methyl acetate, in excess of the yield of the conventional process.     

Transesterification of vegetable oil to biodiesel fuel using alkaline catalyst

Biodiesel is gaining more and more importance as an attractive fuel due to the depleting fossil fuel resources. Chemically biodiesel is monoalkyl esters of long chain fatty acids derived from renewable feed stock like vegetable oils and animal fats. It is produced by transesterification in which, oil or fat is reacted with a monohydric alcohol in presence of a catalyst to give the corresponding monoalkyl esters. This article reports experimental data on the production of fatty acid methyl esters from vegetable oils, soybean and cottonseed oils using sodium hydroxide as alkaline catalyst. The variables affecting the yield and characteristics of the biodiesel produced from these vegetable oils were studied. The variables investigated were reaction time (1-3 h), catalyst concentration (0.5-1.5 w/wt%), and oil-to-methanol molar ratio (1:3-1:9). From the obtained results, the best yield percentage was obtained using a methanol/oil molar ratio of 6:1, sodium hydroxide as catalyst (1%) and 60 ± 1 °C temperature for 1 h. The yield of the fatty acid methyl ester (FAME) was determined according to HPLC. The composition of the FAME was determined according to gas chromatography. The biodiesel samples were physicochemically characterized. From the results it was clear that the produced biodiesel fuel was within the recommended standards of biodiesel fuel.     

Synthesis of biodiesel from edible,non-edible and waste cooking oils via supercritical methyl acetate transesterification

The use of methyl acetate instead of methanol for supercritical synthesis of glycerol-free biodiesel from vegetable oils is a new process and its study is very limited in the literature. In this work, it has been tested for the first time on three edible and non-edible oils with different fatty acid composition. The process was also applied to waste oil with higher free fatty acid (FFA) content. The results demonstrate that the oil composition does not significantly influence the biodiesel yield.The influence of temperature, pressure and molar ratio of reactants was studied. All the oils achieved complete conversion after 50 min at 345 °C, 20 MPa with methyl acetate:oil molar ratio equal to 42:1. The obtained data also allowed calculating the apparent rate coefficients and activation energies.Eventually, some new information on the process was obtained. Thermal degradation of triacetin, which substitutes glycerol as the by-product of the transesterification reaction, was observed. Some indicative experiments were performed to understand the role of the acetic acid produced by FFA esterification.     

Non-catalytic biodiesel process with adsorption-based refining

Different feedstocks of varying acidity ranks and water contents were subjected to a series of discontinuous steps that simulated a biodiesel production process. The three steps comprised: (i) the non-catalytic transesterification with supercritical methanol at 280 °C; (ii) the distillation of the unreacted methanol, water and volatile products; and (iii) the adsorption of the impurities with adequate adsorbents. Refined soy oil, chicken oil and waste cooking oil were subjected to the same simple procedure. The process produced biodiesel complying with the water, acid, glycerides and methyl esters content specifications of the EN 14214 standard.Biodiesel production by the reaction of oils in supercritical methanol at 280 °C and methanol-to-oil molar ratios of 15 and 20 produced amounts of glycerol as small as 0.02%. This simplified the subsequent refining of the biodiesel and is considered an advantage over the classic alkali-catalyzed process (that produces 10% of glycerol by-product) because washing steps can be spared.The contents of methyl esters, water and free fatty acids showed a volcano pattern when plotted as a function of the reaction time. In the case of the free fatty acids this was attributed to the initial reaction of water and triglycerides to form acids and glycerol that increased the acidity of the product mixture. At longer reaction times these acids were likely transformed into methyl esters or were decarboxylated to hydrocarbons and CO₂. Water formation was attributed to glycerol decomposition and esterification of free fatty acids.The design of a simple process for biodiesel production using a single reaction step with negligible glycerol production and an adsorption-based refining step was thus studied. A possible scheme integrating reaction, methanol recycling, biodiesel purification and heat recovery was discussed. Advantages and disadvantages of process units were analyzed on terms of operating cost and simplicity.     

New process for catalyst-free biodiesel production using subcritical acetic acid and supercritical methanol

The production of glycerol as a by-product is unavoidable in the current conventional biodiesel manufacturing processes. Since biodiesel production is expected to increase in the near future, effective utilization of glycerol will become an issue of interest. In this study, therefore, a process consisting of subcritical acetic acid treatment to convert rapeseed oil to fatty acids and triacetin followed by conversion of the obtained fatty acids to their fatty acid methyl esters in supercritical methanol treatment was investigated. The obtained results clearly revealed that this two-step reaction could proceed effectively at a high reaction rate, and that fatty acid methyl esters and triacetin could be obtained under milder reaction condition than the one-step process utilizing supercritical methyl acetate and supercritical methanol.     

