Biodiesel production from palm oil using combined mechanical stirred and ultrasonic reactor

This paper investigates the production of biodiesel from palm oil using a combined mechanical stirred and ultrasonic reactor (MS–US). The incorporation of mechanical stirring into the ultrasonic reactor explored the further improvement the transesterification of palm oil. Initial reaction rate values were 54.1, 142.9 and 164.2 mmol/L min for the mechanical-stirred (MS), ultrasonic (US) and MS–US reactors, respectively. Suitable methanol to oil molar ratio and the catalyst loading values were found to be 6 and 1 of oil, respectively. The effect of ultrasonic operating parameters; i.e. frequency, location, and number of transducer, has been investigated. Based on the conversion yield at the reactor outlet after 1 h, the number of transducers showed a relevant role in the reaction rate. Frequency and transducer location would appear to have no significant effect. The properties of the obtained biodiesel (density, viscosity, pour point, and flash point) satisfy the ASTM standard. The combined MS–US reactors improved the reaction rate affording the methyl esters in higher yield.     

Time reducing process for biofuel production from non edible oil assisted by ultrasonication

Limited resources of conventional fuels such as petrodiesel have led to the search for alternative fuels. Various convention batch/continuous processes for the biodiesel production have been developed before the recent year. All processes are time consuming with high labor cost. Thus, we need a new process for biodiesel production which reduces the reaction time and production cost as well as save the energy. In this work, ultrasonic assisted transesterification of Jatropha curcas oil is carried out in the presence of methanol and potassium hydroxide (KOH) as catalyst, keeping the molar ratio of oil to alcohol 1:5, catalyst concentration 0.75 wt% of oil, ultrasonic amplitude 50% and pulse 0.3 cycle, 7 min reaction time under atmospheric condition. Ultrasonic mixing has increased the rate of transesterification reaction as compare to the mechanical mixing.     

Two-stage continuous production process for fatty acid methyl ester from high FFA crude palm oil using rotor-stator hydrocavitation

Two-stage continuous production process for fatty acid methyl ester (FAME) from crude palm oil was performed using the rotor–stator hydrocavitation reactor. The novel ABS filament printed rotor having spherical holes on the surface of the rotor which is an efficient, fast and cost-effective procedure, was installed in the stainless steel stator of hydrosonic reactor. The 3D printed hydrosonic reactor was used to treat the FFA-rich in MCPO by esterification and followed by transesterification to produce the methyl ester. The optimum conditions of both esterification and transesterification processes were determined using the response surface methodology (RSM). For the 1st step esterification, the conditions of methanol 17.7 vol%, sulfuric acid 2.9 vol%, 3000 rpm rotor speed, hole’s diameter and depth 4 and 6 mm, and 25 L/h MCPO, were used for decreasing the FFA from 11.456 to 1.028 wt%. For the 2nd step, transesterification was employed with the optimal condition of 28.6 vol% methanol, 6.2 g/L of potassium hydroxide, 3000 rpm rotor speed, the dimension of the spherical holes on the rotor’s surface having diameter of 6.4 mm and 6.2 mm in depth, and esterified oil flow rate 25 L/h, for producing the methyl ester to over 99.163 wt%. Moreover, the purified biodiesel yields and the average energy consumption for the entire two-stage continuous process between hydrosonic and ultrasonic clamp reactors were compared. The results of purified methyl ester clearly indicate that the methyl esters of 99.163 wt% and 97.814 wt% were achieved from hydrosonic and ultrasonic clamp reactors, respectively, under the same optimized conditions. The maximum yields of purified biodiesel were 97.51 vol% and 88.69 vol% using hydrosonic and ultrasonic clamp reactors, respectively. The average energy consumption for the entire continuous two-stage process for both hydrosonic and ultrasonic clamp reactors were 0.049 and 0.056 kW h/L, respectively. For practical industrial processes, stainless steel rotors inside the stator was manufactured by CNC machine, which was also verified under the optimum conditions. The results showed that 1.07 wt% FFA and 99.221 wt% methyl ester of were obtained from first step and second step, respectively.     

