Biodiesel Production
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Biodiesel production is the process of producing the
biofuel Biofuel is a fuel that is produced over a short time span from biomass, rather than by the very slow natural processes involved in the formation of fossil fuels, such as oil. According to the United States Energy Information Administration (E ...
,
biodiesel Biodiesel is a form of diesel fuel derived from plants or animals and consisting of long-chain fatty acid esters. It is typically made by chemically reacting lipids such as animal fat (tallow), soybean oil, or some other vegetable oil with ...
, through the
chemical reactions A chemical reaction is a process that leads to the chemical transformation of one set of chemical substances to another. Classically, chemical reactions encompass changes that only involve the positions of electrons in the forming and breaking ...
of
transesterification In organic chemistry, transesterification is the process of exchanging the organic group R″ of an ester with the organic group R' of an alcohol. These reactions are often catalyzed by the addition of an acid or base catalyst. The reaction can ...
and
esterification In chemistry, an ester is a compound derived from an oxoacid (organic or inorganic) in which at least one hydroxyl group () is replaced by an alkoxy group (), as in the substitution reaction of a carboxylic acid and an alcohol. Glycerides ar ...
. This involves
vegetable Vegetables are parts of plants that are consumed by humans or other animals as food. The original meaning is still commonly used and is applied to plants collectively to refer to all edible plant matter, including the flowers, fruits, stems, ...
or
animal Animals are multicellular, eukaryotic organisms in the Kingdom (biology), biological kingdom Animalia. With few exceptions, animals Heterotroph, consume organic material, Cellular respiration#Aerobic respiration, breathe oxygen, are Motilit ...
fats and oils being reacted with short-chain alcohols (typically
methanol Methanol (also called methyl alcohol and wood spirit, amongst other names) is an organic chemical and the simplest aliphatic alcohol, with the formula C H3 O H (a methyl group linked to a hydroxyl group, often abbreviated as MeOH). It is a ...
or
ethanol Ethanol (abbr. EtOH; also called ethyl alcohol, grain alcohol, drinking alcohol, or simply alcohol) is an organic compound. It is an Alcohol (chemistry), alcohol with the chemical formula . Its formula can be also written as or (an ethyl ...
). The alcohols used should be of low molecular weight. Ethanol is the most used because of its low cost, however, greater conversions into biodiesel can be reached using methanol. Although the transesterification reaction can be catalyzed by either acids or bases, the base-catalyzed reaction is more common. This path has lower reaction times and catalyst cost than those acid catalysis. However, alkaline catalysis has the disadvantage of high sensitivity to both water and free
fatty acid In chemistry, particularly in biochemistry, a fatty acid is a carboxylic acid with an aliphatic chain, which is either saturated or unsaturated. Most naturally occurring fatty acids have an unbranched chain of an even number of carbon atoms, fr ...
s present in the oils.


Process steps

The major steps required to synthesize biodiesel are as follows:


Feedstock pretreatment

Common feedstock used in biodiesel production include
yellow grease Yellow grease, also termed used cooking oil (UCO), used vegetable oil (UVO), recycled vegetable oil, or waste vegetable oil (WVO), is recovered from businesses and industry that use the oil for cooking. It is used to feed livestock, and to manufa ...
(recycled vegetable oil), "virgin" vegetable oil, and
tallow Tallow is a rendering (industrial), rendered form of beef or mutton fat, primarily made up of triglycerides. In industry, tallow is not strictly defined as beef or mutton fat. In this context, tallow is animal fat that conforms to certain techn ...
. Recycled oil is processed to remove impurities from cooking, storage, and handling, such as dirt, charred food, and water. Virgin oils are refined, but not to a food-grade level. Degumming to remove
phospholipids Phospholipids, are a class of lipids whose molecule has a hydrophilic "head" containing a phosphate group and two hydrophobic "tails" derived from fatty acids, joined by an alcohol residue (usually a glycerol molecule). Marine phospholipids typ ...
and other plant matter is common, though refinement processes vary. Water is removed because its presence during base-catalyzed transesterification results in the
saponification Saponification is a process of converting esters into soaps and alcohols by the action of aqueous alkali (for example, aqueous sodium hydroxide solutions). Soaps are salts of fatty acids, which in turn are carboxylic acids with long carbon chains. ...
(hydrolysis) of the triglycerides, producing
soap Soap is a salt of a fatty acid used in a variety of cleansing and lubricating products. In a domestic setting, soaps are surfactants usually used for washing, bathing, and other types of housekeeping. In industrial settings, soaps are use ...
instead of biodiesel. A sample of the cleaned feedstock is then tested via
titration Titration (also known as titrimetry and volumetric analysis) is a common laboratory method of quantitative chemical analysis to determine the concentration of an identified analyte (a substance to be analyzed). A reagent, termed the ''titrant'' ...
against a standardized base solution, to determine the concentration of free
fatty acid In chemistry, particularly in biochemistry, a fatty acid is a carboxylic acid with an aliphatic chain, which is either saturated or unsaturated. Most naturally occurring fatty acids have an unbranched chain of an even number of carbon atoms, fr ...
s present in the vegetable oil sample. The acids are then either removed (typically through neutralization), or are
esterified In chemistry, an ester is a compound derived from an oxoacid (organic or inorganic) in which at least one hydroxyl group () is replaced by an alkoxy group (), as in the substitution reaction of a carboxylic acid and an alcohol. Glycerides ar ...
to produce biodiesel (or glycerides).


