EP4071226A1 - Verfahren zur herstellung von fettsäurealkylestern - Google Patents
Verfahren zur herstellung von fettsäurealkylestern Download PDFInfo
- Publication number
- EP4071226A1 EP4071226A1 EP21167432.0A EP21167432A EP4071226A1 EP 4071226 A1 EP4071226 A1 EP 4071226A1 EP 21167432 A EP21167432 A EP 21167432A EP 4071226 A1 EP4071226 A1 EP 4071226A1
- Authority
- EP
- European Patent Office
- Prior art keywords
- phase
- light phase
- separated
- free fatty
- fatty acids
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
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- 238000000034 method Methods 0.000 title claims abstract description 70
- 235000014113 dietary fatty acids Nutrition 0.000 title claims abstract description 58
- 239000000194 fatty acid Substances 0.000 title claims abstract description 56
- 229930195729 fatty acid Natural products 0.000 title claims abstract description 56
- 235000021588 free fatty acids Nutrition 0.000 claims abstract description 82
- 238000005809 transesterification reaction Methods 0.000 claims abstract description 58
- 150000003626 triacylglycerols Chemical class 0.000 claims abstract description 42
- 230000003197 catalytic effect Effects 0.000 claims abstract description 10
- PEDCQBHIVMGVHV-UHFFFAOYSA-N Glycerine Chemical compound OCC(O)CO PEDCQBHIVMGVHV-UHFFFAOYSA-N 0.000 claims description 94
- 235000011187 glycerol Nutrition 0.000 claims description 44
- LFQSCWFLJHTTHZ-UHFFFAOYSA-N Ethanol Chemical compound CCO LFQSCWFLJHTTHZ-UHFFFAOYSA-N 0.000 claims description 42
- 238000006386 neutralization reaction Methods 0.000 claims description 33
- 239000003054 catalyst Substances 0.000 claims description 31
- -1 fatty acid esters Chemical class 0.000 claims description 22
- 238000005886 esterification reaction Methods 0.000 claims description 21
- 239000000203 mixture Substances 0.000 claims description 16
- 238000006243 chemical reaction Methods 0.000 claims description 12
- 238000002156 mixing Methods 0.000 claims description 12
- 238000004064 recycling Methods 0.000 claims description 12
- 125000005233 alkylalcohol group Chemical group 0.000 claims description 10
- 230000003472 neutralizing effect Effects 0.000 claims description 10
- KWYUFKZDYYNOTN-UHFFFAOYSA-M Potassium hydroxide Chemical compound [OH-].[K+] KWYUFKZDYYNOTN-UHFFFAOYSA-M 0.000 claims description 6
- HEMHJVSKTPXQMS-UHFFFAOYSA-M Sodium hydroxide Chemical compound [OH-].[Na+] HEMHJVSKTPXQMS-UHFFFAOYSA-M 0.000 claims description 6
- BDAWXSQJJCIFIK-UHFFFAOYSA-N potassium methoxide Chemical compound [K+].[O-]C BDAWXSQJJCIFIK-UHFFFAOYSA-N 0.000 claims description 5
- ZLMJMSJWJFRBEC-UHFFFAOYSA-N Potassium Chemical compound [K] ZLMJMSJWJFRBEC-UHFFFAOYSA-N 0.000 claims description 4
- WQDUMFSSJAZKTM-UHFFFAOYSA-N Sodium methoxide Chemical compound [Na+].[O-]C WQDUMFSSJAZKTM-UHFFFAOYSA-N 0.000 claims description 4
- 229910052751 metal Inorganic materials 0.000 claims description 4
- 239000002184 metal Substances 0.000 claims description 4
- 230000020477 pH reduction Effects 0.000 claims description 4
- 229910052700 potassium Inorganic materials 0.000 claims description 4
- 239000011591 potassium Substances 0.000 claims description 4
- DGAQECJNVWCQMB-PUAWFVPOSA-M Ilexoside XXIX Chemical compound C[C@@H]1CC[C@@]2(CC[C@@]3(C(=CC[C@H]4[C@]3(CC[C@@H]5[C@@]4(CC[C@@H](C5(C)C)OS(=O)(=O)[O-])C)C)[C@@H]2[C@]1(C)O)C)C(=O)O[C@H]6[C@@H]([C@H]([C@@H]([C@H](O6)CO)O)O)O.[Na+] DGAQECJNVWCQMB-PUAWFVPOSA-M 0.000 claims description 3
- 239000011734 sodium Substances 0.000 claims description 3
- 229910052708 sodium Inorganic materials 0.000 claims description 3
- FGUUSXIOTUKUDN-IBGZPJMESA-N C1(=CC=CC=C1)N1C2=C(NC([C@H](C1)NC=1OC(=NN=1)C1=CC=CC=C1)=O)C=CC=C2 Chemical compound C1(=CC=CC=C1)N1C2=C(NC([C@H](C1)NC=1OC(=NN=1)C1=CC=CC=C1)=O)C=CC=C2 FGUUSXIOTUKUDN-IBGZPJMESA-N 0.000 claims description 2
- GHVZOJONCUEWAV-UHFFFAOYSA-N [K].CCO Chemical compound [K].CCO GHVZOJONCUEWAV-UHFFFAOYSA-N 0.000 claims description 2
- 229910000000 metal hydroxide Inorganic materials 0.000 claims description 2
- 150000004692 metal hydroxides Chemical class 0.000 claims description 2
- 150000002739 metals Chemical class 0.000 claims description 2
- QDRKDTQENPPHOJ-UHFFFAOYSA-N sodium ethoxide Chemical compound [Na+].CC[O-] QDRKDTQENPPHOJ-UHFFFAOYSA-N 0.000 claims description 2