Rapid esterification of fatty acid using dicationic acidic ionic liquid catalyst via ultrasonic-assisted method

Biodiesel production via esterification/transesterification reactions can be catalyzed by homogenous or heterogeneous catalysts. Development of heterogeneous catalysts for biodiesel production is highly advantageous due to the ease of product purification and of catalyst recyclability. In this current work, a novel acidic [DABCODBS][CF₃SO₃]₂ dicationic ionic liquid (DIL) was used as heterogeneous catalyst to produce biodiesel using oleic acid as model oil. The esterification was conducted under ultrasonic irradiation (20 kHz) using a 14 mm ultrasonic horn transducer operated at various duty cycles. It was observed that the duty cycle, amplitude, methanol to oil molar ratio, catalyst amount and reaction temperature were the major factors that greatly impact the necessary reaction time to lead to a high yield of biodiesel. The reaction conditions were optimized with the aid of Response Surface Methodology (RSM) designed according to the Quadratic model of the Box Behnken method. The optimum conditions were found to be at catalyst amount of 0.64 mol%, methanol to oil ratio of 14.3:1, temperature of 59 °C, reaction time of 83 min and amplitude of 60% in continuous mode. The results showed that the oleic acid was successfully converted into esters with conversion value of 93.20% together with significant reduction of reaction time from 7 h (using mechanical stirring) to 83 min (using ultrasonication). The results also showed that the acidic DIL catalyst we designed purposely was efficient to catalyze the ultrasonic-assisted esterification yielding high conversion of oleic acid to methyl oleate on short times. The DIL was also recycled and reused for at least five times without significant reduction in performance. Overall, the procedure offers advantages including short reaction time, good yield, operational simplicity and environmentally benign characteristics.     

Intensification of biodiesel production from soybean oil and waste cooking oil in the presence of heterogeneous catalyst using high speed homogenizer

In the present work, high speed homogenizer has been used for the intensification of biodiesel synthesis from soybean oil and waste cooking oil (WCO) used as a sustainable feedstock. High acid value waste cooking oil (27 mg of KOH/g of oil) was first esterified with methanol using sulphuric acid as catalyst in two stages to bring the acid value to desired value of 1.5 mg of KOH/g of oil. Transesterification of soybean oil (directly due to lower acid value) and esterified waste cooking oil was performed in the presence of heterogeneous catalyst (CaO) for the production of biodiesel. Various experiments were performed for understanding the effect of operating parameters viz. molar ratio, catalyst loading, reaction temperature and speed of rotation of the homogenizer. For soybean oil, the maximum biodiesel yield as 84% was obtained with catalyst loading of 3 wt% and molar ratio of oil to methanol of 1:10 at 50 °C with 12,000 rpm as the speed of rotation in 30 min. Similarly biodiesel yield of 88% was obtained from waste cooking oil under identical operating conditions except for the catalyst loading which was 1 wt%. Significant increase in the rate of biodiesel production with yields from soybean oil as 84% (in 30 min) and from WCO as 88% (30 min) was established due to the use of high speed homogenizer as compared to the conventional stirring method (requiring 2–3 h for obtaining similar biodiesel yield). The observed intensification was attributed to the turbulence caused at microscale and generation of fine emulsions due to the cavitational effects. Overall it can be concluded from this study that high speed homogenizer can be used as an alternate cavitating device to efficiently produce biodiesel in the presence of heterogeneous catalysts.     

Synthesis of biodiesel from waste cooking oil using sonochemical reactors

Investigation into newer routes of biodiesel synthesis is a key research area especially due to the fluctuations in the conventional fuel prices and the environmental advantages of biodiesel. The present work illustrates the use of sonochemical reactors for the synthesis of biodiesel from waste cooking oil. Transesterification of used frying oil with methanol, in the presence of potassium hydroxide as a catalyst has been investigated using low frequency ultrasonic reactor (20 kHz). Effect of different operating parameters such as alcohol–oil molar ratio, catalyst concentration, temperature, power, pulse and horn position on the extent of conversion of oil have been investigated. The optimum conditions for the transesterification process have been obtained as molar ratio of alcohol to oil as 6:1, catalyst concentration of 1 wt.%, temperature as 45 °C and ultrasound power as 200 W with an irradiation time of 40 min. The efficacy of using ultrasound has been compared with the conventional stirring approach based on the use of a six blade turbine with diameter of 1.5 cm operating at 1000 rpm. Also the purification aspects of the final product have been investigated.     

