Production of biofuel from waste cooking palm oil using nanocrystalline zeolite as catalyst: process optimization studies

The catalytic cracking of waste cooking palm oil to biofuel was studied over different types of nano-crystalline zeolite catalysts in a fixed bed reactor. The effect of reaction temperature (400-500 °C), catalyst-to-oil ratio (6-14) and catalyst pore size of different nanocrystalline zeolites (0.54-0.80 nm) were studied over the conversion of waste cooking palm oil, yields of Organic Liquid Product (OLP) and gasoline fraction in the OLP following central composite design (CCD). The response surface methodology was used to determine the optimum value of the operating variables for maximum conversion as well as maximum yield of OLP and gasoline fraction, respectively. The optimum reaction temperature of 458 °C with oil/catalyst ratio=6 over the nanocrystalline zeolite Y with pore size of 0.67 nm gave 86.4 wt% oil conversion, 46.5 wt% OLP yield and 33.5 wt% gasoline fraction yield, respectively. The experimental results were in agreement with the simulated values within an experimental error of less than 5%.     

Ethanesulfonic acid-based esterification of industrial acidic crude palm oil for biodiesel production

An industrial grade acidic crude palm oil (ACPO) pre-treatment process was carried out using ethanesulfonic acid (ESA) as a catalyst in the esterification reaction. ESA was used in different dosages to reduce free fatty acid (FFA) to a minimum level for the second stage of biodiesel production via alkaline transesterification reaction. Different process operating conditions were optimized such as ESA dosage (0.25-3.5% wt/wt), methanol to ACPO molar ratio (1:1-20:1), reaction temperature (40-70 °C), and reaction time (3-150 min). This study revealed the potential use of abundant quantities of ACPO from oil palm mills for biodiesel production. The lab scale results showed the effectiveness of the pre-treatment process using ESA catalyst. Three consecutive catalyst recycling runs were achieved without significant degradation in its performance. Second and third reuse runs needed more reaction time to achieve the target level of FFA content. Esterification and transesterification using ESA and KOH respectively is proposed for biodiesel industrial scale production. The produced biodiesel meets the international standards specifications for biodiesel fuel (EN 14214 and ASTM D6751).     

Optimisation of integrated biodiesel production. Part II: a study of the material balance

A study was made of the material balance for the fatty acid methyl ester (biodiesel) synthesis from sunflower oil using potassium hydroxide as the catalyst. A factorial design of experiments and a central composite design have been used to evaluate the influence of operating conditions on the process material balance. The responses chosen were the biodiesel yield and the yield losses due to triglyceride saponification and methyl ester dissolution in glycerol, while the variables studied were temperature, initial catalyst concentration and the methanol:vegetable oil molar ratio. The biodiesel yield increased and therefore the yield losses decreased by decreasing catalyst concentration and temperature. However, the methanol:sunflower oil molar ratio did not affect the material balance variables significantly. Second-order models were obtained to predict the biodiesel yield and both yield losses. Within the experimental range studied, these models largely matched the results from the experiments.     

Production of biodiesel from Jatropha curcas L. oil catalyzed by SO₄²⁻/ZrO₂ catalyst: effect of interaction between process variables

This study reports the conversion of Jatrophacurcas L. oil to biodiesel catalyzed by sulfated zirconia loaded on alumina catalyst using response surface methodology (RSM), specifically to study the effect of interaction between process variables on the yield of biodiesel. The transesterification process variables studied were reaction temperature, reaction duration, molar ratio of methanol to oil and catalyst loading. Results from this study revealed that individual as well as interaction between variables significantly affect the yield of biodiesel. With this information, it was found that 4h of reaction at 150°C, methanol to oil molar ratio of 9.88 mol/mol and 7.61 wt.% for catalyst loading gave an optimum biodiesel yield of 90.32 wt.%. The fuel properties of Jatropha biodiesel were characterized and it indeed met the specification for biodiesel according to ASTM D6751.     

