SAJJAD KHUDHUR ABBAS Chemical Engineering , Al-Muthanna University, Iraq Oil & Gas Safety and Health Professional – OSHACADEMY Trainer of Trainers (TOT) - Canadian Center of Human Development Episode 4 : PRODUCTION OF 60, 000 MTPA OF OLEOCHEMICAL METHYL ESTER FROM RBD PALM KERNEL OIL
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Episode 4: PRODUCTION OF 60, 000 MTPA OF OLEOCHEMICAL METHYL ESTER FROM RBD PALM KERNEL OIL
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SAJJAD KHUDHUR ABBASChemical Engineering , Al-Muthanna University, IraqOil & Gas Safety and Health Professional – OSHACADEMYTrainer of Trainers (TOT) - Canadian Center of Human Development
Episode 4 : PRODUCTION OF 60, 000 MTPA OF OLEOCHEMICAL METHYL
ESTER FROM RBD PALM KERNEL OIL
WAN ADEEBAH WAN MAHMOOD
SITI IRHITH BUSHRAH NOOR MAHADI
SAJJAD KHUDHUR ABBAS
AIMAN MOHAMMED BELAL SIDAN
PRESENTED BY:
1. To produce 60,000 MTPA of methyl estersfrom RBD palm kernel oil.
2. To achieve the production of methyl estersby using homogeneous base-catalyzedtransesterification method with sodiummethoxide (NaOCH3) as catalyst.
a) OBJECTIVES
What is methyl ester?
Methyl Ester
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Fatty Acid Methyl Ester (FAME)
Biodiesel
One of the Basic Oleochemicals(Others: Fatty acids & Fatty alcohols)
Derived from natural Oils & Fats
Plant Oils
Animal Fats
Waste Oils
Normally produced by:• Transesterification of triglyceride (oil)• Esterification of free fatty acid (FFA)
b) PROCESS BACKGROUND
Transesterification Process
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Methoxide
A Triglyceride (Oil)Glycerol
A Methyl Ester
𝐓𝐓𝐓𝐓 + 𝟑𝟑 𝐌𝐌𝐌𝐌𝐌𝐌𝐌𝐌 ↔ 𝟑𝟑 𝐅𝐅𝐅𝐅𝐌𝐌𝐅𝐅 + 𝐓𝐓𝐆𝐆
Figure 1:Geographic breakdown of global oleochemicals market
60,000 MTPA production capacity of methyl ester products is feasible (EP1>0) at the continuous mode of operation.
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E) Process Selection
POSSIBLE PROCESSES FOR ME SYNTHESIS
• Micro-emulsion
• Pyrolysis (thermal cracking)
• Transesterification
1. Micro-emulsion
Process of reducing the viscosity of vegetable oil by the means of solvent (methanol, ethanol as well as normal butanol).
Advantages:• Clear• Isotropic• thermodynamically stable mixtures of a polar phase .Disadvantages:• Sticky• Heavy carbon deposits when used as fuel • Creates problems with the engine performance
2. Pyrolysis
Pyrolysis is a conversion process by the means of heating with absence of air resulting in ME
Advantages:• Can use any type of raw material • Gases oils/solvents and carbonized materials are produced• Good viscosity Disadvantages:• Sticky • When ME used as:
o fuel Fuel injection system experience damage o High amount of carbon deposition o Inacceptable combustion values in the engine
3. Transesterification
Alcoholysis of triglycerides resulting in a mixture of mono-alkyl esters and glycerol.
Advantages:• Better separation of byproduct• Achieve better viscosity product Disadvantages:• High methanol/oil ratio
Transesterification
Transesterification reaction
Chemical reaction of consumption of intermediate products
Transesterification Catalysis
• Base catalyst
• Acid catalyst
• Enzyme catalyst
Transesterification Catalysis Alternative 1:
Base catalystPKO +methanol methyl ester +glycerol
Advantages:1. High reaction rate and high catalyst activity2. Low methanol/oil ratio3. Mild operation condition
Disadvantages:1. Formation of soap2. Limited free fatty acid,FFA content for oil3. Inhibited by water
Alternative 2:Acid catalyst
PKO +methanol methyl ester +glycerol
Advantages:1. Unlimited free fatty acid, FFA content for oil2. Product can be easily separated3. High conversion
Disadvantages:1. Long reaction time2. High methanol/ oil ratio3. Acid has a stronger affinity for water
Alternative 3:Lipase Enzyme
PKO + methanol methyl ester +glycerol
Advantages:1.More stable2.Lipase can be regenerated and reused
Disadvantages:1.Still under development2.Very high cost of lipase enzyme3.Unfavorable reaction yield and reaction time
(Cost) (Final decision)(Alternative 1: Base catalyzed) Cheap Selected
(Alternative 2: Acid catalyzed) Medium Eliminated
(Alternative 3: Lipase enzyme) Expansive N/A
Catalyst & Alcohol Selection1. Alcohol selection
• Methanol is selected instead of ethanol and butanol.
• Shortest chain alcohol • Low cost
2. Catalyst selection• Sodium methoxide is selected instead of other
LEVEL 3 DECISION- RECYCLE STRUCTURE OF THE FLOWSHEET
Block Flow Fiagram of Recycle Structure
Figure 1-2: Block Flow Diagram of Level 3 Decision
ReactorKinetic data Values
k 0.013 𝑚𝑚𝑀𝑀𝑅𝑅−1 or 0.780 ℎ𝑀𝑀−1Activation energy, Ea 254.5 cal/mol or 1064.81 J/molTemperature 60°CPressure 1 atmMeOH:TG molar ratio 6:1NaOCH3 by weight of TG 1 wt%
Table 1-4: Kinetic data (Rashid et al., 2014)
Species, 𝑀𝑀 Inlet,𝐹𝐹𝑖𝑖,0 𝑀𝑀𝑀𝑀𝑖𝑖 Density 𝜌𝜌𝑖𝑖 (60°C) 𝑅𝑅𝑖𝑖 Source for densitykgmol/hr kg/kgmol kg/m3 m3/hrTG 10.8685 684.8022 891.2 8.3514 (Timms, 1985)