Effect of ultrasonic irradiation on the properties and performance of biodiesel produced from date seed oil used in the diesel engine

In the present study, the effect of ultrasound irradiation on the transesterification parameters, biodiesel properties, and its combustion profiles in the diesel engine was investigated. Moreover, date seed oil (DSO) was firstly utilized in the ultrasound-assisted transesterification reaction. DSO was extracted from Zahidi type date (Phoenix dactylifera) and was esterified to reduce its Free Fatty Acid (FFA) content. Biodiesel yield was optimized in both heating methods, so that the yield of 96.4% (containing 93.5% ester) at 60 °C, with 6 M ratio of methanol/oil, 1 wt% of catalyst (NaOH) and at 90 min of reaction time was reported. The ultrasound irradiation did not influence the reaction conditions except reaction time, reduced to 5 min (96.9% yield and 91.9% ester). The ultrasonic irradiation also influenced on the physicochemical properties of DSO biodiesel and improved its combustion in the diesel engine. The analysis results related to the engine and gas emission confirmed that the ultrasound-assisted produced biodiesel has lower density and viscosity, and higher oxygen content facilitating injection of fuel in the engine chamber and its combustion, respectively. Although, B40 (biodiesel blend consisting of 40% biodiesel and 60% net diesel fuel) as a blend of both fuels presented higher CO₂ and lower CO and HC in the emissions, the DSO biodiesel produced by ultrasound irradiation presented better specifications (caused about 2-fold improvement in emissions than that of conventional method). The findings of the study confirmed the positive effect of the ultrasound irradiation on the properties of the produced biodiesel along with its combustion properties in the diesel engine, consequently reducing air pollution problems.     

Cavitation based cleaner technologies for biodiesel production and processing of hydrocarbon streams: A perspective on key fundamentals,missing process data and economic feasibility – A review

The present review emphasizes the role of hydrodynamic cavitation (HC) and acoustic cavitation in clean and green technologies for selected fuels (of hydrocarbon origins such as gasoline, naphtha, diesel, heavy oil, and crude oil) processing applications including biodiesel production. Herein, the role of cavitation reactors, their geometrical parameters, physicochemical properties of liquid media, liquid oxidants, catalyst loading, reactive oxygen species, and different types of emulsification and formation of radicals, formation as well as extraction of formed by-products are systematically reviewed. Among all types of HC reactors, vortex diode and single hole orifices revealed more than 95 % desulfurization yield and a 20 % viscosity reduction in heavy oil upgrading, while multi-hole orifice (100 holes) and slit Venturi allowed obtaining the best biodiesel production processes in terms of high (%) yield, low cost of treatment, and short processing time (5 min; 99 % biodiesel; 4.80 USD/m³). On the other hand, the acoustic cavitation devices are likely to be the most effective in biodiesel production based on ultrasonic bath (90 min; 95 %; 6.7 $/m³) and desulfurization treatment based on ultrasonic transducers (15 min; 98.3 % desulfurization; 10.8 $/m³). The implementation of HC-based processes reveals to be the most cost-effective method over acoustic cavitation-based devices. Finally, by reviewing the ongoing applications and development works, the limitations and challenges for further research are addressed emphasizing the cleaner production and guidelines for future scientists to assure obtaining comprehensive data useful for the research community.     

Continuous acid-catalyzed esterification using a 3D printed rotor–stator hydrodynamic cavitation reactor reduces free fatty acid content in mixed crude palm oil

Free fatty acid (FFA) content in FFA-rich mixed crude palm oil (MCPO) was reduced through a continuous esterification process. The reaction conditions were optimized, the yield purified esterified oil was determined, and the average total electricity consumption of the entire process was evaluated. The key component of this study was the cost-effective, 3D-printed rotor that was installed in a continuous rotor–stator hydrodynamic reactor. The surface of the rotor was designed with spherical holes where the center-to-center distance between them was fixed. Response surface methodology (RSM) using central composite design (CCD) was employed to analyze the design of experiments (DOE) and optimize FFA-content reduction. The optimized conditions were 17.7 vol% methanol, 2.9 vol% sulfuric acid, a 3000 rpm rotor speed, and surface holes measuring 4 mm in diameter and 6 mm in depth. The experimental results showed that the FFA content in MCPO was reduced from 11.456 to 1.028 wt% upon esterification under these optimal conditions. The maximum yield of esterified oil from the phase separation step was 96.07 vol%, and that of the purified esterified oil was 91.27 vol%. The average total energy consumed by this hydrodynamic cavitation reactor to produce this esterified oil was 0.0264 kW h/L. This 3D printed rotor–stator reactor is a promising, novel reactor technology for producing biodiesel from FFA-rich oils.     

