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Biodiesel: An Alternative Fuel

Article · February 2008


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Recent Patents on Biotechnology 2008, 2, 25-34 25

Biodiesel: An Alternative Fuel


Maximino Manzanera*, Maria L. Molina-Muñoz and Jesús González-López

Group of Environmental Microbiology, Institute of Water Research, University of Granada, C/Ramón y Cajal No. 4, Edificio Fray
Luis de Granada, Granada 18071, Spain

Received: July 16, 2007; Accepted: August 16, 2007; Revised: September 14, 2007
Abstract: Biodiesel is an alternative energy source and could be a substitute for petroleum-based diesel fuel. To be a viable alternative, a
biofuel should provide a net energy gain, have environmental benefits, be economically competitive, and be producible in large quantities
without reducing food supplies.
Most of the sources, methods and apparatus to produce biodiesel are reviewed here. Some of the patents propose the use of oils and fats
of animal or vegetal origin and other kind of sources. Many others focus on the methods for the production or oxidation stability of the
biofuel in order to make its production economically competitive. Several apparatus comprising reactors and refineries are also presented.
This review article summarizes recent and important patents relating to the production of biodiesel to make its production a viable
alternative.
Keywords: Alternative fuels, biodiesel, transesterification, FAEEs, FAMEs, lipase, SCF, refinery, NOx, microdiesel.

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INTRODUCTION biodiesel fuel can be used in diesel engines with little or no
The biggest challenge modern industrial society is facing today modification. Biodiesel has a higher cetane number than diesel fuel,
is the decline and exhaustion of the fossil energy resources. The no aromatics, no sulfur, and contains 10-11% oxygen by weight.

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primary sources of energy that power our civilization are those These characteristics of biodiesel are responsible for a reduction in

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fossil fuels. The International Energy Agency has forecasted that the emissions of carbon monoxide (CO), hydrocarbon (HC) and
the world's total energy requirements will rise by half in the next 25 particulate matter (PM) in the exhaust gas compared to diesel fuel

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years. On the other hand, global oil product demand has been [7,8]. However, to be a viable alternative, a biodiesel should
revised to 84.3 million barrels a day (mb/d) in 2006 and 85.8 mb/d provide a net energy gain, be economically competitive, and be

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in 2007 [1]. Therefore continued use of petroleum-sourced fuels is producible in large quantities without reducing food supplies.
now widely recognized as unsustainable because of depleting
1. BIODIESEL FEEDSTOCK

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supplies and increasing demand.

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Oil prices have been rising steadily over the past 3 years and 1.1. Vegetable Oils
surged to a record high above $60 a barrel in June 2005, sustaining Vegetable oil was exclusively used to run the early diesel

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a rally built on strong demand for gasoline and diesel and on engines since diesel engine was invented in 1892. Nevertheless, the

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concerns about refiners' ability to keep up. This trend continued feedstock shifted to petroleum distillates refined from crude oil
into early August 2005, as NYMEX crude oil futures contracts during gasoline production in the 1920s. But while so-called

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surged past the $65 mark as consumers kept up the demand for petrodiesel was cheaper and more abundant than vegetable oil, it

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gasoline despite its high price. Crude oil futures peaked at a close of was also lighter and less viscous. Vehicle manufacturers had to
over $78.40 per barrel on July 13, 2006 [2]. modify engine designs accordingly, and vegetable oil as a fuel