- 239000003921 oil Substances 0.000 description 28
- 239000003925 fat Substances 0.000 description 27
- 235000019198 oils Nutrition 0.000 description 27
- 239000002585 base Substances 0.000 description 25
- 235000019197 fats Nutrition 0.000 description 25
- OKKJLVBELUTLKV-UHFFFAOYSA-N Methanol Chemical compound OC OKKJLVBELUTLKV-UHFFFAOYSA-N 0.000 description 21
- 238000005191 phase separation Methods 0.000 description 16
- 238000004062 sedimentation Methods 0.000 description 12
- 230000008901 benefit Effects 0.000 description 9
- 239000011541 reaction mixture Substances 0.000 description 9
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 8
- 239000002253 acid Substances 0.000 description 7
- 150000004665 fatty acids Chemical class 0.000 description 7
- 238000000926 separation method Methods 0.000 description 7
- 239000002699 waste material Substances 0.000 description 7
- 125000004432 carbon atom Chemical group C* 0.000 description 6
- 239000003377 acid catalyst Substances 0.000 description 5
- 230000032050 esterification Effects 0.000 description 5
- 238000004519 manufacturing process Methods 0.000 description 5
- 235000019484 Rapeseed oil Nutrition 0.000 description 4
- QAOWNCQODCNURD-UHFFFAOYSA-N Sulfuric acid Chemical compound OS(O)(=O)=O QAOWNCQODCNURD-UHFFFAOYSA-N 0.000 description 4
- 230000015572 biosynthetic process Effects 0.000 description 4
- 239000000344 soap Substances 0.000 description 4
- 238000005406 washing Methods 0.000 description 4
- AFVFQIVMOAPDHO-UHFFFAOYSA-N Methanesulfonic acid Chemical compound CS(O)(=O)=O AFVFQIVMOAPDHO-UHFFFAOYSA-N 0.000 description 3
- 150000001298 alcohols Chemical class 0.000 description 3
- 235000019387 fatty acid methyl ester Nutrition 0.000 description 3
- 235000013305 food Nutrition 0.000 description 3
- 239000000243 solution Substances 0.000 description 3
- 239000003549 soybean oil Substances 0.000 description 3
- 235000012424 soybean oil Nutrition 0.000 description 3
- 239000007858 starting material Substances 0.000 description 3
- 239000000126 substance Substances 0.000 description 3
- 239000003760 tallow Substances 0.000 description 3
- 235000015112 vegetable and seed oil Nutrition 0.000 description 3
- 239000008158 vegetable oil Substances 0.000 description 3
- KBPLFHHGFOOTCA-UHFFFAOYSA-N 1-Octanol Chemical compound CCCCCCCCO KBPLFHHGFOOTCA-UHFFFAOYSA-N 0.000 description 2
- BBMCTIGTTCKYKF-UHFFFAOYSA-N 1-heptanol Chemical compound CCCCCCCO BBMCTIGTTCKYKF-UHFFFAOYSA-N 0.000 description 2
- 241000196324 Embryophyta Species 0.000 description 2
- 244000068988 Glycine max Species 0.000 description 2
- LRHPLDYGYMQRHN-UHFFFAOYSA-N N-Butanol Chemical compound CCCCO LRHPLDYGYMQRHN-UHFFFAOYSA-N 0.000 description 2
- AMQJEAYHLZJPGS-UHFFFAOYSA-N N-Pentanol Chemical compound CCCCCO AMQJEAYHLZJPGS-UHFFFAOYSA-N 0.000 description 2
- 235000019482 Palm oil Nutrition 0.000 description 2
- 235000019486 Sunflower oil Nutrition 0.000 description 2
- 230000001476 alcoholic effect Effects 0.000 description 2
- 238000009835 boiling Methods 0.000 description 2
- BTANRVKWQNVYAZ-UHFFFAOYSA-N butan-2-ol Chemical compound CCC(C)O BTANRVKWQNVYAZ-UHFFFAOYSA-N 0.000 description 2
- 239000006227 byproduct Substances 0.000 description 2
- 150000001875 compounds Chemical class 0.000 description 2
- 230000003247 decreasing effect Effects 0.000 description 2
- 238000004821 distillation Methods 0.000 description 2
- 239000008157 edible vegetable oil Substances 0.000 description 2
- ZSIAUFGUXNUGDI-UHFFFAOYSA-N hexan-1-ol Chemical compound CCCCCCO ZSIAUFGUXNUGDI-UHFFFAOYSA-N 0.000 description 2
- 239000010720 hydraulic oil Substances 0.000 description 2
- 239000000543 intermediate Substances 0.000 description 2
- 235000014593 oils and fats Nutrition 0.000 description 2
- 239000002540 palm oil Substances 0.000 description 2
- 239000000047 product Substances 0.000 description 2
- BDERNNFJNOPAEC-UHFFFAOYSA-N propan-1-ol Chemical compound CCCO BDERNNFJNOPAEC-UHFFFAOYSA-N 0.000 description 2
- 239000002994 raw material Substances 0.000 description 2
- 238000007711 solidification Methods 0.000 description 2
- 230000008023 solidification Effects 0.000 description 2
- 239000002600 sunflower oil Substances 0.000 description 2
- 235000013311 vegetables Nutrition 0.000 description 2
