Acidic Resin Esterification with Reactive Simulated Moving Bed Chromatography
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Solution Overview
Problem
Current methods for producing fatty acid alkyl esters from co-product streams and waste fatty acid stock are inefficient, particularly in converting high levels of free fatty acids and impurities, leading to lower yields and resin degradation due to acid hydrolysis.
Innovation Solution
The method employs an acidic resin in combination with reactive simulated moving bed chromatography and pre-treatment steps like distillation and ion exchange to convert over 95% of fatty acid stock into alkyl esters, with an acid wash step to improve yield and resin longevity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If base catalyzed transesterification is used to produce fatty acid alkyl esters from refined triglyceride feedstocks, then the production process is straightforward, but the method cannot effectively convert high levels of free fatty acids and impurities present in waste or recycled fatty acid stock
Solution Approach 1:
The patent changes the catalytic parameter from base catalyst to acidic resin catalyst, enabling the system to process feedstocks with high free fatty acid content and impurities that would otherwise be incompatible with base-catalyzed methods. This parameter change allows direct conversion of waste and recycled fatty acid stock without extensive pre-refining.
Solution Approach 2:
The patent implements pre-treatment steps including distillation and ion exchange to remove impurities and free fatty acids from the feedstock before the main esterification process. This preliminary action prepares the waste and recycled fatty acid stock to be compatible with the acidic resin catalyst, improving overall conversion efficiency.
2Productivity
If acidic resin is used to convert fatty acid stock into esters, then conversion of free fatty acids is improved, but acid hydrolysis of the ester product occurs reducing yield
Solution Approach 1:
The patent performs pre-treatment of the fatty acid stock through distillation and ion exchange to remove water and impurities before esterification. This preliminary action reduces the water content that would otherwise promote acid-catalyzed hydrolysis of the ester product, thereby improving yield while maintaining high conversion rates.
Solution Approach 2:
The patent employs continuous reactive simulated moving bed chromatography where the esterification reaction and product separation occur simultaneously and continuously. This continuous process prevents accumulation of water and acid byproducts that could cause hydrolysis, maintaining both high conversion and high yield throughout the operation.
3Productivity
If conventional esterification methods are used on waste fatty acid stock, then some ester production is achieved, but resin degradation occurs due to acid hydrolysis reducing process longevity
Solution Approach 1:
The patent implements pre-treatment steps including distillation and ion exchange to remove water, free fatty acids, and impurities from the waste fatty acid stock before it contacts the acidic resin catalyst. This preliminary action creates a cleaner feedstock that reduces acid hydrolysis and resin degradation, extending resin life while maintaining productive esterification.
Solution Approach 2:
The patent uses ion exchange to extract and remove cations and impurities from the fatty acid stock, and distillation to extract and remove volatile impurities and excess water. These extraction processes protect the acidic resin from degradation by removing harmful substances before they can attack the resin structure.
4Productivity
If reactive simulated moving bed chromatography is employed to separate ester product from raffinate stream, then yield is improved, but process complexity increases
Solution Approach 1:
The patent merges the esterification reaction and product separation into a single continuous reactive simulated moving bed chromatography process. The reaction zone and separation zones are combined in one system, allowing the esterification to occur while simultaneously separating the ester product from the raffinate stream. This integration achieves high yield without requiring separate, complex downstream purification equipment.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach significantly increases the yield of fatty acid alkyl esters to at least 95% while prolonging resin life and preventing acid hydrolysis, facilitating efficient production of high-quality esters from recycled and waste fatty acid sources.
Implementation Method 1
The present method utilizes an acidic resin to convert the fatty acid stock into esters
Implementation Method 2
The present method encompasses the use of reactive simulated moving bed chromatography
Implementation Method 3
combining a fatty acid composition with a (C1-5) alkyl alcohol in the presence of an acidic ion exchange resin, wherein prior to combining, the fatty acid composition has been subjected to one or more of the following: (a) distillation, (b) contacting with an ion exchange material
Implementation Method 4
combining a fatty acid composition with a (C1-5) alkyl alcohol in the presence of an acidic ion exchange resin, wherein prior to combining, the fatty acid composition has been subjected to one or more of the following: (a) distillation
Data Source
AI summary
The present invention is directed to a method or preparing fatty acid alkyl esters from fatty acids contained in co-product streams, or waste or recycled fatty acid stock. The present method utilizes an acidic resin to convert the fatty acid stock into esters. The present method encompasses the use of reactive simulated moving bed chromatography, wherein above about 95 percent of the fatty acid stock is converted to fatty acid alkyl esters. The present method has been optimized to separate the ester product from the raffinate stream formed during the chromatographic process, thereby improving the yield of the esterification and preventing acid hydrolysis of the ester.