Continuous biosynthesis of biodiesel from waste cooking palm oil in a packed bed reactor: optimization using response surface methodology (RSM) and mass transfer studies

This study aimed to develop an optimal continuous procedure of lipase-catalyzes transesterification of waste cooking palm oil in a packed bed reactor to investigate the possibility of large scale production further. Response surface methodology (RSM) based on central composite rotatable design (CCRD) was used to optimize the two important reaction variables packed bed height (cm) and substrate flow rate(ml/min) for the transesterification of waste cooking palm oil in a continuous packed bed reactor. The optimum condition for the transesterification of waste cooking palm oil was as follows: 10.53 cm packed bed height and 0.57 ml/min substrate flow rate. The optimum predicted fatty acid methyl ester (FAME) yield was 80.3% and the actual value was 79%. The above results shows that the RSM study based on CCRD is adaptable for FAME yield studied for the current transesterification system. The effect of mass transfer in the packed bed reactor has also been studied. Models for FAME yield have been developed for cases of reaction control and mass transfer control. The results showed very good agreement compatibility between mass transfer model and the experimental results obtained from immobilized lipase packed bed reactor operation, showing that in this case the FAME yield was mass transfer controlled.     

Effect of catalyst additives on the production of biofuels from palm oil cracking in a transport riser reactor

Catalytic cracking of crude palm oil (CPO) and used palm oil (UPO) were studied in a transport riser reactor for the production of biofuels at a reaction temperature of 450 °C, with residence time of 20 s and catalyst-to-oil ratio (CTO) of 5 g g^?1. The effect of HZSM-5 (differrent Si/Al ratios), beta zeolite, SBA-15 and AlSBA-15 were studied as physically mixed additives with cracking catalyst Rare earth-Y (REY). REY catalyst alone gave 75.8 wt% conversion with 34.5 wt% of gasoline fraction yield using CPO, whereas with UPO, the conversion was 70.9 wt% with gasoline fraction yield of 33.0 wt%. HZSM-5, beta zeolite, SBA-15 and AlSBA-15 as additives with REY increased the conversion and the yield of organic liquid product. The transport riser reactor can be used for the continuous production of biofuels from cracking of CPO and UPO over REY catalyst.     

Optimization of Biomass Conversion to Levulinic Acid in Acidic Ionic Liquid and Upgrading of Levulinic Acid to Ethyl Levulinate

Levulinic acid (LA) is a versatile platform chemical that can be derived from biomass as an alternative to fossil fuel resources. Herein, the optimization of LA production from glucose and oil palm fronds (OPF) catalyzed by an acidic ionic liquid; 1-sulfonic acid-3-methyl imidazolium tetrachloroferrate ([SMIM][FeCl₄]) have been investigated. Response surface methodology based on Box-Behnken design was employed to optimize the LA yield and to examine the effect and interaction of reaction parameters on the LA production. The reaction parameters include reaction temperature, reaction time, feedstock loading, and catalyst loading. From the optimization study, the predicted mathematical models for LA production from glucose and OPF covered more than 90 % of the variability in the experimental data. At optimum conditions, 69.2 % of LA yield was obtained from glucose, while 24.8 % of LA yield was attained from OPF and registered 77.3 % of process efficiency. The recycled [SMIM][FeCl₄] gave sufficient performance for five successive cycles. Furthermore, the optimum LA produced from glucose and OPF can be directly converted to ethyl levulinate through esterification over the [SMIM][FeCl₄] catalyst. This study highlights the potential of [SMIM][FeCl₄] for biorefinery processing of renewable feedstocks at mild process conditions.     

Optimisation of integrated biodiesel production. Part I. A study of the biodiesel purity and yield

This study consists of the development and optimisation of the potassium hydroxide-catalysed synthesis of fatty acid methyl esters (biodiesel) from sunflower oil. A factorial design of experiments and a central composite design have been used. The variables chosen were temperature, initial catalyst concentration by weight of sunflower oil and the methanol:vegetable oil molar ratio, while the responses were biodiesel purity and yield. The initial catalyst concentration is the most important factor, having a positive influence on biodiesel purity, but a negative one on biodiesel yield. Temperature has a significant positive effect on biodiesel purity and a significant negative influence on biodiesel yield. The methanol:vegetable oil molar ratio is only significant for the biodiesel purity, having a positive influence. Second-order models were obtained to predict biodiesel purity and yield as a function of these variables. The best conditions are 25 degrees C, a 1.3%wt for the catalyst concentration and a 6:1 methanol:sunflower oil molar ratio.     

