HETEROGENEOUS CATALYST FOR TRANSESTERIFICATION AND METHOD OF PREPARING SAME

Abstract

A transesterification catalyst that is heterogeneous and a method for preparing said transesterification catalyst are provided. The catalyst can be used in a variety of transesterification reactor configurations including CSTR (continuous stirred tank reactors), ebullated (or ebullating) beds or any other fluidized bed reactors, and PFR (plug flow, fixed bed reactors). The catalyst can be used for manufacturing commercial grade biodiesel, biolubricants and glycerin.

Claims

1. A compound having the formula:
Z.sub.xQ.sub.yPO.sub.nMH.sub.20, wherein: Z is selected from the group consisting of potassium, sodium and lithium, Q is selected from the group consisting of calcium, magnesium and barium, x is a rational number in the range from 0.5 to 4, y is a rational integer in the range from 2 to 8, n is a rational integer in the range from 4 to 8, and M is a ceramic substrate; and wherein the compound is a transesterification catalyst.

2. The compound of claim 1, wherein the ceramic substrate is selected from the group consisting of zirconia, silica, alumina, and combinations thereof.

3. The compound of claim 1, wherein the total surface area of the compound is 20 square meters per gram or greater.

4. The compound of claim 1, wherein the active surface area of the compound is 20 square meters per gram or greater.

5. The compound of claim 1, wherein the average diameter of the pores in the compound is in the range from 1-10 nanometers.

6. The compound of claim 1, wherein the compound is active at a temperature in the range from 40 to 70 degrees C.

7. The compound of claim 1, wherein the compound is active at a temperature in the range from 40 to 130 degrees C.

8. The compound of claim 1, wherein the transesterification catalyst is porous.

9. A method of preparing a transesterification catalyst comprising: mixing a metal hydroxide with the metal selected from the group consisting of potassium, sodium and lithium with a metal hydroxide with the metal selected from the group consisting of calcium, magnesium and barium in a ratio of about 1:10 by weight to form a component mixture; dissolving the component mixture in phosphoric acid; heating the component mixture to a temperature in the range from 60-90 degrees C.; precipitating a solid compound; mixing the precipitate with ceramic substrate in a ratio of about 2:10 by weight and washing with water to form a precipitate/ceramic substrate mixture; and calcining the precipitate/ceramic substrate mixture at a temperature in the range from 400-500 degrees C.

10. The method of claim 9, wherein the precipitate/ceramic substrate mixture is calcined by heating for four hours or greater.

11. A method of preparing alkyl ester using a transesterification catalyst, the method comprising: providing a transesterification catalyst comprising a compound having the formula Z.sub.xQ.sub.yPO.sub.nMH.sub.20, wherein: Z is selected from the group consisting of potassium, sodium and lithium, Q is selected from the group consisting of calcium, magnesium and barium, x is a rational number in the range from 0.5 to 4, y is a rational integer in the range from 2 to 8, n is a rational integer in the range from 4 to 8, and M is a ceramic substrate; and reacting one or more triglycerides and an alcohol in the presence of the catalyst and converting the triglycerides and alcohol to alkyl ester and glycerin.

12. The method of claim 1, wherein the ceramic substrate is selected from the group consisting of zirconia, silica, alumina, and combinations thereof.

13. The method of claim 11, wherein the triglycerides comprise triglyceride-containing fats and/or oils.

14. The method of claim 11, wherein the converting of triglycerides comprises producing essentially complete conversion of the triglycerides to alkyl ester and glycerin.

15. The method of claim 11, further comprising: separating the glycerin from the reaction mixture; filtering the reaction mixture to recover the catalyst; and distilling the unreacted alcohol from the alkyl ester and the glycerin.

16. The method of claim 11, wherein the method is at least partially performed in a continuous stirred tank reactor.

17. The method of claim 11, wherein the method is at least partially performed in a fixed bed reactor.

18. The method of claim 11, wherein the method is at least partially performed in a fluidized bed reactor.

19. The method of claim 11, wherein the alkyl ester is capable of being used as biodiesel fuel.

20. The method of claim 11, wherein the alkyl ester is capable of being used as biodiesel additive to conventional diesel fuel.

21. The method of claim 11, wherein the alkyl ester is capable of being used as a biolubricant additive to other lubricants.

22. The method of claim 11, wherein the alkyl ester is capable of being used as a biolubricant.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0013] FIGS. 1A and 1B show an illustrative embodiment of a transesterification reaction.

[0014] FIG. 2 is a line graph comparing reaction conversion at different methanol molar ratios at 1 weight % of UMAKAT in an illustrative embodiment.

[0015] FIG. 3 is a line graph comparing reaction conversion at different temperatures at 1 weight % of UMAKAT in an illustrative embodiment.

[0016] FIG. 4 is a line graph comparing reaction conversion at different UMAKAT weights at a fixed temperature of 60 degrees C. in an illustrative embodiment.

[0017] FIG. 5 is a line graph comparing biodiesel (i.e., alkyl ester) yield using the same UMAKAT for repeat trials in an illustrative embodiment.