Reactions

Base-catalyzed
transesterification In organic chemistry, transesterification is the process of exchanging the organic group R″ of an ester with the organic group R' of an alcohol. These reactions are often catalyzed by the addition of an acid or base catalyst. The reaction can ...
reacts
lipids Lipids are a broad group of naturally-occurring molecules which includes fats, waxes, sterols, fat-soluble vitamins (such as vitamins A, D, E and K), monoglycerides, diglycerides, phospholipids, and others. The functions of lipids include ...
(fats and oils) with alcohol (typically
methanol Methanol (also called methyl alcohol and wood spirit, amongst other names) is an organic chemical and the simplest aliphatic alcohol, with the formula C H3 O H (a methyl group linked to a hydroxyl group, often abbreviated as MeOH). It is a ...
or
ethanol Ethanol (abbr. EtOH; also called ethyl alcohol, grain alcohol, drinking alcohol, or simply alcohol) is an organic compound. It is an Alcohol (chemistry), alcohol with the chemical formula . Its formula can be also written as or (an ethyl ...
) to produce biodiesel and an impure coproduct,
glycerol Glycerol (), also called glycerine in British English and glycerin in American English, is a simple triol compound. It is a colorless, odorless, viscous liquid that is sweet-tasting and non-toxic. The glycerol backbone is found in lipids known ...
. If the feedstock oil is used or has a high acid content, acid-catalyzed
esterification In chemistry, an ester is a compound derived from an oxoacid (organic or inorganic) in which at least one hydroxyl group () is replaced by an alkoxy group (), as in the substitution reaction of a carboxylic acid and an alcohol. Glycerides ar ...
can be used to react
fatty acids In chemistry, particularly in biochemistry, a fatty acid is a carboxylic acid with an aliphatic chain, which is either saturated or unsaturated. Most naturally occurring fatty acids have an unbranched chain of an even number of carbon atoms, f ...
with alcohol to produce biodiesel. Other methods, such as fixed-bed reactors, supercritical reactors, and ultrasonic reactors, forgo or decrease the use of chemical reaction that reduces the quality of substance in chemistry.


Product purification

Products of the reaction include not only biodiesel, but also the byproducts soap, glycerol, excess alcohol, and trace amounts of water. All of these byproducts must be removed to meet the standards, but the order of removal is process-dependent. The density of glycerol is greater than that of biodiesel, and this property difference is exploited to separate the bulk of the glycerol coproduct. Residual methanol is typically recovered by distillation and reused. Soaps can be removed or converted into acids. Residual water is also removed from the fuel.


