Optimization of biodiesel production in a hydrodynamic cavitation reactor using used frying oil

The present work demonstrates the application of a hydrodynamic cavitation reactor for the synthesis of biodiesel with used frying oil as a feedstock. The synthesis involved the transesterification of used frying oil (UFO) with methanol in the presence of potassium hydroxide as a catalyst. The effect of geometry and upstream pressure of a cavitating orifice plate on the rate of transesterification reaction has been studied. It is observed that the micro level turbulence created by hydrodynamic cavitation somewhat overcomes the mass transfer limitations for triphasic transesterification reaction. The significant effects of upstream pressure on the rate of formation of methyl esters have been seen. It has been observed that flow geometry of orifice plate plays a crucial role in process intensification. With an optimized plate geometry of 2 mm hole diameter and 25 holes, more than 95% of triglycerides have been converted to methyl esters in 10 min of reaction time with cavitational yield of 1.28 × 10^?3 (Grams of methyl esters produced per Joule of energy supplied). The potential of UFO to produce good quality methyl esters has been demonstrated.     

Biodiesel production process intensification using a rotor-stator type generator of hydrodynamic cavitation

Triglyceride transesterification for biodiesel production is a model reaction which is used to compare the conversion efficiency, yield, reaction time, energy consumption, scalability and cost estimation of different reactor technology and energy source. This work describes an efficient, fast and cost-effective procedure for biodiesel preparation using a rotating generator of hydrodynamic cavitation (HC). The base-catalyzed transesterification (methanol/sodium hydroxide) has been carried out using refined and bleached palm oil and waste vegetable cooking oil. The novel HC unit is a continuous rotor-stator type reactor in which reagents are directly fed into the controlled cavitation chamber. The high-speed rotation of the reactor creates micron-sized droplets of the immiscible reacting mixture leading to outstanding mass and heat transfer and enhancing the kinetics of the transesterification reaction which completes much more quickly than traditional methods. All the biodiesel samples obtained respect the ASTM standard and present fatty acid methyl ester contents of >99% m/m in both feedstocks. The electrical energy consumption of the HC reactor is 0.030 kW h per L of produced crude biodiesel, making this innovative technology really quite competitive. The reactor can be easily scaled-up, from producing a few hundred to thousands of liters of biodiesel per hour while avoiding the risk of orifices clogging with oil impurities, which may occur in conventional HC reactors. Furthermore it requires minimal installation space due to its compact design, which enhances overall security.     

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.     

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.     

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.     

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.     

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.     

大豆油酯交换法制备生物柴油及气相色谱分析

为获得最佳条件,在单因素试验的基础上,采用正交试验法对大豆油碱催化酯交换法制各生物柴油的工艺参数进行了优化试验,结果表明,制取生物柴油的最佳工艺参数是：醇油摩尔比6：1,催化剂用量为油量的0.8%,反应温度为45℃,反应时间60m in,并且在最优工艺参数下进行了验证试验,得到生物柴油的转化率为97.05%。气相色谱分析结果表明,脂肪酸甲酯含量很高。     

Decolourization of Rhodamine B: A swirling jet-induced cavitation combined with NaOCl

A hydrodynamic cavitation reactor (Ecowirl) based on swirling jet-induced cavitation has been used in order to allow the degradation of a waste dye aqueous solution (Rhodamine B, RhB). Cavitation generated by Ecowirl reactor was directly compared with cavitation generated by using multiple hole orifice plates. The effects of operating conditions and parameters such as pressure, pH of dye solution, initial concentration of RhB and geometry of the cavitating devices on the degradation rate of RhB were discussed. In similar operative conditions, higher extents of degradation (ED) were obtained using Ecowirl reactor rather than orifice plate. An increase in the ED from 8.6% to 14.7% was observed moving from hole orifice plates to Ecowirl reactor. Intensification in ED of RhB by using hydrodynamic cavitation in presence of NaOCl as additive has been studied. It was found that the decolourization was most efficient for the combination of hydrodynamic cavitation and chemical oxidation as compared to chemical oxidation and hydrodynamic cavitation alone. The value of ED of 83.4% was reached in 37 min using Ecowirl combined with NaOCl (4.0 mg L⁻¹) as compared to the 100 min needed by only mixing NaOCl at the same concentration. At last, the energetic consumptions of the cavitation devices have been evaluated. Increasing the ED and reducing the treatment time, Ecowirl reactor resulted to be more energy efficient as compared to hole orifice plates, Venturi and other swirling jet-induced cavitation devices, as reported in literature.     