- GNFTZDOKVXKIBK-UHFFFAOYSA-N 3-(2-methoxyethoxy)benzohydrazide Chemical compound COCCOC1=CC=CC(C(=O)NN)=C1 GNFTZDOKVXKIBK-UHFFFAOYSA-N 0.000 description 1
- 240000002791 Brassica napus Species 0.000 description 1
- BMTAFVWTTFSTOG-UHFFFAOYSA-N Butylate Chemical compound CCSC(=O)N(CC(C)C)CC(C)C BMTAFVWTTFSTOG-UHFFFAOYSA-N 0.000 description 1
- 235000010469 Glycine max Nutrition 0.000 description 1
- KFZMGEQAYNKOFK-UHFFFAOYSA-N Isopropanol Chemical compound CC(C)O KFZMGEQAYNKOFK-UHFFFAOYSA-N 0.000 description 1
- 229920000715 Mucilage Polymers 0.000 description 1
- 240000007594 Oryza sativa Species 0.000 description 1
- 235000007164 Oryza sativa Nutrition 0.000 description 1
- 235000019483 Peanut oil Nutrition 0.000 description 1
- 235000019485 Safflower oil Nutrition 0.000 description 1
- 239000003929 acidic solution Substances 0.000 description 1
- 150000007513 acids Chemical class 0.000 description 1
- 239000000853 adhesive Substances 0.000 description 1
- 230000002411 adverse Effects 0.000 description 1
- 238000006136 alcoholysis reaction Methods 0.000 description 1
- 239000010775 animal oil Substances 0.000 description 1
- OGBUMNBNEWYMNJ-UHFFFAOYSA-N batilol Chemical class CCCCCCCCCCCCCCCCCCOCC(O)CO OGBUMNBNEWYMNJ-UHFFFAOYSA-N 0.000 description 1
- 239000003225 biodiesel Substances 0.000 description 1
- 229910052799 carbon Inorganic materials 0.000 description 1
- 238000007796 conventional method Methods 0.000 description 1
- 239000008162 cooking oil Substances 0.000 description 1
- 235000012343 cottonseed oil Nutrition 0.000 description 1
- 239000002385 cottonseed oil Substances 0.000 description 1
- 239000010779 crude oil Substances 0.000 description 1
- 239000002283 diesel fuel Substances 0.000 description 1
- 238000001035 drying Methods 0.000 description 1
- 239000003995 emulsifying agent Substances 0.000 description 1
- 230000007613 environmental effect Effects 0.000 description 1
- 150000002148 esters Chemical class 0.000 description 1
- 238000001704 evaporation Methods 0.000 description 1
- 230000008020 evaporation Effects 0.000 description 1
- 239000012458 free base Substances 0.000 description 1
- 239000004519 grease Substances 0.000 description 1
- 239000013067 intermediate product Substances 0.000 description 1
- 150000002500 ions Chemical class 0.000 description 1
- 239000000944 linseed oil Substances 0.000 description 1
- 235000021388 linseed oil Nutrition 0.000 description 1
- 239000000463 material Substances 0.000 description 1
- 229940098779 methanesulfonic acid Drugs 0.000 description 1
- 235000019488 nut oil Nutrition 0.000 description 1
- 239000010466 nut oil Substances 0.000 description 1
- 239000004006 olive oil Substances 0.000 description 1
- 235000008390 olive oil Nutrition 0.000 description 1
- 239000000312 peanut oil Substances 0.000 description 1
- 230000000737 periodic effect Effects 0.000 description 1
- 239000012071 phase Substances 0.000 description 1
- 235000015277 pork Nutrition 0.000 description 1
- 235000009566 rice Nutrition 0.000 description 1
- 235000005713 safflower oil Nutrition 0.000 description 1
- 239000003813 safflower oil Substances 0.000 description 1
- 238000007086 side reaction Methods 0.000 description 1
- SYXYWTXQFUUWLP-UHFFFAOYSA-N sodium;butan-1-olate Chemical compound [Na+].CCCC[O-] SYXYWTXQFUUWLP-UHFFFAOYSA-N 0.000 description 1
- 239000007787 solid Substances 0.000 description 1
- 230000003068 static effect Effects 0.000 description 1
- 238000003756 stirring Methods 0.000 description 1
- JOXIMZWYDAKGHI-UHFFFAOYSA-N toluene-4-sulfonic acid Chemical compound CC1=CC=C(S(O)(=O)=O)C=C1 JOXIMZWYDAKGHI-UHFFFAOYSA-N 0.000 description 1
- 235000019871 vegetable fat Nutrition 0.000 description 1
- 238000004065 wastewater treatment Methods 0.000 description 1
Images
Classifications
-
- C—CHEMISTRY; METALLURGY
- C11—ANIMAL OR VEGETABLE OILS, FATS, FATTY SUBSTANCES OR WAXES; FATTY ACIDS THEREFROM; DETERGENTS; CANDLES
- C11C—FATTY ACIDS FROM FATS, OILS OR WAXES; CANDLES; FATS, OILS OR FATTY ACIDS BY CHEMICAL MODIFICATION OF FATS, OILS, OR FATTY ACIDS OBTAINED THEREFROM
- C11C3/00—Fats, oils, or fatty acids by chemical modification of fats, oils, or fatty acids obtained therefrom
- C11C3/02—Fats, oils, or fatty acids by chemical modification of fats, oils, or fatty acids obtained therefrom by esterification of fatty acids with glycerol