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In addition, the combustion of the fossil fuels used is source was sidelined for decades. Then in 1973, the Arab oil
considered as the major factor responsible for global warming due embargo produced a swift price increase. With gas and diesel
to large-scale carbon dioxide emissions. The present atmospheric suddenly four times more expensive than before, interest in biofuels
concentration of CO2 is about 383 parts per million (ppm) by returned. Since 1973, many different sources have been proposed in
volume. Future CO2 levels are expected to rise due to ongoing order to obtain biodiesel. Virgin oil feedstock rapeseed and soybean
burning of these fossil fuels and land-use change. The IPCC Special oils are most commonly used, with soybean oil alone accounting for
Report on Emissions Scenarios gives a wide range of future CO 2 about ninety percent of all biofuel stocks in the US. While in 1994
scenarios, ranging from 541 to 970 ppm by the year 2100. Fossil fuels produced from soybean oil amounted to barely a few thousand
fuel reserves are sufficient to reach this level and continue gallons a year, ten years later, that volume increased to 25 million
emissions past 2100, if coal, tar sands or methane clathrates are gallons. Last year (2006) 200 million gallons were sold. Assuming
extensively used [3]. Fossil fuels are also considered as the main existing and emerging facilities operate at full capacity, USA
source of local environmental pollution. Thus, alternative energy biodiesel production capacity could reach 1.5 billion gallons in
sources based on sustainable, renewable and environmentally 2007 [9].
friendly processes are urgently needed. One of the most prominent If soybean oil is the preferred biodiesel feedstock in North
alternative energy resources, attracting more and more interest in America, rapeseed or canola, is the one preferred in Europe for
recent years with the price for crude oil reaching record heights, is biodiesel production. Nevertheless, rapeseed oil is a promising
biodiesel, which is a possible substitute for petroleum-based diesel source for manufacturing biodiesel in North America as well,
fuel. Biodiesel fuels are the alkyl monoesters of fatty acids from evolving into a major cash crop. Canada and the United States
vegetable oils and animal fats. Many studies have shown that the produce between 7 and 10 million metric tons (tonnes) of rapeseed
properties of biodiesel are very close to diesel fuel [4-6]. Therefore, per year. This is partly because rapeseed produces more oil per unit
of land area as compared with soybean in these areas. Sommerville
*Address correspondence to this author at the Group of Environmental estimated that the average yield of soybean oil is 450 pounds per
Microbiology, Institute of Water Research, University of Granada, acre and the average canola seed oil was 650 pounds per acre in
C/Ramón y Cajal No. 4, Edificio Fray Luis de Granada, Granada 18071, 2005 [10]. Although this is in contrast with the much higher yields
Spain; Tel: +34 958 242981; Fax: +34 958 243094; of cellulosic biomass that could be grown on the same acres to
E-mail: manzanera@ugr.es produce fuel ethanol, alternative feedstocks are needed to obtain

1872-2083/08 $100.00+.00 © 2008 Bentham Science Publishers Ltd.


26 Recent Patents on Biotechnology 2008, Vol. 2, No. 1 Manzanera et al.

biodiesel where ethanol feedstock can not be grown or do not capable of producing different types of hydrocarbons [29] more
render such high yields. In this sense, in 1998 Beer and coworkers suitable for biodiesel production. Genetic and metabolic engi-
developed a variety of transgenic plant considered to be the most neering are likely to have the greatest impact on improving the
disease- and drought-resistant variety of rapeseed to date [11] that economical production of microalgal diesel [17,19,30].
allegedly could be translated in an increase in oil production as a
result of growing this variety in locations where neither cellulosic 1.2. Non-Vegetable Oils as Biodiesel Feedstock
biomass for ethanol production nor rapeseed was viable before. Although, it has been shown that biodiesel from vegetable
A different feedstock of vegetable origin is palm oil, obtained feedstocks have environmental benefits there are as well some
from the fruit of the oil palm tree. Previously the second-most concerns about its use. In this sense, the locations where oil-
widely produced edible oil, after soybean it may have now producing plants are grown is one of the prime worries being that
surpassed soybean oil as the most widely produced vegetable oil in countries, such as the Philippines and Indonesia are clearing cut
the world and certainly is the preferred oil in South East Asia. Thus, large areas of tropical forest in order to grow such lucrative crops,
some Asian governments are refocusing on the use of palm oil to in particular, oil palm [31]. Even more, it has been suggested that
the production of biodiesel to cater to the huge demand from biodiesel might increase pressure on world food supplies,
European countries encouraging the building of biodiesel plants. therefore urging to look for alternative feedstocks for biodiesel
These plants will start operating in the middle of next year and such as waste vegetable oils and waste animal fats. The main
produce 100,000 tons of biodiesel annually. Strong demand for sources of waste animal fats are primarily meat animal processin g
biodiesel from Europe as well as Colombia, India, South Korea and facilities. Recycled grease products are referred to waste grease
Turkey has fueled the industry's growth as more countries seek to being generally classified in two categories, yellow grease and

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reduce their reliance on fossil fuels. Malaysia has already begun brown grease. Yellow grease is produced from vegetable oil or
preparations to change from diesel to bio-fuels by 2008, including animal fat that has been heated and used for cooking. Renderers