Continuous enzymatic production of biodiesel from virgin and waste sunflower oil in supercritical carbon dioxide

A continuous process for biodiesel production in supercritical carbon dioxide was implemented. In the transesterification of virgin sunflower oil with methanol, Lipozyme TL IM led to fatty acid methyl esters yields (FAME) that exceeded 98% at 20 MPa and 40 °C, for a residence time of 20 s and an oil to methanol molar ratio of 1:24. Even for moderate reaction conversions, a fractionation stage based on two separators afforded FAME with >96% purity. Lipozyme TL IM was less efficient with waste cooking sunflower oil. In this case, a combination of Lipozyme TL IM and Novozym 435 afforded FAME yields nearing 99%.     

Methanol recycling in the production of biodiesel in a membrane reactor

Membrane reactor technology was used to overcome challenges in biodiesel production. The membrane reactor produces a permeate stream which readily phase separates at room temperature into a fatty acid methyl ester (FAME)-rich non-polar phase and a methanol- and glycerol-rich polar phase. To decrease the overall methanol:oil molar ratio in the reaction system, the polar phase was recycled. Three recycle ratios were tested: 100%, 75% and 50%, at the same residence time and operating conditions. The permeate consistently separated to yield a FAME-rich non-polar phase containing a minimum of 85 wt.% FAME (the remainder being methanol) as well as a methanol/glycerol polar phase. At the highest recycle ratio, the FAME concentration ranged from 85.7 to 92.4 wt.% in the FAME-rich non-polar phase. In addition, the overall molar ratio of methanol:oil in the reaction system was significantly decreased to 10:1 while maintaining a FAME production rate of 0.04 kg/min. As a result, a high purity FAME product was produced.     

Thermal stability of biodiesel in supercritical methanol

Non-catalytic biodiesel production technologies from oils/fats in plants and animals have been developed in our laboratory employing supercritical methanol. Due to conditions in high temperature and high pressure of the supercritical fluid, thermal stability of fatty acid methyl esters and actual biodiesel prepared from various plant oils was studied in supercritical methanol over a range of its condition between 270 °C/17 MPa and 380 °C/56 MPa. In addition, the effect of thermal degradation on cold flow properties was studied. As a result, it was found that all fatty acid methyl esters including poly-unsaturated ones were stable at 270 °C/17 MPa, but at 350 °C/43 MPa, they were partly decomposed to reduce the yield with isomerization from cis-type to trans-type. These behaviors were also observed for actual biodiesel prepared from linseed oil, safflower oil, which are high in poly-unsaturated fatty acids. Cold flow properties of actual biodiesel, however, remained almost unchanged after supercritical methanol exposure at 270 °C/17 MPa and 350 °C/43 MPa. For the latter condition, however, poly-unsaturated fatty acids were sacrificed to be decomposed and reduced in yield. From these results, it was clarified that reaction temperature in supercritical methanol process should be lower than 300 °C, preferably 270 °C with a supercritical pressure higher than 8.09 MPa, in terms of thermal stabilization for high-quality biodiesel production.     

Influence of impurities on biodiesel production from Jatropha curcas L. by supercritical methyl acetate process

Generally, water and free fatty acid (FFA) content in oils could cause a serious problem during conventional transesterification such as saponification. Thus, without any pre-treatment, vegetable oil, especially with high FFA content, will be affected. In this study, a non-catalytic supercritical methyl acetate (SCMA) process was utilized to produce biodiesel from Jatropha curcas L. oil. The effects of water and FFA content on the yield of biodiesel were investigated. The results obtained for the effects of water on the yield of biodiesel were compared with the supercritical methanol (SCM) process and conventional catalytic reaction. Results revealed that the catalytic reaction suffers from low yield with the presence of high water content in oil. Meanwhile, the yield of both the SCM and SCMA reactions were found to increase slightly with the increment of water content in the mixture. On the other hand, the results for the effect of FFA on the yield of biodiesel were compared with the SCM reaction. It was found that the presence of FFA has a negligible effect in both the SCMA and SCM reactions. These findings demonstrate that pre-treatment procedures are not necessary in the SCMA process for Jatropha oil which normally contains a high FFA content.     

