Performance of heterogeneous ZrO2 supported metaloxide catalysts for brown grease esterification and sulfur removal

In order to achieve a viable biodiesel industry, new catalyst technology is needed which can process a variety of less expensive waste oils, such as yellow grease and brown grease. However, for these catalysts to be effective for biodiesel production using these feedstocks, they must be able to tolerate higher concentrations of free fatty acids (FFA), water, and sulfur. We have developed a class of zirconia supported metaloxide catalysts that achieve high FAME yields through esterification of FFAs while simultaneously performing desulfurization and de-metallization functions. In fact, methanolysis, with the zirconia supported catalysts, was more effective for desulfurization than an acid washing process. In addition, using zirconia supported catalysts to convert waste grease, high in sulfur content, resulted in a FAME product that could meet the in-use ASTM diesel fuel sulfur specification (<500 ppm). Possible mechanisms of desulfurization and de-metallization by methanolysis were proposed to explain this activity.     

Biodiesel production—current state of the art and challenges

Biodiesel is a clean-burning fuel produced from grease, vegetable oils, or animal fats. Biodiesel is produced by transesterification of oils with short-chain alcohols or by the esterification of fatty acids. The transesterification reaction consists of transforming triglycerides into fatty acid alkyl esters, in the presence of an alcohol, such as methanol or ethanol, and a catalyst, such as an alkali or acid, with glycerol as a byproduct. Because of diminishing petroleum reserves and the deleterious environmental consequences of exhaust gases from petroleum diesel, biodiesel has attracted attention during the past few years as a renewable and environmentally friendly fuel. Since biodiesel is made entirely from vegetable oil or animal fats, it is renewable and biodegradable. The majority of biodiesel today is produced by alkali-catalyzed transesterification with methanol, which results in a relatively short reaction time. However, the vegetable oil and alcohol must be substantially anhydrous and have a low free fatty acid content, because the presence of water or free fatty acid or both promotes soap formation. In this article, we examine different biodiesel sources (edible and nonedible), virgin oil versus waste oil, algae-based biodiesel that is gaining increasing importance, role of different catalysts including enzyme catalysts, and the current state-of-the-art in biodiesel production. JIMB 2008: BioEnergy—special issue.     

An effective acid catalyst for biodiesel production from impure raw feedstocks

Biodiesel consists of fatty acids short chain alkyl esters produced through transesterification and esterification of fats and oils. Production of biodiesel is strongly affected by the purity of raw lipids, and catalysts play important role in these processes. Although direct utilization of impure feedstocks is more economical, their use necessitates development of effective catalysts to overcome hindering influences of impurities. In this study, sulfuryl chloride, thionyl chloride, acetyl chloride, p-toluenesulfonic acid, benzenesulfonic acid, methanesulfonic acid, dimethylsulfate and sulfuric acid were investigated as catalysts for the production of biodiesel because acids have higher tolerance to water and free fatty acids in oils and can simultaneously catalyze both the esterification and transesterification reactions. Sulfuryl chloride was found to be an effective catalyst for production of biodiesel from soybean oil, its waste oil and microalgal lipids.     

Development and quantification of biodiesel production from chicken feather meal as a cost-effective feedstock by using green technology

Increased urbanization and increase in population has led to an increased demand for fuels. The result is the prices of fuels are reaching new heights every day. Using low-cost feedstocks such as rendered animal fats in biodiesel production will reduce biodiesel expenditures. One of the low-cost feedstocks for biodiesel production from poultry feathers. This paper describes a new and environmentally friendly process for developing biodiesel production technology from feather waste produced in poultry industry. Transesterification is one of the well-known processes by which fats and oils are converted into biodiesel. The reaction often makes use of acid/base catalyst. If the material possesses high free fatty acid then acid catalyst gives better results. The data resulted from gas chromatography (GC) revealed these percentages for fatty acid compositions: myristic acid, palmitic acid, stearic acid, oleic acid, linoleic acid and arachidonic acid. The biodiesel function group was analyzed by using FTIR. This study concluded that the rooster feathers have superior potential to process them into biodiesel than broiler chicken feathers fat because of fatty acid composition values and it has important properties of biodiesel.     