Lipase-catalysed production of biodiesel fuel from some Nigerian lauric oils

Fatty acids esters were produced from two Nigerian lauric oils, palm kernel oil and coconut oil, by transesterification of the oils with different alcohols using PS30 lipase as a catalyst. In the conversion of palm kernel oil to alkyl esters (biodiesel), ethanol gave the highest conversion of 72%, t-butanol 62%, 1-butanol 42%, n-propanol 42% and iso-propanol 24%, while only 15% methyl ester was observed with methanol. With coconut oil, 1-butanol and iso-butanol achieved 40% conversion, 1-propanol 16% and ethanol 35%, while only traces of methyl esters were observed using methanol. Studies on some fuel properties of palm kernel oil and its biodiesel showed that palm kernel oil had a viscosity of 32.40 mm2/s, a cloud point of 28 degrees C and a pour point of 22 degrees C, while its biodiesel fuel had a viscosity of 9.33 mm2/s, a cloud point of 12 degrees C and a pour point of 8 degrees C. Coconut oil had a viscosity of 28.58 mm(2)/s, a cloud point of 27 degrees C and a pour point of 20 degrees C, while its biodiesel fuel had a viscosity of 7.34 mm2/s, a cloud point of 5 degrees C and a pour point of -8 degrees C. Some of the fuel properties compared favourably with international biodiesel specifications.     

Fuel Characteristics of Solid Biofuel Derived from Oil Palm Biomass and Fast Growing Timber Species in Malaysia

The fuel characteristics of solid biofuels derived from biomass that is abundantly available in Malaysia are presented. The objectives of the study were to characterize fuel properties of oil palm biomass (empty fruit bunch (EFB) and oil palm trunk (OPT)) and wood from a range of fast growing timber species (Albizia falcataria, Acacia spp., Endospermum spp. and Macaranga spp.), inclusive and exclusive of bark. Among the fast-growing timber species, the higher heating values ranged from 4288 cal g^-1 to 4383 cal g^-1 for wood inclusive of bark, and 4134 cal g^-1 to 4343 cal g^-1 for wood exclusive of bark. The inclusive of bark portion in the biomass sample generally increased the heating value except for Macaranga spp. Empty fruit bunch and oil palm trunk had heating values of 4315 cal g^-1 and 4104 cal g^-1, respectively. Ash-forming elements and trace elements were much higher in the timber species samples inclusive of bark than samples exclusive of bark. On the other hand, oil palm biomass contained higher ash-forming elements and trace elements than the wood from the fast growing timber species. The European energy crops show higher HHV, Cl and Si content but lower K, Mg, Na and P compared to the local biomass used in this study. The data obtained from this study can serve as a foundation for the selection of suitable biomass to be used as solid fuel, or as a reference on the fabrication of conversion systems for the selection of biomass solid fuel.     

Preparation and characterization of polyurethane foams using a palm oil-based polyol

Polyurethane (PU) foams were prepared using a palm oil-based polyol (PO-p). At the first stage, palm oil was converted to monoglycerides as a new type of polyol by glycerolysis. A yield of the product reached 70% at reaction temperature of 90 degrees C by using an alkali catalyst and a solvent. At the second stage, PU foams were prepared from mixtures of the polyol and polyethylene glycol (PEG) or diethylene glycol (DEG) and an isocyanate compound. Characterization of the foams was carried out by thermal and mechanical analyses. The analyses showed that the chain motion of polyurethane becomes more flexible at the higher PO-p content in the whole polymer, which indicates that the monoglyceride molecules work as soft segments. The study here may lead to a development of a new type of polyurethane foams using palm oil as a raw material.     