Fast,easy ethanolysis of coconut oil for biodiesel production assisted by ultrasonication

Biodiesel is a renewable fuel, consistituting an alternative to petroleum-based diesel fuel. It is non-toxic and biodegradable and has a low emission profile, is better from environmentally sensitive areas. Research study on alternative fuels is essential for increased energy security. Presently, biodiesel is produced mainly is batch reactor. In this process the required energy is given by heating accompanied by mechanical stirring which has several disadvantages because of time consuming high labour cost. Being methanol is a toxic chemical; the objective of this work is to produce coconut oil ethyl ester by using ultrasonic irradiation. The advantages of ethanol are non-toxic domestic all available, having higher carbon atoms which provide higher heat content. The optical conditions for biodiesel production is the molar ratio oil to ethanol 1:6, KOH catalyst 0.75 wt.% of oil and 7 min reaction time. The reaction time reduced 15–40 times comparing to the conventional batch processes and found ?98% biodiesel yield.     

活性炭负载四氯化锡催化豆油制备生物柴油及光谱性质

以活性炭负载四氯化锡为催化剂,用甲醇和大豆油为原料,合成了生物柴油。考察了反应时间、反应温度、催化剂用量和原料配比对生物柴油产率的影响。当反应时间为5.0h,反应温度75℃,催化剂用量为反应物总质量的4.0%,醇油摩尔比7∶1时,生物柴油产率达94.6%。多次使用后,负载催化剂仍表现出较强的催化活性。并利用XRD、FT IR光谱表征了催化剂的物相和产品结构,用气相色谱-质谱联用法对产品进行了定性和定量分析。     

Enzymatic transesterification of Jatropha curcas oil assisted by ultrasonication

Ultrasonication used for the production of fatty acid methyl ester from non-edible vegetable oil using immobilized lipase (Chromobacterium viscosum) as a catalyst from Enterobacter aerogenes to make the process fully ecologically and environmental friendly. The optimal conditions for biodiesel production is the molar ratio oil to methanol 1:4, catalyst concentration 5 wt.% of oil, reaction time 30 min, ultrasonic amplitude 50% (100 W/m(3)) and cycle 0.7s. ultrasonication reduce the reaction time comparing to the conventional batch process. The purity and conversion of the biodiesel was 84.5±0.5 analyzed by reversed phase HPLC.     

Mechanistic insight into sonochemical biodiesel synthesis using heterogeneous base catalyst

The beneficial effect of ultrasound on transesterification reaction is well known. Heterogeneous (or solid) catalysts for biodiesel synthesis have merit that they do not contaminate the byproduct of glycerol. In this paper, we have attempted to identify the mechanistic features of ultrasound–enhanced biodiesel synthesis with the base–catalyst of CaO. A statistical design of experiments (Box–Behnken) was used to identify the influence of temperature, alcohol to oil molar ratio and catalyst loading on transesterification yield. The optimum values of these parameters for the highest yield were identified through Response Surface Method (with a quadratic model) and ANOVA. These values are: temperature = 62 °C, molar ratio = 10:1 and catalyst loading = 6 wt.%. The activation energy was determined as 82.3 kJ/mol, which is higher than that for homogeneous catalyzed system (for both acidic and basic catalyst). The experimental results have been analyzed vis–à–vis simulations of cavitation bubble dynamics. Due to 3–phase heterogeneity of the system, the yield was dominated by intrinsic kinetics, and the optimum temperature for the highest yield was close to boiling point of methanol. At this temperature, the influence of cavitation bubbles (in terms of both sonochemical and sonophysical effect) is negligible, and ultrasonic micro–streaming provided necessary convection in the system. The influence of all parameters on the reaction system was found to be strongly inter–dependent.     