Efficient production of biodiesel from high free fatty acid-containing waste oils using various carbohydrate-derived solid acid catalysts

In the present study, such carbohydrate-derived catalysts have been prepared from various carbohydrates such as d-glucose, sucrose, cellulose and starch. The catalytic and textural properties of the prepared catalysts have been investigated in detail and it was found that the starch-derived catalyst had the best catalytic performance. The carbohydrate-derived catalysts exhibited substantially higher catalytic activities for both esterification and transesterification compared to the two typical solid acid catalysts (sulphated zirconia and Niobic acid), and gave markedly enhanced yield of methyl esters in converting waste cooking oils containing 27.8wt% high free fatty acids (FFAs) to biodiesel. In addition, under the optimized reaction conditions, the starch-derived catalyst retained a remarkably high proportion (about 93%) of its original catalytic activity even after 50 cycles of successive re-use and thus displayed very excellent operational stability. Our results clearly indicate that the carbohydrate-derived catalysts, especially the starch-derived catalyst, are highly effective, recyclable, eco-friendly and promising solid acid catalysts that are highly suited to the production of biodiesel from waste oils containing high FFAs.     

Low-grade oils and fats: effect of several impurities on biodiesel production over sulfonic acid heterogeneous catalysts

Different lipidic wastes and low-grade oils and fats have been characterized and evaluated as feedstocks for the acid-catalyzed production of FAME. The characterization of these materials has revealed significant contents of free fatty acids, Na, K, Ca, Mg, P, unsaponifiable matter and humidity. Arenesulfonic acid-functionalized SBA-15 silica catalyst has provided yields to FAME close to 80% in the simultaneous esterification-transesterification of the different feedstocks, regardless of their nature and properties, using methanol under the following reaction conditions: 160 °C, 2 h, methanol to oil molar ratio of 30, 8 wt.% catalyst loading, and 2000 rpm stirring rate. Nevertheless, reutilization of the catalyst is compromised by high levels of impurities, especially because of deactivation by strong interaction of unsaponifiable matter with the catalytic sites. The conditioning of these materials by aqueous washing in the presence of cationic-exchange resin Amberlyst-15, followed by a drying step, resulted in a lower deactivation of the catalyst.     

Optimization Studies and Chemical Kinetics of Silica Sulfuric Acid-Catalyzed Biodiesel Synthesis from Waste Cooking Oil

In the present study conversion of waste cooking oil to biodiesel has been carried out via simultaneous esterification and transesterification reaction over silica sulfuric acid as a solid acid catalyst. The process variables that influence the fatty acid methyl ester (FAME) conversion, such as reaction temperature, reaction time, catalyst concentration and methanol to oil molar ratio were investigated and optimized using Taguchi method. Highest FAME production obtained under the optimized condition was 98.66 %. Analysis of variance revealed that temperature was the most significant factor effecting the FAME production among four factors studied. From the kinetic study, the reaction was found to follow pseudo first-order kinetics and rate constant of the reaction under optimum condition was 0.00852 min^?1.     

Rhizopus oryzae IFO 4697 whole cell catalyzed methanolysis of crude and acidified rapeseed oils for biodiesel production in tert-butanol system

Whole cell Rhizopus oryzae (R. oryzae) IFO4697 immobilized within biomass support particles (BSPs) was used as catalyst for biodiesel production in tert-butanol, in which the stability of the catalyst could be enhanced significantly. Different feedstocks (refined, crude and acidified rapeseed oils) were adopted further for biodiesel production in tert-butanol system and it was found that when acidified rapeseed oil was used as feedstocks, the reaction rate and final methyl ester (ME) yield were significantly higher than that of refined and crude rapeseed oil. Major differences among the aforementioned oils were found to be the contents of free fatty acid (FFA), water and phospholipids, which showed varied influences on whole cell mediated methanolysis for biodiesel production. The reaction rate increased with the increase of free fatty acid content in oils; water content had varied influence on reaction rate and biodiesel yield; using adsorbent to remove excessive water could increase biodiesel yield significantly (from 73 to 84%); it was also found interestingly that phospholipids contained in oils could increase the reaction rate to a certain extent.     