Hydrodynamic cavitation as a novel approach for delignification of wheat straw for paper manufacturing

The present work deals with application of hydrodynamic cavitation for intensification of delignification of wheat straw as an essential step in the paper manufacturing process. Wheat straw was first treated with potassium hydroxide (KOH) for 48 h and subsequently alkali treated wheat straw was subjected to hydrodynamic cavitation. Hydrodynamic cavitation reactor used in the work is basically a stator and rotor assembly, where the rotor is provided with indentations and cavitational events are expected to occur on the surface of rotor as well as within the indentations. It has been observed that treatment of alkali treated wheat straw in hydrodynamic cavitation reactor for 10–15 min increases the tensile index of the synthesized paper sheets to about 50–55%, which is sufficient for paper board manufacture. The final mechanical properties of the paper can be effectively managed by controlling the processing parameters as well as the cavitational parameters. It has also been established that hydrodynamic cavitation proves to be an effective method over other standard digestion techniques of delignification in terms of electrical energy requirements as well as the required time for processing. Overall, the work is first of its kind application of hydrodynamic cavitation for enhancing the effectiveness of delignification and presents novel results of significant interest to the paper and pulp industry opening an entirely new area of application of cavitational reactors.     

The use of acids,niobium oxide,and zeolite catalysts for esterification reactions

We have evaluated the influence of alcohol/fatty acid molar ratio (methanol or ethanol), water and catalyst concentrations and temperature by the esterification of palm fatty acids by heterogeneous acid catalysts (varying types, forms, and particle size). Polynaphtalene sulfonic acid (PSA) and niobium oxide (Nb₂O₅) presented better performance than zeolite catalysts. Reaction with methanol presented higher conversion than with ethanol. The experimental design showed that the most relevant variable is the catalyst concentration and all interactions become important in process. A heterogeneous kinetic model was proposed and applied to experimental data. One of the models was adequate for methanol reaction, whereas the homogeneous model was more appropriate for ethanol reaction. Copyright © 2009 John Wiley & Sons, Ltd.     

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。     

A study of chemical transformations of organic compounds under the action of cavitation

The action of ultrasonic and hydrodynamic cavitation on the cracking of organic compounds of various natures (linear alkanes (octane, undecane, and hexadecane), carboxylic acids (decanoic and oleic acids), alcohols (decanol), and esters (ethyl caprate)) and transesterification of rapeseed oil and methanol and ethanol was studied. An analysis of hydrocarbon transformation products by gas chromatography, high-performance liquid chromatography, NMR, and chromato-mass spectrometry showed that cavitation treatment of any class of organic compounds of those mentioned above resulted in transformations no more than 1.1% deep. In experiments with transesterification of rapeseed oil and methanol and ethanol without a catalyst under the action of cavitation, the yield of fatty acid esters did not exceed 2.1 mol %. The energy efficiency of the cavitation apparatus was estimated at 0.002% for endothermic cracking of alkanes. The data obtained led us to conclude that the use of cavitation directly for performing cracking of various organic compounds and noncatalytic transesterification of vegetable oils was ineffective.     

Preparation of biodiesel with the help of ultrasonic and hydrodynamic cavitation

An alkali-catalyzed biodiesel production method with power ultrasonic (19.7 kHz) has been developed that allows a short reaction time and high yield because of emulsification and cavitation of the liquid-liquid immiscible system. Orthogonality experiments were employed to evaluate the effects of synthesis parameters. Furthermore, hydrodynamic cavitation was used for biodiesel production in comparison to ultrasonic method. Both methods were proved to be efficient, and time and energy saving for the preparation of biodiesel by transesterification of soybean oil.     

Dynamics of cavitational bubbles and design of a hydrodynamic cavitational reactor: cluster approach

In the present work, a cavity cluster of predetermined size has been considered to study the bubble dynamics in the hydrodynamic cavitation reactor. The effect of different operating and system parameters on the cavitational intensity has been numerically investigated. The yield of any cavitationally induced physical/chemical transformations depends not only on the collapse pressure of the cavities but also on the active volume of cavitation within the reactor. Empirical correlations have been developed to predict the collapse pressure and the active volume of cavitation as a function of different operating parameters based on the bubble dynamics studies. Recommendations are made for designing a cavitational reactor on the basis of the proposed empirical correlations. This work is a first step towards the designing and optimization of hydrodynamic cavitational reactor with cluster approach.     