Ultrasound assisted intensification of biodiesel production using enzymatic interesterification

Ultrasound assisted intensification of synthesis of biodiesel from waste cooking oil using methyl acetate and immobilized lipase obtained from Thermomyces lanuginosus (Lipozyme TLIM) as a catalyst has been investigated in the present work. The reaction has also been investigated using the conventional approach based on stirring so as to establish the beneficial effects obtained due to the use of ultrasound. Effect of operating conditions such as reactant molar ratio (oil and methyl acetate), temperature and enzyme loading on the yield of biodiesel has been investigated. Optimum conditions for the conventional approach (without ultrasound) were established as reactant molar ratio of 1:12 (oil:methyl acetate), enzyme loading of 6% (w/v), temperature of 40 °C and reaction time of 24 h and under these conditions, 90.1% biodiesel yield was obtained. The optimum conditions for the ultrasound assisted approach were oil to methyl acetate molar ratio of 1:9, enzyme loading of 3% (w/v), and reaction time of 3 h and the biodiesel yield obtained under these conditions was 96.1%. Use of ultrasound resulted in significant reduction in the reaction time with higher yields and lower requirement of the enzyme loading. The obtained results have clearly established that ultrasound assisted interesterification was a fast and efficient approach for biodiesel production giving significant benefits, which can help in reducing the costs of production. Reusability studies for the enzyme were also performed but it was observed that reuse of the catalyst under the optimum experimental condition resulted in reduced enzyme activity and biodiesel yield.     

Ultrasonic-assisted transesterification of Jatropha curcus oil using solid catalyst,Na/SiO2

The production of biodiesel from non-edible vegetable oil using ultrasonication, calls for an efficient solid catalyst to make the process fully ecologically and economically friendly. The methodology allows for the reaction to be run under atmospheric conditions. Solid catalyst and ultrasonication reduced the reaction time comparing to the conventional batch processes and we found 98.53% biodiesel yield. The optimal conditions for biodiesel production is the molar ratio oil to methanol 1:9, Catalyst conc. 3 wt.% of oil and 15 min reaction time.     

Ultrasound assisted aqueous two-phase extraction of polysaccharides from Cornus officinalis fruit: Modeling,optimization, purification,and characterization

Ultrasound assisted aqueous two-phase extraction of polysaccharides from Cornus officinalis fruit was modeled by response surface methodology (RSM) and artificial neural network (ANN), and optimized using genetic algorithm coupled with ANN (GA-ANN). Statistical analysis showed that the models obtained by RSM and ANN could accurately predict the Cornus officinalis polysaccharides (COPs) yield. However, ANN prediction was more accurate than RSM. The optimum extraction parameters to achieve the highest COPs yield (7.85 ± 0.09)% was obtained at the ultrasound power of 350 W, extraction temperature of 51 ℃, liquid-to-solid ratio of 17 mL/g, and extraction time of 38 min. Subsequently, the crude COPs were further purified via DEAE-52 and Sephadex G-100 chromatography to obtain a homogenous fraction (COPs-4-SG, 33.64 kDa) that contained galacturonic acid, arabinose, mannose, glucose, and galactose in a molar ratio of 34.82:14.19:6.75:13.48:12.26. The structure of COPs-4-SG was also characterized with UV–vis, fourier-transform infrared spectroscopy (FT–IR), atomic force microscopy (AFM), scanning electron microscopy (SEM), Congo-red test, and circular dichroism (CD). The findings provide a feasible way for the extraction, purification, and optimization of polysaccharides from plant resources     

A new pilot flow reactor for high-intensity ultrasound irradiation. Application to the synthesis of biodiesel

In recent years, chemistry in flowing systems has become more prominent as a method of carrying out chemical transformations, ranging in scale from microchemistry up to kilogram-scale processes. Compared to classic batch ultrasound reactors, flow reactors stand out for their greater efficiency and flexibility as well as lower energy consumption. This paper presents a new ultrasonic flow reactor developed in our laboratory, a pilot system well suited for reaction scale up. This was applied to the transesterification of soybean oil with methanol for biodiesel production. This reaction is mass-transfer-limited initially because the two reactants are immiscible with each other, then because the glycerol phase separates together with most of the catalyst (Na or K methoxide). In our reactor a mixture of oil (1.6 L), methanol and sodium methoxide 30% in methanol (wt/wt ratio 80:19.5:0.5, respectively) was fully transesterified at about 45 °C in 1 h (21.5 kHz, 600 W, flow rate 55 mL/min). The same result could be achieved together with a considerable reduction in energy consumption, by a two-step procedure: first a conventional heating under mechanical stirring (30 min at 45 °C), followed by ultrasound irradiation at the same temperature (35 min, 600 W, flow rate 55 mL/min).Our studies confirmed that high-throughput ultrasound applications definitively require flow reactors.     