Lipase-catalyzed biodiesel production from waste activated bleaching earth as raw material in a pilot plant

The production of fatty acid methyl esters (FAMEs) from waste activated bleaching earth (ABE) discarded by the crude oil refining industry using lipase from Candida cylindracea was investigated in a 50-L pilot plant. Diesel oil or kerosene was used as an organic solvent for the transesterification of triglycerides embedded in the waste ABE. When 1% (w/w) lipase was added to waste ABE, the FAME content reached 97% (w/w) after reaction for 12 h at 25 degrees C with an agitation rate of 30 rpm. The FAME production rate was strongly dependent upon the amount of enzyme added. Mixtures of FAME and diesel oil at ratios of 45:55 (BDF-45) and 35:65 (BDF-35) were assessed and compared with the European specifications for biodiesel as automotive diesel fuel, as defined by pr EN 14214. The biodiesel quality of BDF-45 met the EN 14214 standard. BDF-45 was used as generator fuel, and the exhaust emissions were compared with those of diesel oil. The CO and SO2 contents were reduced, but nitrogen oxide emission increased by 10%. This is the first report of a pilot plant study of lipase-catalyzed FAME production using waste ABE as a raw material. This result demonstrates a promising reutilization method for the production of FAME from industrial waste resources containing vegetable oils for use as a biodiesel fuel.     

The potential of restaurant waste lipids as biodiesel feedstocks

Biodiesel is usually produced from food-grade vegetable oils that are more expensive than diesel fuel. Therefore, biodiesel produced from food-grade vegetable oil is currently not economically feasible. Waste cooking oils, restaurant grease and animal fats are potential feedstocks for biodiesel. These inexpensive feedstocks represent one-third of the US total fats and oil production, but are currently devoted mostly to industrial uses and animal feed. The characteristics of feedstock are very important during the initial research and production stage. Free fatty acids and moisture reduce the efficiency of transesterification in converting these feedstocks into biodiesel. Hence, this study was conducted to determine the level of these contaminants in feedstock samples from a rendering plant. Levels of free fatty acids varied from 0.7% to 41.8%, and moisture from 0.01% to 55.38%. These wide ranges indicate that an efficient process for converting waste grease and animal fats must tolerate a wide range of feedstock properties.     

Integrated reactive absorption process for synthesis of fatty esters

Reactive separations using green catalysts offer great opportunities for manufacturing fatty esters, involved in specialty chemicals and biodiesel production. Integrating reaction and separation into one unit provides key benefits such as: simplified operation, no waste, reduced capital investment and low operating costs.This work presents a novel heat-integrated reactive absorption process that eliminates all conventional catalyst related operations, efficiently uses the raw materials and equipment, and considerably reduces the energy requirements for biodiesel production - 85% lower as compared to the base case. Rigorous simulations based on experimental results were carried out using Aspen Plus and Dynamics. Despite the high degree of integration, the process is well controllable using an efficient control structure proposed in this work. The main results are provided for a plant producing 10 ktpy fatty acid methyl esters from methanol and waste vegetable oil with high free fatty acids content, using sulfated zirconia as solid acid catalyst.     

Rapeseed oil methyl esters preparation using heterogeneous catalysts

The classical method of fatty acids methyl esters (FAME) production is based on triglyceride transesterification to methyl esters. Sodium hydroxide dissolved in methanol is used as a catalyst. The purpose of this work was to examine a heterogeneous catalyst, in particular calcium compounds, to produce methyl esters of rapeseed oil. This research showed that the transesterification of rapeseed oil by methyl alcohol can be catalysed effectively by basic alkaline-earth metal compounds: calcium oxide, calcium methoxide and barium hydroxide. Calcium catalysts, due to their weak solubility in the reaction medium, are less active than sodium hydroxide. However, calcium catalysts are cheaper and lead to decreases in the number of technological stages and the amount of unwanted waste products. It was found that the transesterification reaction rate can be enhanced by ultrasound as well as by introducing an appropriate reagent into a reactor to promote methanol solubility in the rapeseed oil. Tetrahydrofuran was used as additive to accelerate the transesterification process.     

Metabolic engineering of fatty acid biosynthesis in plants.

Fatty acids are the most abundant form of reduced carbon chains available from nature and have diverse uses ranging from food to industrial feedstocks. Plants represent a significant renewable source of fatty acids because many species accumulate them in the form of triacylglycerol as major storage components in seeds. With the advent of plant transformation technology, metabolic engineering of oilseed fatty acids has become possible and transgenic plant oils represent some of the first successes in design of modified plant products. Directed gene down-regulation strategies have enabled the specific tailoring of common fatty acids in several oilseed crops. In addition, transfer of novel fatty acid biosynthetic genes from noncommercial plants has allowed the production of novel oil compositions in oilseed crops. These and future endeavors aim to produce seeds higher in oil content as well as new oils that are more stable, are healthier for humans, and can serve as a renewable source of industrial commodities. Large-scale new industrial uses of engineered plant oils are on the horizon but will require a better understanding of factors that limit the accumulation of unusual fatty acid structures in seeds.     