Treatment of cyanide containing wastewater using cavitation based approach

Industrial wastewater streams containing high concentrations of biorefractory materials like cyanides should ideally be treated at source. In the present work, degradation of potassium ferrocyanide (K₄F_e(CN)₆) as a model pollutant has been investigated using cavitational reactors with possible intensification studies using different approaches. Effect of different operating parameters such as initial concentration, temperature and pH on the extent of degradation using acoustic cavitation has been investigated. For the case of hydrodynamic cavitation, flow characteristics of cavitating device (venturi) have been established initially followed by the effect of inlet pressure and pH on the extent of degradation. Under the optimized set of operating parameters, the addition of hydrogen peroxide (ratio of K₄F_e(CN)₆:H₂O₂ varied from 1:1 to 1:30 mol basis) as process intensifying approach has been investigated. The present work has conclusively established that under the set of optimized operating parameters, cavitation can be effectively used for degradation of potassium ferrocyanide. The comparative study of hydrodynamic cavitation and acoustic cavitation suggested that hydrodynamic cavitation is more energy efficient and gives higher degradation as compared to acoustic cavitation for equivalent power/energy dissipation. The present work is the first one to report comparison of cavitation based treatment schemes for degradation of cyanide containing wastewaters.     

Niobium oxide solid catalyst: esterification of fatty acids and modeling for biodiesel production

Biodiesel can be obtained from fatty acid raw materials through esterification. The reactivity of lauric, palmitic, stearic, oleic, and linoleic fatty acids with methanol using powdered niobic acid as a heterogeneous catalyst was investigated in this work, both experimentally (in a batch reactor) and theoretically. A 2³ experimental design was used, with methanol/fatty acid molar ratio, catalyst concentration, and temperature as main factors. An empirical model demonstrated that temperature is the most important variable. Fourteen heterogeneous and 56 homogeneous‐like kinetic models were tested. A homogeneous‐like model considering zero order for all species and inhibition by water was the most adequate for experiments without catalyst. A homogeneous‐like model considering a second‐order reaction in relation to the fatty acid and no water inhibition was the most adequate for niobic acid catalyzed reaction. Molecular modeling confirmed the experimental results showing that the reactivity is directly related to the increase of unsaturated bonds and the reduction of carbon chain length. The polarity of the fatty acid is determinant in the reactivity. At the molecular level, reaction occurs between the HOMO orbital of methanol and LUMO orbitals of fatty acids and reactivity is higher when the energy difference between these orbitals is lower. Copyright © 2010 John Wiley & Sons, Ltd.     

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.     

A review and assessment of hydrodynamic cavitation as a technology for the future

In the present work, the current status of the hydrodynamic cavitation reactors has been reviewed discussing the bubble dynamics analysis, optimum design considerations, design correlations for cavitational intensity (in terms of collapse pressure)/cavitational yield and different successful chemical synthesis applications clearly illustrating the utility of these types of reactors. The theoretical discussion based on the modeling of the bubble dynamics equations aims at understanding the design information related to the dependency of the cavitational intensity on the operating parameters and recommendations have been made for the choice of the optimized conditions of operating parameters. The design information based on the theoretical analysis has also been supported with some experimental illustrations concentrating on the chemical synthesis applications. Assessment of the hydrodynamic cavitation reactors and comparison with the sonochemical reactors has been done by citing the different industrially important reactions (oxidation of toluene, o-xylene, m-xylene, p-xylene, mesitylene, o-nitrotoluene, p-nitrotoluene, m-nitrotoluene, o-chlorotoluene and p-chlorotoulene, and trans-esterification reaction i.e., synthesis of bio-diesel). Some recommendations have also been made for the future work to be carried out as well as the choice of the operating conditions for realizing the dream of industrial scale applications of the cavitational reactors.     

Characterization of cavitation under ultrasonic horn tip – Proposition of an acoustic cavitation parameter

Acoustic cavitation, generated by a piezo-driven transducer, is a commonly used technique in a variety of processes, from homogenization, emulsification, and intensification of chemical reactions to surface cleaning and wastewater treatment. An ultrasonic horn, the most commonly used acoustic cavitation device, creates unique cavitation conditions under the horn tip that depend on various parameters such as the tip diameter, the driving frequency of the horn, its amplitude, and fluid properties. Unlike for hydrodynamic cavitation, the scaling laws for acoustic cavitation are poorly understood. Empirical relationships between cavitation dynamics, ultrasonic horn operating conditions, and fluid properties were found through systematic characterization of cavitation under the tip. Experiments were conducted in distilled water with various sodium chloride salt concentrations under different horn amplitudes, tip geometries, and ambient pressures. Cavitation characteristics were monitored by high-speed (200,000 fps) imaging, and numerous relations were found between operating conditions and cavitation dynamics. The compared results are discussed along with a proposal of a novel acoustic cavitation parameter and its relationship to the size of the cavitation cloud under the horn tip. Similar to the classical hydrodynamic cavitation number, the authors propose for the first time an acoustic cavitation parameter based on experimental results.