Ultrasound assisted two-stage biodiesel synthesis from non-edible Schleichera triguga oil using heterogeneous catalyst: Kinetics and thermodynamic analysis

Present work deals with the ultrasound-assisted biodiesel production from low cost, substantial acid value kusum (Schleichera triguga) oil using a two-step method of esterification in presence of acid (H₂SO₄) catalyst followed by transesterification using a basic heterogeneous barium hydroxide (Ba(OH)₂) catalyst. The initial acid value of kusum oil was reduced from 21.65 to 0.84 mg of KOH/g of oil, by acid catalyzed esterification with 4:1 methanol to oil molar ratio, catalyst concentration 1% (v/v), ultrasonic irradiation time 20 min at 40 °C. Then, Ba(OH)₂ concentration of 3% (w/w), methanol to oil molar ratio of 9:1, ultrasonic irradiation time of 80 min, and temperature of 50 °C was found to be the optimum conditions for transesterification step and triglyceride conversion of 96.8% (wt) was achieved. This paper also examined the kinetics as well as the evaluation of thermodynamic parameters for both esterification and transesterification reactions. The lower value of activation energy and higher values of kinetic constants indicated a fast rate of reaction, which could be attributed to the physical effect of emulsification, in which the microturbulence generated due to radial motion of bubbles, creates an intimate mixing of the immiscible reactants causing the increase in the interfacial area, giving faster reaction kinetics. The positive values of Gibbs-free energy (ΔG), enthalpy (ΔH) and negative value of entropy (ΔS) revealed that both the esterification and transesterification were non-spontaneous, endothermic and endergonic reactions. Therefore, the present work has not only established the escalation obtained due to ultrasonication but also exemplified the two-step approach for synthesis of biodiesel from non-edible kusum oil based on the use of heterogeneous catalyst for the transesterification step.     

Fast, easy ethanomethanolysis of Jatropha curcus oil for biodiesel production due to the better solubility of oil with ethanol in reaction mixture assisted by ultrasonication

Biodiesel was obtained by transesterification of Jatropha curcus oil with anhydrous methanol, ethanol, and various mixtures of methanol/ethanol system. The present research work ultrasonic assisted transesterification of J. curcus oil was carried out in the presence of various mixtures of methanol/ethanol system and potassium hydroxide (KOH) as a catalyst, keeping the molar ratio of oil to alcohol 1:6. The methodology allows for the reaction to be run under atmospheric conditions. The ethanomethanolysis and ultrasonic mixing promote the rate of transesterification reaction due to the better solubility of oil with ethanol in reaction mixture and obtained methyl esters as well as ethyl esters.     

A novel enzyme-assisted ultrasonic approach for highly efficient extraction of resveratrol from Polygonum cuspidatum

Resveratrol is a promising multi-biofunctional phytochemical, which is abundant in Polygonum cuspidatum. Several methods for resveratrol extraction have been reported, while they often take a long extraction time accompanying with poor extraction yield. In this study, a novel enzyme-assisted ultrasonic approach for highly efficient extraction of resveratrol from P. cuspidatum was developed. According to results, the resveratrol yield significantly increased after glycosidases (Pectinex® or Viscozyme®) were applied in the process of extraction, and better extraction efficacy was found in the Pectinex®-assisted extraction compared to Viscozyme®-assisted extraction. Following, a 5-level-4-factor central composite rotatable design with response surface methodology (RSM) and artificial neural network (ANN) was selected to model and optimize the Pectinex®-assisted ultrasonic extraction. Based on the coefficient of determination (R²) calculated from the design data, ANN model displayed much more accurate in data fitting as compared to RSM model. The optimum conditions for the extraction determined by ANN model were substrate concentration of 5%, acoustic power of 150 W, pH of 5.4, temperature of 55 °C, the ratio of enzyme to substrate of 3950 polygalacturonase units (PGNU)/g of P. cuspidatum, and reaction time of 5 h, which can lead to a significantly high resveratrol yield of 11.88 mg/g.