The Fatty Acid Composition and Quality of Oils from Post‐Industrial Waste of Quince Chaenomeles japonica

In the food industry, quince seeds are discarded as waste in the production process. Their use therefore creates added value and opens up the possibility of using no‐waste processing technologies. Three types of waste were investigated: after juicing, after the manufacture of puree and syrup. The results showed that the yield of quince seeds (Chaenomeles japonica (Thunb .) Lindl . ex Spach from waste left after different production methods varies from 29.8 to 38.3 %. The cold pressed oil yield ranges from 4.9±0.03 to 7.1±0.06 %. The oil yield obtained by Soxhlet extraction varies from 14.6±0.64 to 17.3±0.9 %. Unsaturated fatty acid, especially polyunsaturated fatty acid is predominant in quince seed oil. The linoleic acid content of the quince seed oils was between 47.12 % and 58.49 % of the total fatty acids. The fatty acid composition of oils from post‐industrial waste is more appropriate in the skin care industry than in the food industry because of the high ratio of omega‐6/omega‐3 and high linoleic acid content.     

Alternative Oils Tested as Feedstocks for Enzymatic FAMEs Synthesis: Toward a More Sustainable Process

Previously isolated and characterized Pseudomonas lipases were immobilized in a low‐cost MP‐1000 support by a re‐loading procedure that allowed a high activity per weight of support. Immobilized LipA, LipC, and LipCmut lipases, and commercial Novozym® 435 were tested for fatty acid methyl ester (FAMEs) synthesis using conventional and alternative feedstocks. Triolein and degummed soybean oils were used as model substrates, whereas waste cooking oil and M. circinelloides oil were assayed as alternative, low cost feedstocks, whose free fatty acid (FFA), and acylglyceride profile was characterized. The reaction conditions for FAMEs synthesis were initially established using degummed soybean oil, setting up the best water and methanol concentrations for optimum conversion. These conditions were further applied to the alternative feedstocks and the four lipases. The results revealed that Pseudomonas lipases were unable to use the FFAs, displaying a moderate FAMEs synthesis, whereas a 44% FAMEs production was obtained when M. circinelloides oil was used as a substrate in the reaction catalysed by Novozym® 435, used under the conditions established for degummed soybean oil. However, when Novozym® 435 was tested under previously described optimal conditions for this lipase, promising values of 85 and 76% FAMEs synthesis were obtained for waste cooking oil and M. circinelloides oil, respectively, which might result in promising, nonfood, alternative feedstocks for enzymatic biodiesel production. © 2017 American Institute of Chemical Engineers Biotechnol. Prog., 33:1209–1217, 2017     

Synthesis of fatty acid methyl ester from crude jatropha (Jatropha curcas Linnaeus) oil using aluminium oxide modified Mg-Zn heterogeneous catalyst

The synthesis of fatty acid methyl esters (FAME) as a substitute to petroleum diesel was investigated in this study from crude jatropha oil (CJO), a non-edible, low-cost alternative feedstock, using aluminium modified heterogeneous basic oxide (Mg-Zn) catalyst. The transesterification reaction with methanol to methyl esters yielded 94% in 6 h with methanol-oil ratio of 11:1, catalyst loading of 8.68 wt.% at 182 °C and the properties of CJO fuel produced were determine and found to be comparable to the standards according to ASTM. In the range of experimental parameters investigated, it showed that the catalyst is selective to production of methyl esters from oil with high free fatty acid (FFA) and water content of 7.23% and 3.28%, respectively in a single stage process. Thus, jatropha oil is a promising feedstock for methyl ester production and large scale cultivation will help to reduce the product cost.     