Biofuel production from palm oil with supercritical alcohols: effects of the alcohol to oil molar ratios on the biofuel chemical composition and properties

Biofuel production from palm oil with supercritical methanol (SCM) and supercritical ethanol (SCE) at 400 °C and 15 MPa were evaluated. At the optimal alcohol to oil molar ratios of 12:1 and 18:1 for the SCM and SCE processes, respectively, the biofuel samples were synthesized in a 1.2-L reactor and the resulting biofuel was analyzed for the key properties including those for the diesel and biodiesel standard specifications. Biofuel samples derived from both the SCM and SCE processes could be used as an alternative fuel after slight improvement in their acid value and free glycerol content. The remarkable advantages of this novel process were: the additional fuel yield of approximately of 5% and 10% for SCM and SCE, respectively; the lower energy consumption for alcohol preheating, pumping and recovering than the biodiesel production with supercritical alcohols that use a high alcohol to oil molar ratio of 42:1.     

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.     

Biocatalytic ethanolysis of palm oil for biodiesel production using microcrystalline lipase in tert-butanol system

Biocatalytic synthesis is a promising environmentally friendly process for the production of biodiesel, a sustainable alternative fuel from renewable plant resources. In order to develop an economical heterogeneous biocatalyst, protein-coated microcrystals (PCMCs) were prepared from a commercial enzyme preparation from a recombinant Aspergillus strain expressing Thermomyces lanuginosus lipase and used for synthesis of biodiesel from palm olein by ethanolysis. Reaction parameters, including catalyst loading, temperature, and oil/alcohol molar ratio have been systematically optimized. Addition of tert-butanol was found to markedly increase the biocatalyst activity and stability resulting in improved product yield. Optimized reactions (20%, w/w PCMC-lipase to triacylglycerol and 1:4 fatty acid equivalence/ethanol molar ratio) led to the production of alkyl esters from palm olein at 89.9% yield on molar basis after incubation at 45 °C for 24 h in the presence of tert-butanol at a 1:1 molar ratio to triacylglycerol. Crude palm oil and palm fatty acid distillate were also efficiently converted to biodiesel with 82.1 and 75.5% yield, respectively, with continual dehydration by molecular sieving. Operational stability of PCMC-lipase could be improved by treatment with tert-butanol allowing recycling of the biocatalyst for at least 8 consecutive batches with only slight reduction in activity. This work thus shows a promising approach for biodiesel synthesis with microcrystalline lipase which could be further developed for cost-efficient industrial production of biodiesel.     

Carbonisation of oil palm trunks at moderate temperatures

Thousands of tonnes of dry oil palm trunks will be produced annually in Malaysia after about 1990. A project was initiated to study the feasibility of converting palm trunks into charcoal. Carbonisation was done at terminal temperatures of 400–550°C with holding times of 1–3 h and at two heating rates. From laboratory-scale pyrolysis studies, it was found that holding time does not affect the quantity and quality of the charcoal produced, while heating rate has a minor influence. However, as terminal temperature increases, both yield and volatile content decrease while the fixed carbon content increases. The calorific value and ash contents are independent of the parameters studied and their respective values are 4032 kcal/kg and 37.2%. Since the calorific value is low and the ash content high, it is concluded that oil palm trunks are not suitable for the production of charcoal fuel.     

Synthesis of methyl esters from palm (Elaeis guineensis) oil using cobalt doped MgO as solid oxide catalyst

The potential of Mg(x)Co(2-)(x)O(2) as heterogeneous reusable catalyst in transesterification of palm oil to methyl ester was investigated. The catalyst was prepared via co-precipitation of the metal hydroxides at different Mg-Co ratios. Mg(1.7)Co(0.3)O(2) catalyst was more active than Mg(0.3)Co(1.7)O(2) in the transesterification of palm oil with methanol. The catalysts calcined at temperature 300 °C for 4 h resulted in highly active oxides and the highest transesterification of 90% was achieved at methanol/oil molar ratio of 9:1, catalyst loading of 5.00 wt.%, reaction temperature of 150 °C and reaction time of 2 h. The catalyst could easily be removed from reaction mixture, but showed 50% decrease in activity when reused due to leaching of active sites.     

Transesterification of palm oil to methyl ester on activated carbon supported calcium oxide catalyst

In this study, methyl ester (ME) was produced by transesterification of palm oil (CPO) (cooking grade) using activated carbon supported calcium oxide as a solid base catalyst (CaO/AC). Response surface methodology (RSM) based on central composite design (CCD) was used to optimize the effect of reaction time, molar ratio of methanol to oil, reaction temperature and catalyst amount on the transesterification process. The optimum condition for CPO transesterification to methyl ester was obtained at 5.5 wt.% catalyst amount, 190 °C temperature, 15:1 methanol to oil molar ratio and 1 h 21 min reaction time. At the optimum condition, the ME content was 80.98%, which is well within the predicted value of the model. Catalyst regeneration studies indicate that the catalyst performance is sustained after two cycles.     