[0018] While certain preferred illustrative embodiments will be described herein, it will be understood that this description is not intended to limit the subject matter to those embodiments. On the contrary, it is intended to cover all alternatives, modifications, and equivalents, as may be included within the spirit and scope of the subject matter as defined by the appended claims.

DETAILED DESCRIPTION

[0019] For the purposes of this disclosure, the transesterification catalysts of the various illustrative embodiments will hereinafter be referred to as UMAKAT. Various means for transesterification using UMAKAT are also provided. According to the various illustrative embodiments provided herein, UMAKAT is a porous, solid, heterogeneous compound having the general formula Z.sub.xQ.sub.yPO.sub.nMH.sub.20, where Z is selected from Group 1 metals including potassium, sodium and lithium, Q is selected from Group 2 metals including calcium, magnesium and barium, x is a rational number in the range from 0.5 to 4, y is a rational integer in the range from 2 to 8, and n is a rational integer in the range from 4 to 8. M can be any ceramic substrate such as, for example, zirconia, silica, alumina, or combinations thereof. The Group 1 and Group 2 alkali metals form a double metal salt catalyst, the phosphate (PO.sub.n) makes it insoluble and the ceramic provides the solid support, in certain illustrative embodiments. UMAKAT's porous structure includes nanometer-sized pores which result in the material having substantial surface area.

[0020] The generic process for the transesterification reaction is shown in FIGS. 1A and 1B. FIG. 1A represents the overall transesterification reaction, while FIG. 1B represents not only the overall reaction but al so the stepwise chemical reactions where the triglyceride (TG) ester is first converted to alkyl ester and diglyceride (DG) ester, then the DG ester is converted to alkyl ester and monoglyceride (MG) ester, and then the MG ester is converted to alkyl ester and glycerin.

[0021] In certain illustrative embodiments, UMAKAT can have a total surface area greater than 20 m.sup.2/gm and an active surface area greater than 20 m.sup.2/gm. As used herein, the term total surface area means surface area totally available, and the term active surface area means surface area available for reaction. The active surface area of UMAKAT is significant because the higher the active surface area, the greater the availability of active catalyst sites. Total surface area and active surface area are measured by nitrogen adsorption.

[0022] In certain illustrative embodiments, the heterogeneous compound can be porous. For example, UMAKAT can have an average pore diameter in the range from 1-10 nanometers (Nm). Pore diameter is measured by nitrogen adsorption. The pore diameter of UMAKAT is sufficient to allow migration or diffusion of reactant molecules into and out of the UMAKAT pores, in certain illustrative embodiments. This will determine the rate and extent of absorption of reactant molecules at the catalyst surfaces.

[0023] Other homogeneous transesterification processes call for the catalyst being dissolved in an alcohol, for example, methanol or ethanol, which needs to be removed post reaction. Further, the homogeneous catalyst is soluble in reactants and products, which requires steps to cleanse the alkyl ester and glycerin products. In contrast, in certain illustrative embodiments UMAKAT can form a slurry with triglyceride-containing oils and/or fats rather than alcohol for a better reaction conversion and easier separation of reactants and catalyst at the end of the reaction. In general, a catalyst slurry can be made with any oil/fat rather than methanol/ethanol solution (or any other alcohol) for CSTR type reactions. Further, in certain illustrative embodiments UMAKAT provides a uniform suspension throughout the reaction media. By comparison, a heterogeneous catalyst suspension in methanol/ethanol is not uniform and the catalyst particles settle at the bottom of the reactor vessel.

[0024] In certain illustrative embodiments, UMAKAT can be active at significantly less severe conditions than other heterogeneous catalyst systems. For example, other methanolysis transesterification heterogeneous catalysts require temperatures from 150 to 250 degrees C. and pressures of 300 to 400 psi. These operating conditions require that other processes using heterogeneous catalysts are carried out in fixed bed reactors.

[0025] In contrast, methanolysis transesterification using UMAKAT to manufacture biodiesel requires temperatures in the range from 40 to 70 degrees C. and atmospheric pressure conditions, in certain illustrative embodiments. Similarly, transesterification using UMAKAT to react, for example, dodecanol or other higher alcohols and triglycerides to manufacture biolubricants requires temperatures up to and slightly above 100 degrees C. and atmospheric pressure conditions, in certain illustrative embodiments. For these services, UMAKAT can be used in CSTR, fluidized bed and PFR reactor systems.

[0026] To ensure complete conversion of triglycerides, alcohol is added in excess of stoichiometric requirements, for instance 2 to 4 times that required to ensure the complete conversion of triglycerides to alkyl ester, in certain illustrative embodiments.

[0027] Furthermore, UMAKAT is an efficient catalyst in that it can be reusable. UMAKAT can also be used in existing transesterification process equipment without major revamping.

[0028] UMAKAT can be used for manufacturing ASTM D 6751 biodiesel and Technical Grade glycerin as well as biolubricants. Also, UMAKAT does not need water wash for post reaction treatment and does not require steps such as pH neutralization to cleanse products.

[0029] In order to facilitate a better understanding of the presently disclosed subject matter, the following examples of certain aspects of certain embodiments are given. In no way should the following examples be read to limit, or define, the scope of the presently disclosed subject matter.