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drafting legislation that will make the switch mandatory. From filter out the solids and heat the spent cooking oil to drive out
2007, all diesel sold in this country must contain 5% palm oil. moisture until it meets industry specifications for yellow grease.
Yellow grease is required to have a free fatty acid level of less than

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Being the world's largest producer of crude palm oil, Malaysia
intends to take advantage of the rush to find cleaner fuels. Palm- 15%. If the free fatty acid level exceeds 15%, it is called brown

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based biodiesel exhibits a relatively high pour point (approximately grease, sometimes referred to as trap grease. Waste vegetable oil
15oC) due to its high content of saturated fatty compounds; hence, from restaurants and rendered animal fats are inexpensive

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its use is only suitable for tropical countries and unsuitable for low compared with food-grade vegetable oil hence biodiesel production
from waste grease can be expected to benefit from a raw material

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temperate or cold climate countries where operational temperature

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is below its pour point. Nevertheless, palm-based biodiesel cost advantage and it will help to reduce overall biodiesel cost [32].
formulations with enhanced cold flow properties are provided using There are patents that provide methods for producing biodiesel fuel

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new formulation comprising at least 60% vol/vol petroleum-based from waste vegetable or animal oils and fats, and methanol that
fuel oil mixed with palm-based fuel oil [12]. Similarly, a novel does not use a catalyst and does not generate glycerol as a by-

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alkyl-ester composition derived from specific blend of rapeseed and product [33], or smaller processing plant that enables site selection

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sunflower, in particular from Brassica napus and Helianthus closer to the raw material supplies, thereby minimizing or
annuus to be used in diesel engines to solve the same kind of eliminating transportation costs for yellow grease [34]. More

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problem [13]. important is the method by Hammond Earl G. and Wang Tong of

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converting free fatty acids in acid oil, and the acid fat into FAMEs
In certain parts of the world, governments and some
(biodiesel) using a small amount of methanol and an acid catalyst.

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corporations consider the jatropha plant, common in hot climates,
A method especially useful for the generation of biodiesel using
one of the most promising sources of biodiesel. The plant can grow
animal oils and fats that contain a relatively high level of free fatty

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in wastelands, and it yields more than four times as much fuel per
acids as starting material [35]. A different application developed in
unit of area as soybean, and more than ten times that of corn [14].
order to use waste oils and fats as biodiesel feedstock focus on
Another example of crop, recently proposed for biodiesel’s
reducing the viscosity of these wastes in order to facilitate a
feedstock is the oil extracted from the nuts of the desert plant
filtering process particularly needed for biodiesel synthesis from
Balanites aegyptiaca [15]. Other crops such as cottonseed [16],
this kind of oils and fats [36]. Similarly a mobile refinery has been
mustard, flax, sunflower, hemp and even algae are considered
developed in order to separate contaminants of waste fryer oil used
promising biodiesel feedstocks too.
for cooking including food particles, and water and emulsified or
The advantages of deriving biodiesel from algae include rapid congealed grease by vacuuming and heating these wastes into a
growth rates, a high per-acre yield. Some species of algae are container and passing the heated fluid via a strainer [37]. The use of
ideally suited to biodiesel production due to their high oil content whole microorganisms producing lipases or the purified lipases
[17-21]; The National Renewable Energy Laboratory (NREL) in themselves has been proposed as an invention in order to use waste
Golden, Colorado had demonstrated oil production from algae rates lipids and fat to produce fatty acid lower alcohol esters as well [38].
200 times greater per acre than achievable with fuel production
Finally, different waste fats are proposed for lower production
from soybean farming [22]. Unlike other oil crops, microalgae grow
cost such as those present in sewage sludge that contains high levels
extremely rapid and commonly double their biomass within 24 h.
of lipids, in the form of triglycerides, phospholipids, phospho-
Biomass doubling times during exponential growth are commonly
glycerides, sphinolipids, glycolipids, and fat-soluble vitamins. In
as short as 3.5 h. Oil content in microalgae can exceed 80% by
this method, sludge produced under wastewater treatment is
weight of dry biomass [23,24]. Depending on species, microalgae
collected then partially dehydrated by sludge thickeners, filter
produce many different kinds of lipids, hydrocarbons and other
presses, centrifuges, and driers to a final solid concentration ranging
complex oils [20,25,26]. And although not all algal oils are
from 60% to 100% solids by weight. After drying, lipids are
satisfactory for making biodiesel, suitable oils occur commonly.
extracted from the processed material using any of the methods of
The strains of race A of microalgae Botryococcus braunii have
chemical extraction such as chemical solvents including aliphatics,
been proposed as a renewable source of liquid fuel via CO2 fixation
supercritical gases and liquids, hexane, acetone, or primary alcohols
[27] with hydrocarbon content as high as 30% of biomass. Recent
[39]. Alternatively, a different waste material proposed as biodiesel
patents comprise a novel variety of Botryococcus (Ninsei) distinct
feedstock is the one produced by the diary industry resulting from
from the previously cultured variety in color, biochemistry, size,
their wastewater processing plants. In these plants, dissolved air
shape, and habit in order to facilitate its cultivation [28], or a race
flotation (DAF) systems are commonly used to separate the
Biodiesel Recent Patents on Biotechnology 2008, Vol. 2, No. 1 27