Separation of glycerol from FAME using ceramic membranes

International standards (e.g., ASTM D6751 and EN14214) limit the presence of free glycerol in biodiesel. The traditional water wash method for removing glycerol from crude fatty acid methyl esters (FAME) obtained in the production of biodiesel results in waste waters that cannot be readily discharged. To circumvent the water wash purification method, a membrane separation system using ceramic membranes was designed, constructed and tested for the removal of glycerol from crude FAME from a biodiesel production process. Ceramic membranes in the ultrafiltration (0.05 μm) and microfiltration (0.2 μm) ranges were tested at three different operating temperatures: 0, 5 and 25 °C. All runs separated glycerol from the crude FAME. International standards for glycerol content in biodiesel were met after 3 h when utilizing the ultrafiltration membrane setup at 25 °C with a concentration factor greater than 1.6.     

Utilization of biodiesel and glycerol for the synthesis of epoxidized acyl glycerides and its application as a plasticizer

In many regions, even if waste vegetable oil is used as raw material, the profits of biodiesel (fatty acid methyl ester, FAME) enterprises still remain restricted, and they are facing environmental problems caused by the by-product glycerol. Hence, value-added utilization of FAME and glycerol is a promising alternative to improve the competitiveness of biodiesel enterprises in the economy and environmental protection. In this paper, FAME and glycerol were utilized to prepare epoxidized acyl glycerides by transesterification and epoxidation. In the transesterification, acyl glycerides were prepared by reacting FAME and glycerol catalyzed by K₂CO₃. The contents of monoacyl glyceride, diacyl glyceride, and triacyl glyceride in the acyl glycerides were about 50%, 40%, and 10%, and the optimal conditions were a temperature of 200°C and the molar ratio of FAME to glycerol of 1:1. In the epoxidation, selectivity of epoxides was significantly affected by monoacyl glyceride content, and a treatment method was developed to control the monoacyl glyceride content <5%. In addition, the plasticity of epoxidized acyl glycerides to partially substitute dioctyl phthalate in polyvinyl chloride was studied, the overall mechanical properties, thermal stability, and extraction resistance were improved. In this work, FAME and glycerol were utilized to prepare epoxidized acyl glycerides with higher value-added, which provide a potential solution for improving the market competitiveness of biodiesel enterprises.     

Glycerol removal from biodiesel using membrane separation technology

Membrane separation technology was used to remove free glycerol from biodiesel in order to meet the ASTM D6751 and EN 14214 standards. Fatty acid methyl esters (FAME) produced from canola oil and methanol were purified using ultra-filtration. The effect of different materials present in the transesterification reaction, such as water, soap, and methanol, on the final free glycerol separation was studied. A modified polyacrylonitrile (PAN) membrane, with 100 kD molecular weight cut-off was used in all runs. Tests were performed at 25 °C and 552 kPa operating pressure. The free glycerol content in the feed, retentate and permeate of the membrane system was analyzed using gas chromatography according to ASTM D6584. Results showed low concentrations of water had a considerable effect in removing glycerol from the FAME even at approx. 0.08 mass%. This is four orders of magnitude less than the amount of water required in a conventional biodiesel purification process using water washing. It is suggested that the mechanism of separation of free glycerol from FAME was due to the removal of an ultrafine dispersed glycerol-rich phase present in the untreated FAME. This was confirmed by the presence of particulates in the untreated FAME. The size of the particles and the free glycerol separation both increased with increasing water content of the FAME. The trends of separation and particle size vs. water content in the FAME phase were very similar and exhibited a sudden increase at 0.08 mass% water in the untreated FAME. This supports the conclusion that water increased the size of the distributed glycerol phase in the untreated FAME leading to its separation by the ultra-filtration membrane. The technology for the removal of free glycerol from biodiesel was found to use 2.0 g of water per L of treated FAME (0.225 mass% water) vs. the current 10 L of water per L of treated FAME.     