-
- C—CHEMISTRY; METALLURGY
- C11—ANIMAL OR VEGETABLE OILS, FATS, FATTY SUBSTANCES OR WAXES; FATTY ACIDS THEREFROM; DETERGENTS; CANDLES
- C11C—FATTY ACIDS FROM FATS, OILS OR WAXES; CANDLES; FATS, OILS OR FATTY ACIDS BY CHEMICAL MODIFICATION OF FATS, OILS, OR FATTY ACIDS OBTAINED THEREFROM
- C11C3/00—Fats, oils, or fatty acids by chemical modification of fats, oils, or fatty acids obtained therefrom
- C11C3/003—Fats, oils, or fatty acids by chemical modification of fats, oils, or fatty acids obtained therefrom by esterification of fatty acids with alcohols
-
- C—CHEMISTRY; METALLURGY
- C11—ANIMAL OR VEGETABLE OILS, FATS, FATTY SUBSTANCES OR WAXES; FATTY ACIDS THEREFROM; DETERGENTS; CANDLES
- C11B—PRODUCING, e.g. BY PRESSING RAW MATERIALS OR BY EXTRACTION FROM WASTE MATERIALS, REFINING OR PRESERVING FATS, FATTY SUBSTANCES, e.g. LANOLIN, FATTY OILS OR WAXES; ESSENTIAL OILS; PERFUMES
- C11B3/00—Refining fats or fatty oils
- C11B3/02—Refining fats or fatty oils by chemical reaction
- C11B3/06—Refining fats or fatty oils by chemical reaction with bases
Definitions
- the present invention relates to a process for producing fatty acid alkyl esters.
- Fatty acid alkyl esters are widely used in the chemical and pharmaceutical industries both as raw materials and as intermediates. In addition, such compounds are also used in the food industry and, more recently, as diesel fuel (biodiesel).
- unrefined oils often contain considerable amounts of free fatty acids, the presence of which negatively impact the transesterification reaction.
- the free fatty acids react with the basic transesterification catalyst, thereby neutralizing the catalyst, which is then no longer available for the transesterification reaction.
- the oils and/or fats are first treated with a non-miscible basic glycerol phase so that the free fatty acids are neutralized and pass into the glycerol phase, and then the triglycerides, after separation from the glycerol phase, are transesterified with monohydric alcohols using a base as catalyst in a stirred vessel to give the fatty acid esters. Further, the basic glycerol phase resulting from the transesterification of the triglycerides is used, after separation of the fatty acid esters, for the treatment of the oils and/or fats to remove the free fatty acids.
- a problem to be solved by the present invention was thus the provision of an improved process for the production of fatty acid alkyl esters.
- it was an object to render the process more suitable to accept unrefined oils and fats with varying amounts of free fatty acids and / or to increase the economy, while at the same time keep the complexity of the process low.
- the present invention is based on the innovation of the inventors that a crude feedstock can be fed to different process steps. Thereby, it is possible to process with the same process different crude feedstocks, in particular crude feedstocks having relatively low as well as rather high amounts of free fatty acids as further explained herein. In comparison to the process of EP 1 183 225 B1 , where only feedstocks can be economically processed that do not contain too much free fatty acids (otherwise more than catalytic amounts of catalyst would be necessary), it is possible to directly use feedstocks with higher free fatty acid contents.
- a crude feedstock of any origin can be generally processed as starting material as long as the crude feedstock contains triglycerides.
- the benefits of the invention will be achieved only when the crude feedstock also contains free fatty acids, usually as unwanted by-products. Examples include: rapeseed oil, soybean oil, sunflower oil, tallow, palm oil and palm fat, olive oil, peanut oil, safflower oil, linseed oil, pure nut oil, cottonseed oil, rice oil, pork fat.
- the process according to the invention is suitable for a large number of crude feedstocks of varying quality
- the palette ranges from vegetable oils of edible oil quality to unrefined oils to animal fats or fat wastes, such as used hydraulic oils based on fat, and used edible oils, waste food fats, animal fats category I, II and III, trap grease from waste water treatment, POME (Palm oil mill effluent) and further side strains from the oleochemical industry.