insoluble solids from the liquid by injecting gas bubbles into the 2.1. The Alkali-Catalyzed Transesterification
wastewater solution. These bubbles adhere to the insoluble particles For the alkali-catalyzed transesterification, both the glycerides
and form a floating layer of sludge, which is mechanically scraped and alcohol must be substantially anhydrous, and oils should be
off producing an emulsion of fat and protein in water in significant neutral or weak acids since a too high proportion of fatty acids
quantities whose disposal is both problematic and expensive. The (higher than 0.5%) would inhibit the reaction by consuming catalyst
method by Hamilton RB involves adjustment of the DAF sludge pH to form soaps, lowering the reaction yield and making more
between 2.5 and 4.5, mixing it with an emulsifying agent and difficult the separation of the products, in a process known as
heating the mixture to boiling point. By allowing the mixture to saponification [46,47]. On the other hand, if absolute alcohol is
cool down the fat and protein component parts separate out, and fat used, the formed glycerol does not settle spontaneously and the
rich component is then used as biodiesel feedstock [40]. alcohol excess must be evaporated or water added, nevertheless not
obtaining a complete conversion. In order to use hydrated alcohol
2. METHODS FOR BIODIESEL PRODUCTION
with success Robert and coworkers proposed a process for
Biodiesel production is mainly performed by the transes- preparing a composition of fatty acid esters, by acid
terification of a triglyceride with an alcohol in a chemical reaction transesterification where the alcohol could contain up to 60% by
known as alcoholysis outlined in Fig. (1). In the transesterification weight of water. This method consists of reducing the free acidity
of different types of oils, triglycerides react with an alcohol, of the ester phase, followed by a basic esterification in the presence
generally methanol or ethanol, to produce esters and glycerol. The of a monoalcohol, finished with the recovery of the ester phase
overall process is normally a sequence of three consecutive [48]. The process is simplified since, in the presence of hydrated
reversible reactions [41,42]. During the first reaction, triglycerides alcohol, glycerol is easily settled and the ester phase is purer and

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are transformed into diglycerides. Then from diglycerides, the glycerol content lower despite of the high water content of the
monoglycerides are produced in the second reaction and in the last alcohol phase. Sometimes, there might be special interest in

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reaction glycerol is obtained from monoglycerides. In all these obtaining concentrated glycerol in the process of making biodiesel
reactions esters are produced which are the products used as [49] as added value byproduct for the synthesis of chemicals such
biodiesel, that finally as the resulting product has to be purified.

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as dichloropropanol [50] polyglycerols [51] or glyceryl ethers or
The stechiometric relation between alcohol and oil is 3:1. However, syngas [52-56] currently extracted from petrochemical resources

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an excess of alcohol is usually added to improve the reaction that can be alternatively extracted from biological feedstock.
towards the desired product. To make the reaction possible, a
One of the advantages of the alkali transesterification is that

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catalyst is added as well. This transesterification reaction is affected
basically any kind of vegetable oil can be used. The amount of
by alcohol type, molar ratio of alcohol to oil, temperature, purity of

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catalyst that should be added to the reactor varies from 0.5% to 1%

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the reactants and type and amount of catalyst see [43] for a review.
w/w [57], but some authors prefer advice values between 0.005%
Different types of catalysts are used, from basic ones such as and 0.35% w/w [43,58]. Other important reason for the great

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sodium or potassium hydroxides, acids such as sulfuric acid, ion interest in the alkali process is due to its higher reaction efficiency