Biodiesel production using supercritical methanol/carbon dioxide mixtures in a continuous reactor

Fatty acid methyl esters (biodiesel) were produced by the transesterification of triglycerides with compressed methanol (critical point at 240 °C and 81 bar) in the presence of solid acids as heterogeneous catalyst (SAC-13). Addition of a co-solvent, supercritical carbon dioxide (critical point at 31 °C and 73 bar), increased the rate of the supercritical alcohols transesterification, making it possible to obtain high biodiesel yields at mild temperature conditions. Experiments were carried out in a fixed bed reactor, and reactions were studied at 150-205 °C, mass flow rate 6-24 ml/min at a pressure of 250 bar. The molar ratio of methanol to oil, and catalyst amount were kept constant (9 g). The reaction temperature and space time were investigated to determine the best way for producing biodiesel. The results obtained show that the observed reaction rate is 20 time faster than conventional biodiesel production processes. The temperature of 200 °C with a reaction time of 2 min were found to be optimal for the maximum (88%) conversion to methyl ester and the free glycerol content was found below the specification limits.     

Phase transition at subcritical and supercritical conditions of triglycerides methanolysis

The analysis of phase equilibrium between methanol and glycerides during methyl esters of fatty acids (FAME or biodiesel) synthesis at high pressure and temperature is very important for describing the kinetic and process design. It was studied at pressure between 1.1 and 28.0 MPa and temperature from 150 to 270 °C. The transition of phases and composition of identified phases was calculated using RK-Aspen EOS and obtained values were also compared to experimentally determined data at subcritical condition (1.1-4.5 MPa and 150-210 °C).Results of experimental investigation, as well as performed simulation of some specified composition of reaction mixture, showed that system of triglycerides and methanol, at the beginning of reaction (at all analysed conditions except for supercritical state of mixture) is in equilibrium between two liquid phases. During the methanolysis of triglycerides, the phase's distribution was changed accordingly and it highly depends on actual composition of reaction mixture, temperature and pressure. Calculated and measured values indicated that distribution of methanol between the oil phase, the methyl esters, and the glycerol rich phase exists and depends of working condition. As a consequence of fact, that the methanolysis of triglycerides (oil) is mainly realized in the oil-rich phase, at the end of reaction, after all triglycerides are converted into FAME and glycerol, the oil phase disappears. Furthermore, according to the results of phase composition calculation, it was shown that from the beginning to the end of reaction one phase only exists, for methanolysis performed at 270 °C and 20.0 MPa.     

Production of biodiesel with glycerol carbonate by non‐catalytic supercritical dimethyl carbonate

New biodiesel production processes comprising one‐step and two‐step supercritical dimethyl carbonate methods have been pioneered. The use of dimethyl carbonate allows the reaction conditions to be mild and thus avoid unwanted deterioration of substrates during reaction. In this process, without any catalyst applied, supercritical dimethyl carbonate converts triglycerides (rapeseed oil) into fatty acid methyl esters (FAME) along with glycerol carbonate as a value‐added by‐product, instead of glycerol. Free fatty acids could be also converted into FAME so that the total yield of biodiesel for both methods resulted in over 96 wt%. In addition, the produced FAME satisfy the fuel requirements for the international standards of biodiesel specification.     

Evaluation of biodiesel obtained from cottonseed oil

Esters from vegetable oils have attracted a great deal of interest as substitutes for petrodiesel to reduce dependence on imported petroleum and provide a fuel with more benign environmental properties. In this work biodiesel was prepared from cottonseed oil by transesterification with methanol, using sodium hydroxide, potassium hydroxide, sodium methoxide and potassium methoxide as catalysts. A series of experiments were conducted in order to evaluate the effects of reaction variables such as methanol/oil molar ratio (3:1–15:1), catalyst concentration (0.25–1.50%), temperature (25–65 °C), and stirring intensity (180–600 rpm) to achieve the maximum yield and quality. The optimized variables of 6:1 methanol/oil molar ratio (mol/mol), 0.75% sodium methoxide concentration (wt.%), 65 °C reaction temperature, 600 rpm agitation speed and 90 min reaction time offered the maximum methyl ester yield (96.9%). The obtained fatty acid methyl esters (FAME) were analyzed by gas chromatography (GC) and ¹H NMR spectroscopy. The fuel properties of cottonseed oil methyl esters (COME), cetane number, kinematic viscosity, oxidative stability, lubricity, cloud point, pour point, cold filter plugging point, flash point, ash content, sulfur content, acid value, copper strip corrosion value, density, higher heating value, methanol content, free and bound glycerol were determined and are discussed in the light of biodiesel standards such as ASTM D6751 and EN 14214.     

