Chapter three
Process Description
3-1 Biodiesel Production Processes
After reviewing various traditional and advanced methods for biodiesel production, the
base-catalyzed transesterification process has been selected as the preferred technique to
be implemented.
Biodiesel production is the process of converting vegetable oils, animal fats, or waste oils
and fats into the biofuel known as biodiesel. This is achieved through a series of chemical
reactions, primarily transesterification and esterification.
The transesterification process involves reacting the vegetable or animal fat/oil feedstock
with a short-chain alcohol, typically methanol or ethanol. This reaction, catalyzed by a
base such as sodium or potassium hydroxide, results in the production of biodiesel (fatty
acid methyl or ethyl esters) and glycerol as a byproduct.
Figure 3-1 below shows the flow sheet for manufacturing biodiesel from waste vegetable
oil (WVO) using the base-catalyzed transesterification method:
Figure 3-1: Biodiesel manufacturing flow sheet from waste vegetable oil (WVO)
3-2 Process Detailed Steps
3-2-1 Filtration and Heating of Waste Vegetable Oil (WVO)
The non-oil components of the waste vegetable oil are removed by filtration. The oil is
then heated to a temperature of 110°C and maintained at this temperature for 5 minutes to
remove any residual moisture. Typically, an electric heater is used to bring the oil to the
required temperature.
3-2-2 Mixing of Methanol and Catalyst
The purpose of mixing methanol and a catalyst, such as sodium hydroxide (NaOH) or
potassium hydroxide (KOH), is to form methoxide. Methanol and the alkaline catalysts
are hazardous chemicals that require proper handling. Skin contact and inhalation of
vapors should be avoided. Necessary safety precautions, such as the use of gloves and
proper ventilation, must be observed when working with these substances.
3-2-3 Transesterification (Biodiesel Reaction)
Transesterification is the key chemical reaction that converts the vegetable oil or animal
fat into biodiesel. In this reaction, the oil is reacted with a short-chain alcohol, typically
methanol, in the presence of a catalyst (such as NaOH or KOH) to produce fatty acid
methyl esters (biodiesel) and glycerol as a byproduct.
The transesterification reaction can be carried out in batches or continuously. In the batch
process, the methanol-catalyst mixture is added to the oil in a beaker, which serves as the
reaction vessel. The mixture is then agitated for approximately 60 minutes, after which it
is left to settle overnight to allow for phase separation due to gravity. The biodiesel (fatty
acid methyl esters) and glycerol layers separate, allowing for their subsequent
purification and processing.
The overall transesterification reaction can be represented as follows:
Vegetable oil + Methanol ------> Biodiesel + Glycerol
This catalyzed chemical reaction is the core of the biodiesel production process,
converting the feedstock oil or fat into the desired biofuel product.
Figure 3-2: Transesterification reaction[69]
3-2-4 Draining of Glycerol
After the transesterification reaction, the mixture needs to be left to settle so that the
glycerol, being denser than the biodiesel, separates and settles to the bottom of the
container. This phase separation typically takes a minimum of 8 to 12 hours to complete.
3-2-5 Washing of Biodiesel
The purpose of washing the biodiesel is to remove any remaining catalyst and other
impurities. The preferred method is water washing, where lukewarm water (about one-
third the volume of the raw biodiesel) is added to the biodiesel, stirred briefly, and then
allowed to settle. The impurities will then settle to the bottom with the water, leaving the
purified biodiesel on top.
3-3 Parameters Affecting Base-Catalyzed Transesterification
3-3-1 Alcohol Formulation
The most commonly used alcohols for the transesterification reaction are short-chain
alcohols such as methanol, ethanol, and butanol. While the choice of alcohol can affect
the reaction kinetics, the final yield of esters (biodiesel) remains largely unaffected.
Therefore, the selection of the alcohol is primarily based on cost and performance
considerations.
In the literature reviewed, methanol was the predominant alcohol used, as methyl esters
are the most common form of biodiesel produced.
Excellent, let me continue the summary of the key parameters affecting base-catalyzed
transesterification:
3-3-2 Molar Ratio of Alcohol to Triglyceride
The molar ratio of alcohol to triglyceride is a critical variable affecting the yield of esters
(biodiesel). The stoichiometric ratio is 3:1 (3 moles of alcohol to 1 mole of triglyceride),
but an excess of alcohol is required to drive the equilibrium reaction to the right and
maximize the yield of biodiesel. However, too much excess alcohol can make the
recovery of glycerol more difficult, so the ideal ratio has to be determined empirically.
3-3-3 Catalyst Formulation
The most commonly used alkaline catalysts in the biodiesel industry are potassium
hydroxide (KOH) and sodium hydroxide (NaOH). These are inexpensive and easy to
handle. Commercially available alkoxide solutions like sodium methoxide or potassium
methoxide in methanol are preferred for large-scale continuous production processes.
Many studies have found that biodiesel with the best properties is obtained using
potassium hydroxide as the catalyst, while others have achieved the best results with
NaOH.
3-3-4 Catalyst Concentration
For alkaline catalysis, most literature indicates that the best catalyst concentrations are
between 0.5 to 1.0 wt%. Higher concentrations can lead to lower yields.
The catalyst concentration is closely related to the free fatty acid content of the oil. More
catalyst is needed to neutralize a higher free fatty acid content and avoid catalyst
deactivation. However, excessive catalyst can also lead to emulsion formation, increased
viscosity, and poorer glycerol separation, which reduces the overall biodiesel yield.
Thank you for the additional details on the reaction parameters for base-catalyzed
transesterification. Let me summarize the key points:
3-3-5 Reaction Temperature:
- Temperature has no significant effect on the ultimate conversion to esters, but higher
temperatures can decrease the time required to reach maximum conversion.
- Typical temperatures used are in the range of 60-65°C, which is below the boiling point
of methanol (68°C). Going above the boiling point can cause methanol vaporization and
hinder the reaction.
3-3-6 Reaction Time:
- Most studies have observed an optimum reaction time around 1 hour.
- Excess reaction time does not increase conversion but can favor the backward
hydrolysis reaction, reducing product yield.
3-3-7 Agitation:
- Vigorous mixing is required to increase the contact area between the immiscible liquid
phases (oil and alcohol).
- Magnetic stirring at around 600 rpm is commonly used.
- Methanol has been reported to give the best results in terms of biodiesel yield and
byproduct recovery.
In summary, the optimum conditions for base-catalyzed transesterification (methanolysis)
involve:
- 100% excess methanol (6:1 molar ratio)
- 1 wt% KOH or NaOH catalyst
- Temperature of 60-65°C
- Reaction time of around 1 hour
- Vigorous agitation/mixing