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exchange resins, lipases and supercritical fluids. For a basic and for showing a lower corrosive effect than that for the acid
catalyst, either sodium hydroxide (NaOH) or potassium hydroxide process, making alkali the preferred catalyst to be used in

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(KOH) is normally used with methanol or ethanol as well as any industries. However, as mentioned before, in the alkali catalyzed
kind of oils, although sodium and potassium alkoxides such as

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transesterification, the presence of water causes a partial reaction
sodium methoxide, sodium ethoxide, sodium propoxide, sodium change to saponification, which produces soap. The soap consumes

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butoxideto have been proposed as alkali catalysts as well. In this the catalyst and reduces catalyst activity, causing an increase in

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process it is better to produce the alcoxide before the reaction to viscosity, formation of gels and difficulty in separation of glycerol.
obtain a better global efficiency [44]. The alcohol-oil molar ratio Freedam et al. reported that sodium hydroxide or sodium

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that should be used varies from 1:1-6:1. However, 6:1 is the most methoxide reacted with moisture and carbon dioxide in the air
used ratio giving an important conversion for the alkali catalyst leading to lowering of their effectiveness to catalyze the
without using a great amount of alcohol. The types of alcohol are transesterification of oil [47].
usually methanol and ethanol. The last one has fewer safety
Although transesterification processes using alkali catalysts
problems because it is less toxic, but methanol is most frequently
give high conversion of fatty oil glycerides to esters in relatively
used because of its lower cost and its physical and chemical
shorter residence time, besides interference of water and free fatty
advantages (polar and shortest chain alcohol), although in some
acids with the reaction, the processes based on alkali catalysts have
countries such as Brazil, there is a special interest in developing an
several drawbacks. These drawbacks are the intensive energy
appropriate technology for the use of ethanol instead of methanol
required for the reaction, the difficulty in recovering the glycerol,
[45] since ethanol is easily available due to the extensive
the fact that the alkaline catalyst has to be removed from the
fermentation industry in the country.
product, and the high production of alkaline waste water that is

Fig. (1). Transesterification of triglyceride with alcohol.


Triglycerides from oils and fats are reacted with an alcohol in a reaction known as transesterification or alcoholisis in presence of a catalyst. The products of
the reaction are esters of fatty acids (biodiesel) and glycerol.
28 Recent Patents on Biotechnology 2008, Vol. 2, No. 1 Manzanera et al.

required for the treatment. Additionally, further several steps such In general, there are two basic disadvantages related to
as evaporation of methanol, removal of saponified products, chemical catalyzed biodiesel. The first one is that during catalysis,
neutrali-zation and concentration are needed to recover glycerol. the process is relatively slow and secondly, these methods require
removal of the catalyst. Additionally, and as we have mentioned
2.2. The Acid Transesterification before, during basic catalysis as well as purification of the catalyst
The acid process is the second method most commonly used for product, the by-products of the saponification reaction must be
producing biodiesel. It consists of using an acid as catalyst, either a removed. In conclusion some of the disadvantages of the homo-
homogeneous acidic catalyst or a heterogeneous acidic catalyst. As geneous chemical catalysis such as product purification can be
homogeneous acidic catalysts, we find compounds such as sulfuric overcome by using heterogeneous catalysts or enzymes as catalysts.
acid, hydrochloric acid, para-toluene sulfonic acid, methane
sulfonic acid, etc. Although, sulfuric acid is the preferred catalyst 2.3. The Enzymatic Catalyst
for this kind of reaction [47,42,59,60]. Among the heterogeneous In the enzymatic approach, the transesterification is carried out
acidic catalysts, we can use strong acidic sulfonated ion exchange by a protein called lipase overcoming some drawbacks, such as
resins and acidic zeolites. difficulty in the recovery of glycerol and the energy-intensive
Similarly to the alkali reaction, if an excess of alcohol is used in nature of the process. In contrast to chemically catalysts,
the experiment a better conversion of triglycerides is obtained, but biocatalysts allow synthesis of specific alkyl esters, easy recovery
recovering glycerol becomes more difficult and that is why optimal of glycerol, and transesterification of glycerides with high free fatty
relation between alcohol and raw material should be determined acid content [69]. Lipases are enzymes used to catalyze some
experimentally considering each process as a new problem. The reactions such as hydrolysis of glycerol, alcoholysis and acidolysis,

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possible operation condition is, usually, molar ratio 30:1. The type but it has been discovered that they can be used as catalyst for
transesterification and esterification reactions too. Biocompatibility,