Reactions


Transesterification

Animal and plant fats and oils are composed of
triglyceride A triglyceride (TG, triacylglycerol, TAG, or triacylglyceride) is an ester derived from glycerol and three fatty acids (from ''tri-'' and ''glyceride''). Triglycerides are the main constituents of body fat in humans and other vertebrates, as w ...
s, which are
ester In chemistry, an ester is a compound derived from an oxoacid (organic or inorganic) in which at least one hydroxyl group () is replaced by an alkoxy group (), as in the substitution reaction of a carboxylic acid and an alcohol. Glycerides ar ...
s formed by the reactions of three free
fatty acid In chemistry, particularly in biochemistry, a fatty acid is a carboxylic acid with an aliphatic chain, which is either saturated or unsaturated. Most naturally occurring fatty acids have an unbranched chain of an even number of carbon atoms, fr ...
s and the trihydric alcohol,
glycerol Glycerol (), also called glycerine in British English and glycerin in American English, is a simple triol compound. It is a colorless, odorless, viscous liquid that is sweet-tasting and non-toxic. The glycerol backbone is found in lipids known ...
. In the transesterification process, the added alcohol (commonly,
methanol Methanol (also called methyl alcohol and wood spirit, amongst other names) is an organic chemical and the simplest aliphatic alcohol, with the formula C H3 O H (a methyl group linked to a hydroxyl group, often abbreviated as MeOH). It is a ...
or
ethanol Ethanol (abbr. EtOH; also called ethyl alcohol, grain alcohol, drinking alcohol, or simply alcohol) is an organic compound. It is an Alcohol (chemistry), alcohol with the chemical formula . Its formula can be also written as or (an ethyl ...
) is
deprotonated Deprotonation (or dehydronation) is the removal (transfer) of a proton (or hydron, or hydrogen cation), (H+) from a Brønsted–Lowry acid in an acid–base reaction.Henry Jakubowski, Biochemistry Online Chapter 2A3, https://employees.csbsju.edu ...
with a base to make it a stronger
nucleophile In chemistry, a nucleophile is a chemical species that forms bonds by donating an electron pair. All molecules and ions with a free pair of electrons or at least one pi bond can act as nucleophiles. Because nucleophiles donate electrons, they are ...
. As can be seen, the reaction has no other inputs than the triglyceride and the alcohol. Under normal conditions, this reaction will proceed either exceedingly slowly or not at all, so heat, as well as catalysts (
acid In computer science, ACID ( atomicity, consistency, isolation, durability) is a set of properties of database transactions intended to guarantee data validity despite errors, power failures, and other mishaps. In the context of databases, a sequ ...
and/or base) are used to speed the
reaction Reaction may refer to a process or to a response to an action, event, or exposure: Physics and chemistry *Chemical reaction *Nuclear reaction *Reaction (physics), as defined by Newton's third law *Chain reaction (disambiguation). Biology and me ...
. It is important to note that the acid or base are not consumed by the transesterification reaction, thus they are not reactants, but catalysts. Common catalysts for transesterification include
sodium hydroxide Sodium hydroxide, also known as lye and caustic soda, is an inorganic compound with the formula NaOH. It is a white solid ionic compound consisting of sodium cations and hydroxide anions . Sodium hydroxide is a highly caustic base and alkali ...
,
potassium hydroxide Potassium hydroxide is an inorganic compound with the formula K OH, and is commonly called caustic potash. Along with sodium hydroxide (NaOH), KOH is a prototypical strong base. It has many industrial and niche applications, most of which exp ...
, and
sodium methoxide Sodium methoxide is the simplest sodium alkoxide. With the formula , it is a white solid, which is formed by the deprotonation of methanol. Itis a widely used reagent in industry and the laboratory. It is also a dangerously caustic base. P ...
. Almost all biodiesel is produced from virgin vegetable oils using the base-catalyzed technique as it is the most economical process for treating virgin vegetable oils, requiring only low temperatures and pressures and producing over 98% conversion yield (provided the starting oil is low in moisture and free fatty acids). However, biodiesel produced from other sources or by other methods may require acid catalysis, which is much slower. Since it is the predominant method for commercial-scale production, only the base-catalyzed transesterification process will be described Triglycerides (1) are reacted with an alcohol such as ethanol (2) to give ethyl esters of fatty acids (3) and glycerol (4): : ::R1, R2, R3 :
Alkyl group In organic chemistry, an alkyl group is an alkane missing one hydrogen. The term ''alkyl'' is intentionally unspecific to include many possible substitutions. An acyclic alkyl has the general formula of . A cycloalkyl is derived from a cycloalk ...
The alcohol reacts with the fatty acids to form the mono-alkyl ester (biodiesel) and crude glycerol. The reaction between the biolipid (fat or oil) and the alcohol is a
reversible reaction A reversible reaction is a reaction in which the conversion of reactants to products and the conversion of products to reactants occur simultaneously. : \mathit aA + \mathit bB \mathit cC + \mathit dD A and B can react to form C and D or, in the ...
so excess alcohol must be added to ensure complete conversion.