Soda-anthraquinone pulping of palm oil empty fruit bunches and beating of the resulting pulp

The influence of soda-anthraquinone pulping variables (temperature, time and soda concentration) and beating (number of PFI beating revolution) of palm oil empty fruit bunches (EFB) on the resulting paper sheets was studied, with a view to identifying the optimum operating conditions. Equations were derived that reproduced the properties of the paper sheets with errors less than 10-12% in 90-95% of cases. An optimum compromise was found as regards operating conditions (15% soda, 170 degrees C, 70 min and 2400 number of PFI beating revolutions) that provided paper properties departing by less than 12% from their optimum values (59.63 Nm/g tensile index, 4.48% stretch, 4.17 kN/g burst index and 7.20 m Nm(2)/g tear index), and a beating grade of 47.5 degrees SR, acceptable to obtain paper sheets. Because these conditions involve a lower soda, temperature, time and beating than those required to maximize the studied paper properties, they can save chemical reagents, energy and immobilized capital for industrial facilities. On the other hand, the stretch properties of these pulp beaten are higher than those of others non-wood pulps, as wheat straw and olive wood.     

Effects of land use on surface-atmosphere exchanges of trace gases and energy in Borneo: comparing fluxes over oil palm plantations and a rainforest

This paper reports measurements of land-atmosphere fluxes of sensible and latent heat, momentum, CO(2), volatile organic compounds (VOCs), NO, NO(2), N(2)O and O(3) over a 30 m high rainforest canopy and a 12 m high oil palm plantation in the same region of Sabah in Borneo between April and July 2008. The daytime maximum CO(2) flux to the two canopies differs by approximately a factor of 2, 1200 mg C m(-2) h(-1) for the oil palm and 700 mg C m(-2) h(-1) for the rainforest, with the oil palm plantation showing a substantially greater quantum efficiency. Total VOC emissions are also larger over the oil palm than over the rainforest by a factor of 3. Emissions of isoprene from the oil palm canopy represented 80 per cent of the VOC emissions and exceeded those over the rainforest in similar light and temperature conditions by on average a factor of 5. Substantial emissions of estragole (1-allyl-4-methoxybenzene) from the oil palm plantation were detected and no trace of this VOC was detected in or above the rainforest. Deposition velocities for O(3) to the rainforest were a factor of 2 larger than over oil palm. Emissions of nitrous oxide were larger from the soils of the oil palm plantation than from the soils of the rainforest by approximately 25 per cent. It is clear from the measurements that the large change in the species composition generated by replacing rainforest with oil palm leads to profound changes in the net exchange of most of the trace gases measured, and thus on the chemical composition of the boundary layer over these surfaces.     

Novozym 435 for production of biodiesel from unrefined palm oil: Comparison of methanolysis methods

Biodiesel (BD) is commonly produced from refined vegetable oils by alkali-catalyzed methanolysis. Unrefined vegetable oils are economically attractive but not suitable for alkali catalysis because of their high content of free fatty acids (FFAs). Novozym 435 (immobilized Candida antarctica lipase B), which accepts both FFA and oil as substrates, was, therefore, employed to convert unrefined palm oil to BD. Three different methanolysis methods, namely, t-butanol mediated system (method-1), LiCl solution based controlled release system for methanol (method-2) and solvent-free system with three successive additions of methanol (method-3), were compared. The optimal methanol to oil molar ratios in the method-1, -2 and -3 are 6:1, 3:1 and 3:1, respectively. BD yield at an optimal methanol concentration reaches 91–92% after 10, 20 and 24 h in the method-1, -2 and -3, respectively. BD yield remains the same over five repeated cycles in the method-1, while it drops to 68 and 71% by the fifth cycle in the method-2 and -3, respectively. The results show that the method-1 is the most effective for production of BD from a low cost feedstock like unrefined palm oil.