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of alcohol, as well as the oils, is the same as the one that can be
used in alkali catalyst reaction. The amount of catalyst supposed to biodegradability and environmental acceptability of this biotech-
be added to the reactor varies from 0.5 to 1 mol%, and if the typical nological procedure are the desired properties in a green technology
such as the biodiesel production. The extracellular and the

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value is 1%, some authors prefer to use 3.5 mol% [61,62].
Temperature is another important factor for this kind of reaction intracellular lipases are also able to catalyze the transesterification

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with a range varying from 55 to 80oC. Thus the acid transesteri- of triglycerides effectively. Much work has been done on the lipase-
fication is a great way to make biodiesel if the sample has relatively catalyzed transesterification of triglyceride [69-75]. Furthermore,

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high free fatty acid content. In general, 1 mol% of sulfuric acid is a transesterification using a lipase is carried out in a nonaqueous
system. When waste oil containing a large amount of water is used,

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good amount for a final conversion of 99% in a time around 50 h.

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the progress of the reaction would be inhibited. Therefore, facilities
The acid catalyzed reactions give very high yield in esters, for removing water should be necessary, which increases the cost.

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though the drawback of that method is the long time required for A method for producing a fatty acid alcohol ester in the presence of
the reaction to happen since the reaction usually requires longer water was described in [76] by using lipases. However, in this

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than 24 hrs to finish. Several groups have proposed the method, the enzyme has to be purified, and isolation of the enzyme
esterification of triglycerides in fats and oils in a two-step process

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takes time and increases the production costs. Thus, in the
using an acidic catalyst in the first step followed by a second transesterification using a lipase, none of the above problems has

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esterification using an alkaline catalyst. The methods can include been solved so that there is a demand for a method for producing a
specifications such as a reaction temperature of 60 to 120oC in

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fatty acid ester more efficiently.
order to restrain the interesterification reaction of the fat component

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[63]; the use of an acidic cation exchange resin as a solid Foglia et al. proposed a method that utilizes lipases to
esterification catalyst [64]; or the removal of the glycerol after the transesterify triglyceride-containing substances and to esterify free

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first step before the second step is started [65] in order to optimize fatty acids to alkyl esters using short chain alcohols such as 1-
the reaction. Nevertheless, Basu et al. and Gupta et al. proposed butanol and isobutanol. The proposed enzymes included 1,3-
single step processes for producing esters from fat or from oil. The specific lipase from Mucor miehei and Rhizopus delemar, the acyl-
first group presented a process by mixing the feedstock with an specific lipase from Geotrichum candidum, and the nonspecific
alcohol, and a mixture of calcium acetate and barium acetate as lipase from Candida antarctica and Pseudomonas cepacia, for the
catalyst, heating the reaction mixture to 200-250oC for about 3 production of biodiesel [77]. But still and as mentioned earlier, one
hours and cooling the mixture rapidly [66], while the second group common drawback with the use of enzyme-based processes is the
presented a method based in the use of alkyl Tin oxide as catalyst high cost of the enzyme. In this respect, immobilization of enzymes
where glycerol can be separated from the fatty acid alkyl ester, as has generally been used to obtain reusable enzyme derivatives,
immiscible phase, by decantation, the excess alcohol can be enabling in the recycling of the biocatalyst and hence lowering this
recovered by evaporation or distillation and, the fatty acid alkyl cost. In the case of biocatalysts in nonaqueous media, immobili-
esters can be purified by washing with water [67]. zation is also reported to result in better activity. Thus, many trans-
esterification processes employing lipases have used an
Due to the slow diffusion of triglycerides through the catalyst immobilized form of the enzyme [74,75,78-80].
pores in heterogeneous catalysts such as supported metals, basic
oxides and zeolites this type of transesterification reaction is slow, Wu and Chen described a technique to increase and regenerate
so higher alcohol to glyceride molar ratio is required to achieve the activity of immobilized lipases. The technique deals with the
appreciable conversion of above 70%. effect caused by physical factors, such as the immiscibility between
the alcohol and the fatty acid glycerides. When methanol or ethanol
In order to accelerate the reaction, the reactants can be exposed is absorbed into the voids of an immobilized lipase, the entry of
to microwaves or radio frequency energy, followed by the transfer fatty acid glyceride into the voids will be blocked, stopping the
of these reactants over a heterogeneous catalyst at sufficiently high reaction from taking place. To wash the deactivated immobilized
velocity to produce high shear conditions. Then these emulsified lipase, we need to use a solvent that has to be harmless to the lipase,
reactants can be maintained at a pressure above autogeneous and with a good solubility to oil, grease, moisture, and methanol or
pressure for an improvement of the reaction. Using one or more of ethanol. The proposed solvents were iso-propanol, 2-butanol and
these steps can result in higher process rates, higher conversion tert-butanol [81-83]. The inventors also discover that the activity of
levels, or both [68]. an immobilized lipase can be significantly increased when such an
Biodiesel Recent Patents on Biotechnology 2008, Vol. 2, No. 1 29