- Preferred crude feedstocks are selected from the group consisting of animal or vegetable fats and oils, in particular as they are traditionally used for the production of fatty acid esters.
- Rapeseed oil, soybean oil and tallow are particularly suitable as crude feedstock, whereby the transesterification produces rapeseed oil fatty acid methyl ester, soybean fatty acid methyl ester and tallow fatty acid methyl ester if methanol is used as the alcohol.
- waste oil and / or waste fat such as used cooking oil and / or deep-frying fat or used hydraulic oils based on fat, is / are used as crude feedstock.
- the crude feedstock is fed to the neutralization reaction in step a) and / or to the esterification reaction in step c), depending on the amount of free fatty acids contained in the crude feedstock.
- the free fatty acid content should not be too high, when the crude feedstock is fed to the neutralization reaction.
- the crude feedstock is fed to the neutralization reaction in step a), if the crude feedstock contains free fatty acids in an amount of 8.0 wt.-% or less, preferably 7.5 wt.-% or less, more preferably 7.0 wt.-% or less, yet more preferably 6.5 wt.-% or less, most preferably 6.0 wt.-% or less, relative to the total weight of the crude feedstock, and /or if the crude feedstock contains free fatty acids in an amount 0.2 wt.-% or more, preferably 0.4 wt.-% or more, more preferably 0.6 wt.-% or more, yet more preferably 0.8 wt.-% or more, most preferably 1.0 wt.-% or more, relative to the total weight of the crude feedstock.
- the crude feedstock is preferably fed to the esterification reaction. Accordingly, a process is preferred, wherein the crude feedstock is fed to the esterification reaction in step c), if the crude feedstock contains free fatty acids in an amount of 10 wt.-% or more, preferably 15 wt.-% or more, more preferably 20 wt.-% or more, yet more preferably 25 wt.-% or more, most preferably 30 wt.-% or more, relative to the total weight of the crude feedstock.
- Fig. 1 the processes for producing fatty acid alkyl esters by catalytic transesterification of triglycerides from an oil and / or fat based crude feedstock containing triglycerides and free fatty acids of the invention as well as further embodiments thereof will be described below.
- the process comprises the step:
- the mixture 13 used in step a) comprises oil and / or fat as well as free fatty acids and triglycerides primarily originating from the crude feedstock, which may be directly fed to the neutralization reaction 10 of step a) and / or indirectly fed to the neutralization reaction 10 of step a) via the esterification reaction 30 in step c) and recycling 60 the separated third light phase 36 to the neutralization reaction of step a).
- the neutralizing reaction preferably comprises mixing the mixture 13 with the alkaline glycerine phase. Mixing may be carried out in a first stirred tank reactor 12. Thereby, free fatty acids and residual water, if present, are largely extracted into the glycerine phase.
- a preferred embodiment pertains to a process as described herein, wherein the neutralization 10 in step a) comprises mixing for less than 1 minute, preferably less than 55 seconds, more preferably less than 50 seconds and most preferably less than 45 seconds and/or wherein step a) comprises mixing for at least 10 seconds, preferably at least 15 seconds, more preferably at least 20 seconds, even more preferably at least 25 second and most preferably at least 30 seconds.
- step a) comprises mixing for at least 10 seconds, preferably at least 15 seconds, more preferably at least 20 seconds, even more preferably at least 25 second and most preferably at least 30 seconds.
- the reaction conditions during neutralization 10 are primarily limited by the solidification point of the components present in step a), in particular the oil and / or fat as well as free fatty acids and triglycerides originating from the crude feedstock. From an economic point of view, the neutralization 10 should be carried out at moderate temperatures, for instance at a temperature of 20 to 65 °C, preferably 25 to 60 °C, more preferably 30 to 55 °C. As the reaction preferably takes place in a pipe against a large vessel, e.g. a full vessel of 15 m height, the pressure preferably ranges between 0 and 3 bar.
- the alkaline glycerine phase preferably contains enough free base to neutralize substantially all or the free fatty acids.
- the base content may be 1 to 30 %, preferably 3 to 8 % (w/w).
- the glycerine content can be 20 to 99 %, preferably 50 to 70 % (w/w).
- the alkaline glycerine phase resulting from the transesterification reaction 40 of step e) is recycled to the neutralization reaction 10 in step a), as set forth further below.
- the content of transesterification alcohol may be 5 to 40 % (w/w), preferably 15 to 25 % (w/w).
- the amount of added alkaline glycerine phase, relative to the amount of added crude feedstock, may vary in a range of 1 to 100 % (w/w), preferably 5 to 20 % (w/w).
- the alkaline glycerine phase can be supplemented by adding solid base or an alcohol/base mixture. It is possible to use any grade of glycerine, from technical to pharmaceutical grade as well as mixtures of different grades.
- the base may be used with or without an alcohol. All base catalysts used for the transesterification reaction 40 of step e) can also be used as base in the neutralization reaction 10 in step a). Preferred bases / catalysts are described further below.