Rapid transesterification of soybean oil with phase transfer catalysts

Biodiesel is a renewable, non-toxic and biodegradable alternative fuel for compression ignition engines. Biodiesel is produced mainly through base-catalyzed transesterification of animal fats or vegetable oils. However, the conventional base-catalyzed transesterification is characterized by slow reaction rates at both initial and final reaction stages limited by mass transfer between polar methanol/glycerol phase and non-polar oil phase.In our study we used phase transfer catalysts (PTCs) to facilitate anion transfer between polar methanol/glycerol phase and non-polar oil phase to speed up transesterification. The benefits of transesterification by PTCs include no need for expensive aprotic solvents, potentially simpler scaleup and higher activity (shorter reaction time). Various PTCs were investigated for base-catalyzed transesterification. Experimental results showed that base-catalyzed transesterification was enhanced with an effective PTC, indicated by the formation of high methyl ester (ME) content within a relatively short time. Individual operating variables such as molar ratios of methanol to oil, total OH⁻ to oil, PTC to base catalyst and agitation including ultrasound were investigated for transesterification with PTC. Product analyses showed that ME content higher than 96.5 wt.% was achieved after only 15 min of rapid transesterification with PTC (tetrabutylammonium hydroxide or tetrabutylammonium acetate as PTC, MeOH/oil molar ratio of 6, total OH⁻/oil molar ratio of 0.22, PTC/KOH molar ratio of 1 and 60 °C). Free and total glycerol contents in the final product from 15 min rapid transesterification with PTC were lower than maximum allowable limits in the standard specification for biodiesel.     

Continuous production of biodiesel fuel from vegetable oil using supercritical methanol process

A system for continuous transesterification of vegetable oil using supercritical methanol was developed using a tube reactor. Increasing the proportion of methanol, reaction pressure and reaction temperature can enhance the production yield effectively. However, side reactions of unsaturated fatty acid methyl esters (FAME) occur when the reaction temperature is over 300 °C, which lead to much loss of material. There is also a critical value of residence time at high reaction temperature, and the production yield will decrease if the residence time surpasses this value. The optimal reaction condition under constant reaction temperature process is: 40:1 of the molar ratio of alcohol to oil, 25 min of residence time, 35 MPa and 310 °C. However, the maximum production yield can only be 77% in the optimal reaction condition of constant reaction temperature process because of the loss caused by the side reactions of unsaturated FAME at high reaction temperature. To solve this problem, we proposed a new technology: gradual heating that can effectively reduce the loss caused by the side reactions of unsaturated FAME at high reaction temperature. With the new reaction technology, the methyl esters yield can be more than 96%.     

Catalytic acetylation of glycerol with acetic anhydride

We studied the acetylation of glycerol with acetic anhydride using different solid acid catalysts. The results indicated that at 60 °C, zeolite Beta and K-10 Montmorillonite showed 100% selectivity to triacetin within 20 min, with a molar ratio of 4:1. Amberlyst-15 acid resin yielded 100% triacetin after 80 min, whereas niobium phosphate gave diacetin and triacetin in 53% and 47% selectivity, respectively. All catalysts were more selective to triacetin than the uncatalyzed reaction. By contrast, zeolite Beta gave poor yield of triacetin when acetic acid was used as acetylating agent. The different behavior was explained in terms of the stabilization of the acylium ion intermediate.     

Transesterification of vegetable oil to biodiesel fuel using acid catalysts in the presence of dimethyl ether

The immiscibility of methanol and vegetable oil leads to a mass-transfer resistance in the transesterification of vegetable oil. To overcome this problem, dimethyl ether (DME) was used as an environmentally friendly cosolvent to produce a homogeneous solution. Methylesterifications of corn oil in both the presence and the absence of DME were performed using p-toluenesulfonic acid (PTSA), benzenesulfonic acid and sulfuric acid. PTSA showed highest catalytic activity. The yield of FAME reached 97.1% when 4 wt% of PTSA based on the oil weight was used at 80 °C with a reaction time of 2 h in the presence of DME. The obtained biodiesel was composed of methyl palmitate (9.1 wt%), methyl oleate (33.9 wt%), methyl linoleate (53.5 wt%), methyl linolenate (3.0 wt%) and methyl arachidate (0.5 wt%), and it was similar to the biodiesel compositions from corn oil as reported. The effects of concentrations of FFA and water on FAME yields were also investigated. All results suggested that the reaction rate was greatly improved by the addition of DME to the reaction system.