Bio-diesel Production via Alkyl Ester Co-solvent Mixing
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Solution Overview
Problem
Current methods for producing bio-diesel oil face challenges such as slow reaction rates due to immiscibility of oil/fat and alcohol, requiring large reactor volumes and high energy costs, as well as inefficient separation processes and additional solvent costs.
Innovation Solution
The method involves adding alkyl ester as a subsidiary solvent to facilitate homogeneous mixing of oil/fat and alcohol, recycling alkyl ester to enhance reaction efficiency, and incorporating a pre-esterification step to convert free fatty acids into bio-diesel oil, using a batch or continuous reactor system.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If alcohol and oil/fat are used as reactants for bio-diesel production, then the reaction produces desired ester product, but the reaction rate is slow due to immiscibility of the two reactants
Solution Approach 1:
The patent introduces a co-solvent as an intermediary substance that is miscible with both polar alcohol and non-polar oil/fat. This co-solvent acts as a bridge between the two immiscible reactants, enabling homogeneous mixing and increasing the reaction rate by providing a single liquid phase environment for the transesterification reaction to proceed efficiently.
2Productivity
If turbulent flow is maintained to increase reaction rate, then mixing of alcohol and oil/fat is improved, but reactor volume and power costs increase
Solution Approach 1:
The patent changes the physical-chemical parameters of the reaction system by introducing a co-solvent that modifies the polarity and miscibility characteristics of the reactant mixture. This parameter change allows the system to achieve effective mixing without requiring turbulent flow conditions, thereby reducing reactor volume requirements and power consumption while maintaining high reaction rates.
3Productivity
If additional subsidiary solvent is added to promote mixing, then reaction rate increases, but production cost increases due to additional solvent separation
Solution Approach 1:
The patent employs the co-solvent in a self-service manner where it facilitates the reaction and then is easily separated and recovered along with the product ester. The co-solvent's properties allow it to be integrated into the existing separation process without requiring additional complex separation steps, thereby avoiding increased production costs while maintaining enhanced reaction rates.
4Productivity
If batch reactor is used to maintain high reactant concentrations, then reaction rate is high, but production amount is limited
Solution Approach 1:
The patent makes the reaction system multi-functional by developing a continuous reactor configuration that incorporates the co-solvent system. This allows the same chemical system to operate in continuous mode for large-scale production while maintaining the high reaction rates achieved in batch mode, thereby achieving both high productivity and large production quantities through a single versatile process design.
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 reaction rate, reduces production time, and minimizes reactor size, while improving economic efficiency by eliminating the need for additional solvents and reducing separation complexities.
Implementation Method 1
alkyl ester is added to two reactants immiscible with each other to promote the homogeneous mixing of the two reactants to form a sigle liquid phase
Implementation Method 2
when the oil/fat and alcohol are transesterified with each other
Data Source
AI summary
The object of this invention is to provide a method of producing a bio-diesel oil in a great amount in a relatively short time, in which oil/fat and alcohol, used as reactants, are homogeneously mixed with each other to form a single liquid phase mixture which effectively react with each other. The method includes transesterifying the oil/fat and alcohol in the presence of alkyl ester. Additionally, in the method, alkyl ester is added to a mixture of the oil/fat and alcohol by recycling alkyl ester as a product to the mixture. Furthermore, the method includes (a) an acidic catalyst, and (b) transesterifying the pre-esterified oil/fat with alcohol in the presence of alkyl ester.