Intensified Process for Biodiesel Production

Although interest in biodiesel is rapidly increasing, the process by which biodiesel is synthesized has not changed much in the last two decades. Currently, biodiesel is made 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 is mixed with the biodiesel and the glycerol byproduct. Purifying both the biodiesel and the glycerol, by removing the homogeneous alkaline catalyst, is an energy and labor-intensive operation that produces a waste stream. The process is far from efficient, and the cost of biodiesel production is generally much higher than that of petroleum-based diesel. This project will develop a heterogeneous-catalyst-based catalytic reactor for highly-efficient, high-throughput, low-cost biodiesel production. The reactor will consist of thousands of micro-reactors coated with a highly efficient heterogeneous catalyst. In Phase I, the bench scale structured catalytic reactor will be developed. The transesterification reaction of soybean oil with methanol will be performed to evaluate the effectiveness of this reactor for biodiesel production. Optimal reactor configuration and operating conditions will be obtained, and the technical feasibility of this new technology will be determined. Commercial Applications and other Benefits as described by the awardee: The use of this reactor in biodiesel production should significantly increase biodiesel productivity, simplify product separation and purification, improve glycerin quality, and eliminate the washing step and associated waste stream, making it a revolutionary change to the current homogeneous catalyst process. In turn, the new process will expedite the substitution of petroleum diesel with a domestically produced alternative fuel, decrease energy consumption and its associated environmental impact, reduce U.S. dependence on foreign oil imports, and enable the U.S. transportation industry to sustain a strong competitive position in domestic and world markets.