- the mixture 13 is allowed to settle in order to allow the light phase and the heavy phase to separate from each other.
- the mixture 13 can be transferred into a first settling tank 14.
- Phase separation preferably occurs by sedimentation. Usual sedimentation times are 1 to 72 h, preferably 5 to 10 h.
- the sedimentation temperature is preferably between 0 to 100 °C, preferably 45 to 60 °C, more preferably 47 to 55 °C. The skilled person will further appreciate that the temperature is limited by the solidification point of the components contained in the mixture / crude feedstock.
- the temperature should be at least 30 °C, in the case of animal body and deep-fryer fats, the temperature should be 40 to 50 °C.
- Phase separation results in formation of the first light phase 16 and the first heavy phase 18.
- triglycerides are enriched. It may further contain up to 0.5 %, preferably up to 0.2 %, more preferably up to 0.1 % (w/w) free fatty acids, relative to the total weight of the first light phase 16.
- neutralized free fatty acids also referred to herein as soaps or fatty acid salts
- It further contains glycerine and optionally one or more of water and alcohol.
- the process further comprises the step: b) separating the first light phase 16 and the first heavy phase 18 from each other, and acidifying 20 the separated first heavy phase 18.
- the separated first heavy phase 18 may be transferred in a second stirred tank reactor 22 (alternatively, a static mixer can be used) and mixed with an acidic solution.
- the pH value is preferably decreased to 1 to 4, preferably 2 to 3.
- other side streams like washing water (from washing step h), methanol containing condensate (from esterification 30 and or from drying step g) etc. also may be added.
- a glycerine-rich phase 18 is obtained as a by-product. This phase also contains soaps.
- the glycerine phase is treated with an acid. This treatment releases the fatty acids from the soaps.
- the released fatty acids and the fatty acid esters themselves are not miscible with glycerin and therefore separate from the glycerin phase as a separate phase.
- the reaction mixture 23 is allowed to settle in order to allow the light phase and the heavy phase to separate from each other.
- the mixture 23 can be transferred into a second settling tank 24.
- Phase separation preferably occurs by sedimentation. Usual sedimentation times are 1 to 48 h, preferably 3 to 8 h.
- the sedimentation temperature is preferably between 0 to 100 °C, preferably 45 to 60 °C, more preferably 47 to 55 °C.
- Phase separation results in formation of the second light phase 26 and the second heavy phase 28. In the second light phase 26 free fatty acids are enriched, whereas the second heavy phase 28 is rich in glycerine. Further components of the second heavy phase 28 include water and alcohol.
- the process further comprises the step: c) separating the second light phase 26 and the second heavy phase 28 from each other, and esterifying 30 free fatty acids in the separated second light phase 26 in the presence of an alcohol to enrich fatty acid esters in a third light phase 36 and the alcohol in a third heavy phase 38.
- the esterification 30 allows both reacting the free fatty acids present in the processed feedstock having a relatively high free fatty acid content, e.g., above 10 %, to form fatty acid esters, and recovering the fatty acid compounds from all streams that were added to the reaction mixture 23.
- the esterification 30 can be carried out by known processes.
- An esterification 30 in the presence of an acid catalyst is preferred.
- the separated second light phase 26 is mixed with the alcohol and the acid catalyst, for instance in a third stirred tank reactor 32.
- the acid catalyst is not particularly limited and can, for example, be selected from the group consisting of sulfuric acid, paratoluenesulfonic acid, ion exchangers in H + form and methanesulfonoic acid . Sulfuric acid or methanesulfonic acid is particularly preferred.
- the alcohol added in step c) is preferably a linear, branched or cyclic alkyl alcohol with 1 to 10 carbon atoms, preferably 1 to 8 carbon atoms. Examples include: methanol, ethanol, propanol, i-propanol, butanol, sec-butanol, pentanol, hexanol, heptanol and octanol. It is further preferred that the alcohol has 1 to 6 carbon atoms, preferably 1 to 4 carbon atoms. Most preferably, the alcohol is methanol, ethanol and / or propanol; methanol is particularly preferred.
- the alcohol added in step e) is preferably independently selected from the aforementioned alcohols. The same or a different alcohol may be used. Preferably, the same alcohol is used in steps c) and e).
- the esterification reaction 30 it is possible to add to the esterification reaction 30 a crude feedstock, which has a relative high content of free fatty acids.
- the total amount of free fatty acids, which will undergo esterification 30, is the sum of the free fatty acids present in the separated second light phase 26 and the free fatty acids present in the crude feedstock.
- the esterification reaction may take place at about 40 to 160 °C, preferably 50 to 140 °C, more preferably 60 to 75°C and / or at a pH value of 0 to 1.
- the pressure preferably ranges between 900 to 1200 mbar, whereas at 160°C the pressure can be up to or even more than 4 bar.
- the reaction may be allowed to proceed for 1 to 8 hours, preferably 4 to 6 hours and / or until the desired content decrease of free fatty acids has been achieved. It is further preferred that the reaction proceeds under mixing e.g. stirring.