Example 1

[0030] UMAKAT preparation is illustrated as a double metal salt catalyst with ceramic base support of zirconium oxide. In a typical catalyst preparation, 3 moles of Group 1 metal hydroxide, in this Example potassium hydroxide, is mixed with 1 mole of a Group 2 metal hydroxide, in this Example calcium hydroxide, and dissolved in dilute phosphoric acid. The reaction of the metal hydroxides and the acid produces a double metal salt. This is then heated in a temperature range from 60 to 90 degrees C. As a result, a white precipitate is formed which is then washed with water and mixed with 4 moles of zirconium oxide powder. This material is calcined at 400-500 degrees C. for a minimum of 4 hours. The resulting material is porous, solid and heterogeneous with nanometer-sized pores with a structure that has significant surface area.

Example 2

[0031] This example describes the preparation of fatty acid methyl esters by transesterification of soybean oil with methanol using UMAKAT. In a typical reaction, commercial soybean oil (100 gms) and methanol (oil to methanol molar weight ratio of 1:6) and UMAKAT (2 to 6 wt % UMAKAT in oil) were charged to a 500 ml glass beaker and stirred at a speed of 300 to 500 rpm at a temperature of 60-80 degrees C. for about 10 to 30 minutes. It was then allowed to cool.

[0032] The UMAKAT was separated by filtration from the mixture of reaction products. The product mixture included unreacted methanol plus an upper layer of methyl ester and a lower layer of glycerin. Then, unreacted methanol was separated from each layer by distillation. The methyl ester was tested in a gas chromatograph.

[0033] The methyl ester analysis report is summarized in Table 1 below along with the ASTM spec for biodiesel.

TABLE-US-00001 TABLE 1 UMAKAT ASTM SPEC Water & Sediment 0.000 .05 max Cetane Number 47.8 47 min Cold Soak Filtration 90 seconds for 300 ml 300 sec max Free glycerin 0.005% .02 max Total glycerin 0.191% .24 max Calcium, ppm <1 Magnesium, ppm <1 Sodium, ppm <1 Potassium, ppm <2

[0034] Table 1 generally shows: no water and sediments are present in the alkyl ester product, only trace amounts of metals solids are present, and, as measured by the amount of glycerin in the product, the reaction is essentially complete conversion to methyl ester. The biodiesel made with UMAKAT was also assessed via the Cold Soak Filtration Test. In this test, a biodiesel liquid sample is chilled to below 32 degrees F. for 16 hours, restored to room temperature and passed thru a 0.5 micron filter. This ASTM test is passed if the filtration is complete within 300 seconds. The UMAKAT biodiesel passed thru the filter in 90 seconds.

[0035] Different oils and fats were tested for oil conversion to methyl ester using UMAKAT and the results are tabulated in the following table:

TABLE-US-00002 TABLE 2 % Oil Test No. Oil/Fat Alcohol conversion Notes 2 Canola Oil Methanol 97.7 3 Yellow grease Methanol 96.8 4 Coconut Oil Methanol 98.2 5 Cottonseed Oil Methanol 97.5 6 Chicken Fat Methanol 97.2 High Free Fatty Acid (FFA) Oil first esterified with acid catalyst

[0036] Table 2 shows that UMAKAT is effective for a wide variety of oils and fats.

[0037] FIGS. 2 thru 5 are heterogeneous catalytic kinetics graphs showing how the reaction proceeds at different temperatures, methanol ratios, and catalyst weight concentrations.

[0038] In certain illustrative embodiments, UMAKAT can be easily separated from reactants and products and reused, no leaching of metal ions into the reactant mixture was observed, and UMAKAT processing temperature and pressure are at moderate conditions which are significantly less severe than other heterogeneous catalytic transesterification processes.

[0039] Additionally, in certain illustrative embodiments UMAKAT can be used to process low cost/unrefined oils and/or fats containing impurities that, for example, cause discoloration of the feedstock. Further, post reaction process waste is reduced as neutralization and water wash of products are not required. Relative to other catalysts and processes, UMAKAT is highly active at comparatively low temperature and pressure. Also, UMAKAT produces much fewer impurities in the alkyl ester and glycerin products and thus the products are much cleaner at the end of the reaction. Further, no pH neutralization water wash is required and salts from glycerin neutralization do not end up in the alcohol distillation column. Finally, UMAKAT transesterification facilities are comparatively lower in cost to install, maintain and operate.

[0040] As used herein, the term in the range from and like terms is inclusive of the values at the high and low end of said ranges, as well as reasonable equivalents.

[0041] While the disclosed subject matter has been described in detail in connection with a number of embodiments, it is not limited to such disclosed embodiments. Rather, the disclosed subject matter can be modified to incorporate any number of variations, alterations, substitutions or equivalent arrangements not heretofore described, but which are commensurate with the scope of the disclosed subject matter.

[0042] Additionally, while various embodiments of the disclosed subject matter have been described, it is to be understood that aspects of the disclosed subject matter may include only some of the described embodiments. Accordingly, the disclosed subject matter is not to be seen as limited by the foregoing description, but is only limited by the scope of the appended claims.