Base-catalysed transesterification mechanism

The transesterification reaction is base catalyzed. Any strong base capable of deprotonating the alcohol will work (e.g. NaOH, KOH,
sodium methoxide Sodium methoxide is the simplest sodium alkoxide. With the formula , it is a white solid, which is formed by the deprotonation of methanol. Itis a widely used reagent in industry and the laboratory. It is also a dangerously caustic base. P ...
, etc.), but the sodium and potassium hydroxides are often chosen for their cost. The presence of water causes undesirable base
hydrolysis Hydrolysis (; ) is any chemical reaction in which a molecule of water breaks one or more chemical bonds. The term is used broadly for substitution reaction, substitution, elimination reaction, elimination, and solvation reactions in which water ...
, so the reaction must be kept dry. In the transesterification mechanism, the carbonyl carbon of the starting ester (RCOOR1) undergoes nucleophilic attack by the incoming alkoxide (R2O) to give a tetrahedral intermediate, which either reverts to the starting material, or proceeds to the transesterified product (RCOOR2). The various species exist in equilibrium, and the product distribution depends on the relative energies of the reactant and product. :


Production methods


Supercritical process

An alternative, catalyst-free method for transesterification uses supercritical methanol at high temperatures and pressures in a continuous process. In the supercritical state, the oil and methanol are in a single phase, and reaction occurs spontaneously and rapidly. The process can tolerate water in the feedstock, free fatty acids are converted to methyl esters instead of soap, so a wide variety of feedstocks can be used. Also the catalyst removal step is eliminated. High temperatures and pressures are required, but energy costs of production are similar or less than catalytic production routes.


Ultra- and high-shear in-line and batch reactors

Ultra- and High Shear in-line or batch reactors allow production of biodiesel continuously, semi- continuously, and in batch-mode. This drastically reduces production time and increases production volume. The reaction takes place in the high-energetic shear zone of the Ultra- and High Shear mixer by reducing the droplet size of the immiscible liquids such as oil or fats and methanol. Therefore, the smaller the droplet size the larger the surface area the faster the catalyst can react.


Ultrasonic reactor method

In the ultrasonic reactor method, the ultrasonic waves cause the reaction mixture to produce and collapse bubbles constantly; this cavitation simultaneously provides the mixing and heating required to carry out the transesterification process. Use of an ultrasonic reactor for biodiesel production can drastically reduce reaction time and temperatures, and energy input. Using such reactors, the process of transesterification can run inline rather than using the time-consuming batch processing. Industrial scale ultrasonic devices allow for processing of several thousand barrels per day.


Lipase-catalyzed method

Large amounts of research have focused recently on the use of enzymes as a catalyst for the transesterification. Researchers have found that very good yields could be obtained from crude and used oils using
lipase Lipase ( ) is a family of enzymes that catalyzes the hydrolysis of fats. Some lipases display broad substrate scope including esters of cholesterol, phospholipids, and of lipid-soluble vitamins and sphingomyelinases; however, these are usually tr ...
s. The use of lipases makes the reaction less sensitive to high free fatty-acid content, which is a problem with the standard biodiesel process. One problem with the lipase reaction is that methanol cannot be used because it inactivates the lipase catalyst after one batch. However, if methyl acetate is used instead of methanol, the lipase is not in-activated and can be used for several batches, making the lipase system much more cost-effective.


Volatile fatty acids from anaerobic digestion of waste streams

Lipids have been drawing considerable attention as a substrate for biodiesel production owing to its sustainability, non-toxicity and energy efficient properties. However, due to cost reasons, attention must be focused on the non-edible sources of lipids, in particular oleaginous microorganisms. Such microbes have the ability to assimilate the carbon sources from a medium and convert the carbon into lipid storage materials. The lipids accumulated by these oleaginous cells can then be transesterified to form biodiesel.


See also

* Biodiesel from CO2 *
Dehulling Husk (or hull) in botany is the outer shell or coating of a seed. In the United States, the term husk often refers to the leafy outer covering of an ear of maize (corn) as it grows on the plant. Literally, a husk or hull includes the protective ...
*
Vegetable oil fuel Vegetable oil can be used as an alternative fuel in diesel engines and in heating oil burners. When vegetable oil is used directly as a fuel, in either modified or unmodified equipment, it is referred to as straight vegetable oil (SVO) or pure pl ...


References


Further reading

* Gerpen, J.V., "Biodiesel processing and production", ''Fuel Processing Technology'', 2005, 86, 1097–1107. * Ma, F. & Hanna, M.A., "Biodiesel production: a review", ''Bioresource Technology'', 1999, 70, 1–15.


External links

* Commercial mixing and processing relevant to biodiesel production
Fast-Transesterification of Soybean Oil Using Ultrasonication


* ttp://www.nrel.gov/docs/fy04osti/36244.pdf Biodiesel Production Technology August 2002 – January 2004
UNL Chemical and Biomolecular Engineering Research and Publications

Continuous Process for the Conversion of Vegetable Oils into Methyl Esters of Fatty Acids

Biodiesel Safety and Best Management Practices for Small-Scale Noncommercial Use and Production
{{Bioenergy Biodiesel Base catalyzed reactions