- the separated second heavy phase 28 can be further processed.
- the second heavy phase 28 includes an alcohol, it may be separated from the glycerine-rich phase.
- a convenient way of separation is by means of thermal separation, in particular rectification.
- the separated alcohol may further be recovered and / or recycled to the esterification reaction 30 in step c) and / or to the transesterification reaction 40 in step e).
- the reaction mixture 33 is allowed to settle in order to allow the light phase and the heavy phase to separate from each other.
- the reaction mixture 33 can be transferred into a third settling tank 34.
- Phase separation preferably occurs by sedimentation. Usual sedimentation times are 1 to 72 h, preferably 5 - 10 h.
- the sedimentation temperature is preferably between 0 to 100 °C, preferably 30 to 60 °C, more preferably 40 to 50 °C.
- Phase separation results in formation of the third light phase 36 and the third heavy phase 38.
- fatty acid esters are enriched. It may further contain up to about 5 % (w/w), preferably up to about 2 % (w/w), free fatty acids.
- the alcohol is enriched. It may further contain the acid catalyst and water.
- step d) the third light phase 36 and the third heavy phase 38 are separated and the separated third light phase 36 is recycled 60 to the neutralization reaction 10 of step a). Due to the recycling step 60, it is possible to add the crude feedstock to the esterification reaction 30 in step c) and, thus, to process crude feedstocks with an increased free fatty acid content.
- fatty acid alkyl esters are formed by catalytic transesterification 40 of the triglycerides contained in the separated first light phase 16.
- Transesterification is to be understood as an alcoholysis of triglycerides, that is to say a reaction with alcohols, preferably alkyl alcohols, in particular methanol and ethanol, whereby monoesters of fatty acids and glycerol are formed via di- and monoglycerides as intermediates.
- the fatty acids are not miscible with glycerin and therefore separate from the glycerin phase as a separate phase.
- the process comprises the step: f) recycling 50 the separated third heavy phase 38 to the acidification 20 in step b).
- the separated third light phase 36 is not recycled to step e).
- the separated third light phase is not recycled to steps e) and b). More preferably, the separated third light phase is only recycled to the neutralization reaction of step a).
- the advantages achieved by this embodiment include the possibility to save the fatty acid esters contained in the separated third light phase 36, and to further reduce the fatty acid content in order to not waste transesterification catalyst by neutralization.
- the catalyst used in step e) is selected from the group of alkaline catalysts.
- the catalyst is selected from the group of metal hydroxides, metal alcoholates and combinations thereof.
- the metals used in this group are preferably selected from the first to third main groups of the periodic system.
- the catalyst is selected from the group of sodium hydroxide, potassium hydroxide, sodium alcoholates, potassium alcoholates, such as sodium methylate, sodium ethylate, sodium butylate, potassium methylate, potassium ethylate, potassium butylate, and combinations thereof.
- Most preferred is a process, wherein the catalyst comprises or is potassium methylate.
- the advantages associated with potassium methylate include lower reaction temperatures, less side reactions and a higher solubility of K-soaps in glycerine.
- step e) comprises:
- the triglycerides contained in the separated first light phase 16 is mixed with a base as transesterification catalyst and an alkyl alcohol to carry out transesterification 40 of the triglycerides to fatty acid alkyl esters.
- the required components may be added to and mixed in a fourth stirred tank reactor 42.
- the total amount of alkyl alcohol used for the transesterification reaction 40 may be distributed among several transesterification stages, for instance 1 to 5 stages, preferably 2 stages. In total, about 1.05 to 2 mol, preferably 1.2 to 1.4 mol, alkyl alcohol per mol of bound fatty acid function may be used in this step. In a two-stage process (as further described below), 40 to 99%, preferably 90 to 95%, are used in the first stage and 0 to 60%, preferably 0 to 10%, in the second stage.
- alkyl alcohol that can be employed in step e) is not limited. However, linear, branched or cyclic alkyl alcohols with 1 to 10 carbon atoms, in particular 1 to 4 carbon atoms, are preferred; methanol is particularly preferred.
- the base can be dissolved in alcohol and added as an alcoholic solution.
- the total amount of base (transesterification catalyst) added in this process step depends, on one hand, on the further process steps (e.g. the further transesterification stages) and, on the other hand, on the nature (i.e. composition) of the crude feedstock.
- the total amount of base is used in this single stage, whereas in the case of a two-stage transesterification, only 20 to 95%, and preferably 80 to 90%, of the total quantity is used in the first stage.
- the minimum amount of base at low free fatty acid content is primarily determined by the transesterification reaction 40.
- the amount of free fatty acids to be neutralized primarily determines the required catalyst amount.
- the required amounts can be routinely determined by a person skilled in the art, for example by the method disclosed in EP 1 183 225 B1 .
- 0,088 mol base / 1000 g oil ensures an acceptable reaction rate.
- 0,084 mol base / 1000 g oil is available for the neutralization reaction 10 of free fatty acids.
- the transesterification 40 is performed at 40 to 65°C, preferably 45 to 60°C, more preferably 50 to 55°C and/or the transesterification 40 is performed for 10 to 100 min, preferably 30 to 80 min, more preferably 35 to 60°C, most preferably 40 to 50 min.