Synthesis of fatty acid methyl ester from palm oil (Elaeis guineensis) with Ky(MgCa)2xO3 as heterogeneous catalyst

Fatty acid methyl esters (FAME) were produced from palm oil using eggshell modified with magnesium and potassium nitrates to form a composite, low-cost heterogeneous catalyst for transesterification. The catalyst, prepared by the combination of impregnation/co-precipitation was calcined at 830 °C for 4 h. Transesterification was conducted at a constant temperature of 65 °C in a batch reactor. Design of experiment (DOE) was used to optimize the reaction parameters, and the conditions that gave highest yield of FAME (85.8%) was 5.35 wt.% catalyst loading at 4.5 h with 16:1 methanol/oil molar ratio. The results revealed that eggshell, a solid waste, can be utilized as low-cost catalyst after modification with magnesium and potassium nitrates for biodiesel production.     

Homogeneous,heterogeneous and enzymatic catalysis for transesterification of high free fatty acid oil (waste cooking oil) to biodiesel: A review

In the last few years, biodiesel has emerged as one of the most potential renewable energy to replace current petrol-derived diesel. It is a renewable, biodegradable and non-toxic fuel which can be easily produced through transesterification reaction. However, current commercial usage of refined vegetable oils for biodiesel production is impractical and uneconomical due to high feedstock cost and priority as food resources. Low-grade oil, typically waste cooking oil can be a better alternative; however, the high free fatty acids (FFA) content in waste cooking oil has become the main drawback for this potential feedstock. Therefore, this review paper is aimed to give an overview on the current status of biodiesel production and the potential of waste cooking oil as an alternative feedstock. Advantages and limitations of using homogeneous, heterogeneous and enzymatic transesterification on oil with high FFA (mostly waste cooking oil) are discussed in detail. It was found that using heterogeneous acid catalyst and enzyme are the best option to produce biodiesel from oil with high FFA as compared to the current commercial homogeneous base-catalyzed process. However, these heterogeneous acid and enzyme catalyze system still suffers from serious mass transfer limitation problems and therefore are not favorable for industrial application. Nevertheless, towards the end of this review paper, a few latest technological developments that have the potential to overcome the mass transfer limitation problem such as oscillatory flow reactor (OFR), ultrasonication, microwave reactor and co-solvent are reviewed. With proper research focus and development, waste cooking oil can indeed become the next ideal feedstock for biodiesel.     

Catalytic upgrading of oil fractions separated from food waste leachate

In this work, catalytic cracking of biomass waste oil fractions separated from food waste leachate was performed using microporous catalysts, such as HY, HZSM-5 and mesoporous Al-MCM-48. The experiments were carried out using pyrolysis gas chromatography/mass spectrometry (Py-GC/MS) to allow the direct analysis of the pyrolytic products. Most acidic components, especially oleic acid, contained in the food waste oil fractions were converted to valuable products, such as oxygenates, hydrocarbons and aromatics. High yields of hydrocarbons within the gasoline-range were obtained when microporous catalysts were used; whereas, the use of Al-MCM-48, which exhibits relatively weak acidity, resulted in high yields of oxygenated and diesel-range hydrocarbons. The HZSM-5 catalyst produced a higher amount of valuable mono aromatics due to its strong acidity and shape selectivity. Especially, the addition of gallium (Ga) to HZSM-5 significantly increased the aromatics content.     

Plant triacylglycerols as feedstocks for the production of biofuels

Triacylglycerols produced by plants are one of the most energy-rich and abundant forms of reduced carbon available from nature. Given their chemical similarities, plant oils represent a logical substitute for conventional diesel, a non-renewable energy source. However, as plant oils are too viscous for use in modern diesel engines, they are converted to fatty acid esters. The resulting fuel is commonly referred to as biodiesel, and offers many advantages over conventional diesel. Chief among these is that biodiesel is derived from renewable sources. In addition, the production and subsequent consumption of biodiesel results in less greenhouse gas emission compared to conventional diesel. However, the widespread adoption of biodiesel faces a number of challenges. The biggest of these is a limited supply of biodiesel feedstocks. Thus, plant oil production needs to be greatly increased for biodiesel to replace a major proportion of the current and future fuel needs of the world. An increased understanding of how plants synthesize fatty acids and triacylglycerols will ultimately allow the development of novel energy crops. For example, knowledge of the regulation of oil synthesis has suggested ways to produce triacylglycerols in abundant non-seed tissues. Additionally, biodiesel has poor cold-temperature performance and low oxidative stability. Improving the fuel characteristics of biodiesel can be achieved by altering the fatty acid composition. In this regard, the generation of transgenic soybean lines with high oleic acid content represents one way in which plant biotechnology has already contributed to the improvement of biodiesel.