Fatty Acid Alkyl Ester Refining for Crude Lipid Feedstocks
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Solution Overview
Problem
Low-cost lipid feedstocks are difficult to process due to impurities and contaminants, which can interfere with biodiesel production, and existing methods require expensive high-quality feedstocks or solvents that are costly and hazardous.
Innovation Solution
Using fatty acid alkyl ester solutions as refining agents to preprocess low-cost feedstocks, solubilize desirable components, and convert them into a liquid form suitable for biodiesel production, eliminating the need for costly solvent recovery and reducing energy consumption.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If low-cost lipid feed stocks are used, then production cost is reduced, but processing difficulty increases due to impurities and contaminants
Solution Approach 1:
The patent applies preliminary action by using fatty acid alkyl ester solutions to preprocess and refine low-cost lipid feed stocks before the main biodiesel production process. This preliminary refinement step removes impurities and contaminants that would otherwise interfere with subsequent processing, thereby enabling the use of low-cost feed stocks without sacrificing processing efficiency or product quality
Solution Approach 2:
The patent uses fatty acid alkyl ester solutions as an intermediary substance that facilitates the processing of low-cost feed stocks. These solutions act as a mediator between the crude feed stock and the biodiesel production process, solubilizing desirable components while leaving impurities behind, thus bridging the gap between low-cost raw materials and high-quality fuel production
2Manufacturing precision
If traditional solvent extraction is used, then feed stock purification is achieved, but energy consumption and operational complexity increase
Solution Approach 1:
The patent applies self-service by using the fatty acid alkyl ester product itself (or similar esters) as the refining agent in the extraction process. This eliminates the need for separate, energy-intensive solvent recovery systems, as the ester phase naturally separates from water and insoluble impurities, and can be directly used or recycled without additional processing steps
Solution Approach 2:
The patent changes the physical and chemical parameters of the extraction system by using fatty acid alkyl esters with specific solubility characteristics that allow desirable lipid components to dissolve while impurities remain insoluble. This parameter change enables selective extraction at moderate temperatures and pressures, avoiding the high energy input required by traditional solvent systems
3Manufacturing precision
If traditional solvent extraction is used, then feed stock purification is achieved, but device complexity and operational hazards increase
Solution Approach 1:
The refining system performs self-service through natural phase separation, where fatty acid alkyl esters automatically separate from water and insoluble impurities without requiring complex filtration or recovery equipment. This simplifies the overall process design and reduces operational hazards associated with handling and recovering traditional solvents
Solution Approach 2:
The patent employs a disposable or easily regenerable refining approach where fatty acid alkyl ester solutions can be used once and then discarded or简单地 regenerated by phase separation, eliminating the need for expensive, complex solvent recovery infrastructure and reducing operational complexity
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 allows for efficient production of biodiesel from low-cost feedstocks by separating desirable components from insoluble impurities, reducing the risk of reactor plugging, and lowering energy costs, while utilizing the fatty acid alkyl esters as both a refining agent and a product in the process.
Implementation Method 1
mixing a crude lipid feed stock with a refining solution to form a crude product mixture... extracting the liquid phase from the crude product mixture to obtain a purified lipid feed stock
Implementation Method 2
extracting the liquid phase from the crude product mixture to obtain a purified lipid feed stock
Data Source
AI summary
The present invention relates to systems and methods of using fatty acid alkyl ester solutions to refine feed stocks before converting the feed stocks into fatty acid fatty acid alkyl esters. In an embodiment, the invention includes a method for producing fatty acid alkyl esters. The method can include mixing a crude lipid feed stock with a refining solution to form a crude product mixture, the refining solution comprising greater than about 10 wt. % fatty acid alkyl esters. The method can include extracting the liquid phase from the crude product mixture to obtain a purified lipid feed stock. The method can also include reacting the purified lipid feed stock with an alcohol to form a product mixture comprising fatty acid alkyl esters. In an embodiment, the invention includes a method of making a fatty acid alkyl ester composition. The method can include extracting lipids from a corn-based ethanol production byproduct, adding an alcohol solution to the lipids to form a reaction mixture, and contacting the reaction mixture with a metal oxide catalyst. Other embodiments are included herein.