- the reaction mixture 43 can be worked up in a suitable manner, whereas phase separation has proven to be particularly advantageous.
- the obtained reaction mixture 43 may be fed into a fourth settling tank 44.
- the reaction mixture 43 is allowed to settle in order to allow the light phase and the heavy phase to separate from each other.
- Phase separation preferably occurs by sedimentation. Usual sedimentation times are 1 to 72 h, preferably 5 to 10 h.
- the sedimentation temperature is preferably between 0 to 100 °C, preferably 45 to 60 °C, more preferably 47 to 55 °C.
- Phase separation results in formation of the fourth light phase 46 and the fourth heavy phase 48.
- fatty acid alkyl esters are enriched.
- the fourth heavy phase 48 is rich in glycerine. It may further contain the base catalyst and the transesterification alcohol.
- a fourth light phase 46 rich in fatty acid alkyl esters can be withdrawn.
- the fourth light phase 46 is further processed by conventional methods or subjected to a second transesterification stage.
- step e-2) further comprises:
- a further (second) transesterification stage is particularly advantageous, if the first light phase 16 contains a relatively high amount of mono-, di- and/or triglycerides and a single transesterification stage is expected to be not sufficient to achieve the desired degree of conversion into fatty acid alkyl esters.
- the separated fourth light phase 46 can be transferred to a fifth stirred tank reactor in which a second transesterification stage is carried out.
- the second transesterification stage can be performed under the same reaction conditions as the first transesterification stage.
- alkyl alcohol and base should be added to the second transesterification stage.
- the alkyl alcohol and / or base may be added directly to the fifth stirred tank reactor and / or may be first mixed with each other and then fed into the fifth stirred tank reactor.
- the base catalyst the same substance can be conveniently used as in the first transesterification stage. In terms of handling, an alcoholic solution containing 25 to 50 % (w/w) base is preferred.
- the further (second) transesterification in step e-3 comprises mixing for at least 1 minute, preferably for at least 2 minutes, more preferably at least 3 minutes, even more preferably at least 4 minutes and most preferably at least 5 minutes and/or mixing less than 15 minutes, preferably less than 14 minutes, more preferably less than 13 minutes, even more preferably less than 12 minutes, even more preferably less than 11 minutes and most preferably less than 10 minutes.
- reaction mixture obtained after the second transesterification stage can be worked up, whereby a phase separation carried out in the manner described above has proved advantageous.
- the process may further comprise step h) washing the fourth light phase.
- step h) washing the fourth light phase After the final phase separation, one or more washing steps may be carried out, wherein the fourth light phase is washed with at least 5 % (w/w) water, relative to the weight of the light phase.
- Low-boiling components may be removed from the light phase rich in fatty acid alkyl esters. Removal may be achieved by evaporation. For instance, the light phase may be heated to 90 to 140 °C by passing over a heated surface. Thereby, the low-boiling components are evaporated and can be removed.
- the process further comprises the step: g) recycling 70 the separated fourth heavy phase 48, and / or the separated fifth heavy phase, if present, to the neutralization reaction 10 in step a).
- the glycerine, alcohol and base catalyst can be reused.
- the base catalyst coming from the transesterification 40 can thus be used for neutralizing free fatty acids in the neutralization reaction 10 of step a).
- steps a), b), d) and e) are performed continuously. More preferably, steps a), b), d) and e) as well as step f), if present, are performed continuously. Most preferably, steps a), b), d) and e) as well as steps f) and g), if present, are performed continuously.
- first, second, third, fourth and / or fifth settling tank(s) may be dimensioned larger than the respective first, second, third, fourth and / or fifth stirred tank reactor(s).
- the advantage of an increased dimension is that the settling tank(s) can be used as a reservoir, which means that, on the one hand, the settling times can be longer than the time required for the respective reaction and, on the other hand, a continuous withdrawal of the separated phase(s) is possible.
- the settling tanks should also be designed in such a way that the light phase and the heavy phase can be removed separately from each other through outlets that are located at suitable heights of the settling tanks. It has proved to be advantageous to feed the respective reaction mixture to the settling tanks close to the interface, and to remove the respective phases remote from the interface. In this way, the phase separation can be performed efficiently.
- the process comprises the steps:
- step(s) a), b), c) and / or d) are preferably carried out as specified above or in the claims. This does also apply to one, some or all components employed in step(s) a), b), c) and / or d).
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| EP21167432.0A EP4071226A1 (de) | 2021-04-08 | 2021-04-08 | Verfahren zur herstellung von fettsäurealkylestern |
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| EP21167432.0A EP4071226A1 (de) | 2021-04-08 | 2021-04-08 | Verfahren zur herstellung von fettsäurealkylestern |
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Cited By (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| WO2024223722A1 (en) | 2023-04-27 | 2024-10-31 | Novozymes A/S | Fatty acid esterification pretreatment process |
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| WO2024223722A1 (en) | 2023-04-27 | 2024-10-31 | Novozymes A/S | Fatty acid esterification pretreatment process |
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