Structured Catalyst for Biodiesel Production

Currently, most biodiesel is produced commercially by a homogeneous-catalyst-based transesterification process, wherein soybean oil is reacted with methanol in the presence of sodium methoxide. After transesterification, the homogeneous alkaline catalyst remains mixed with the biodiesel and the byproduct glycerol. The purification of the biodiesel and glycerol, by removing the homogeneous alkaline catalyst, is an energy and labor-intensive operation that produces a waste stream. Productivity is restricted by the need to use a batch reactor and the need for a long reaction time. In addition, the glycerol byproduct has low quality. This project will develop a novel structured heterogeneous-catalyst technology for high-efficiency, high-throughput, and low-cost biodiesel production in a continuous-flow fixed-bed reactor. The unique design of the structured catalyst will improve the catalyst utilization efficiency and overall activity, and will protect the catalyst from deactivation. In Phase I, the structured catalyst was successfully prepared with the required physical properties and catalytic performance. The operating conditions for the fixed-bed reactor were determined, and an economic analysis was conducted. Phase II will move the technology from laboratory scale to pilot scale, and demonstrate commercial viability. Commercial Applications and other Benefits as described by the awardee: The use of the structured-catalyst fixed-bed technology in biodiesel production should significantly simplify product separation and purification, increase biodiesel productivity, reduce plant size, remove the need for a constant feed of catalyst, improve glycerol quality, eliminate the waste stream, and reduce capital and processing costs. In turn, the substitution of petroleum diesel with domestically produced alternative fuel would be expedited, leading to reductions in energy consumption, environmental impact, and U.S. dependence on foreign oil imports