ideal solvent is used to perform an immersion pretreatment on an Finally, the separation procedures necessary to adequately clean the
immobilized lipase. two product-streams produce large quantities of wastewater thereby
The enzymatic method has been proposed to make biodiesel creating additional cost and process complexity therefore affecting
directly from the soapstock generated after the alkali refining the environment.
processes. The soapstock contains 10-60% water, but also contains Such processes are also costly due to the high cost of catalysts,
35-85% of fatty derivatives including partial glycerides. The heterogenization of catalysts, which is even more remarkable for
combination of this technology with feedstock availability offers an the enzymatic transformation. Recently, a non-catalytic transes-
economic and competitive approach to produce biodiesel, since for terification reaction in supercritical methanol has been proposed
each metric ton of alkali refined vegetable produced by this method, [87-94]. A Super Critical Fluid is defined as a substance above its
approximately 30 kg of soapstock is generated too. In this way, the critical temperature and critical pressure. The critical point
feedstock (the soaps) can be neutralized and split with strong acids represents the highest temperature and pressure at which the
until pH 2-8 is reached, and then they can be subjected to an substance can exist as a vapor and liquid in equilibrium. In order to
enzymatic esterification using lipases at a temperature of 30 to 45oC reach the super critical state the alcohol and vegetable oil are
[84]. To reduce the cost of keeping these temperatures, a special pumped into a reactor with the pressure between 20 Bar and 400
type of lipase has been described for the production of biodiesel at Bar and a temperature between 150oC and 450oC. A mixture of
low temperature. The lipase is produced by Micrococcus antarc- non-reacted alcohol, glycerol, and esters is thereby formed, and is
ticus and has good activity and stability at lower temperatures released via a flow and pressure control valve. The mixture of non-
saving the cost of warming up the reaction [85]. reacted alcohol, glycerol, and esters is then cooled in a cooler, and
Nevertheless, there are three major difficulties in using lipases an upper phase of non-reacted alcohol is separated from the

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to produce biodiesel. Still the first difficulty is that the price of intermediate phase of esters and the lower phase of glycerol. The
intermediate phase of esters and the lower phase of glycerol are

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lipase is much higher than the price of alkali even when the lipase is
reused. Secondly, the lipase process requires up to 48 hours to then directed to a separation reservoir where the esters are separated
complete the reaction, which is significantly longer than that for the from the glycerol. There are specific protocols for the Super Critical

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base catalysis. The third difficulty with enzyme catalysis is that, for Method in continuous mode such as the described by Dall et al.
transesterification with methanol which is the preferred alcohol for [95] or where the supercritical state is only applied to the alcohol

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biodiesel preparation of the reaction is extremely sluggish and [96]. However, the main disadvantage of this method is the energy
proceeds in most cases with only low conversion efficiency, if at required to obtain the supercritical state that increases greatly the

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all. In this way, the use of intact microorganisms containing lipases production cost of the chemical catalyzed methods.

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has been described as well for the esterification of glycerides where A summary of the advantages and disadvantages of each

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fatty acid esters can be prepared in a simple manner avoiding the technological possibility to produce biodiesel could be found in
cost of enzyme purification [86]. In contrast, synthesizing biodiesel Table 1 (from Marchetti et al. [97]).

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through bio-methods has the following advantages: the reaction

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conditions are milder, there are no toxic emissions, the reactions are 3. APPARATUS AND REFINERIES
not affected by free fatty acid nor by small amounts of water in the Another area of research of interest is the use of different

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renewable oils used as raw materials. On top of that there is a apparatus and refineries in order to perform reactions easily,

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possibility of regeneration and reuse of the immobilized residue, quickly, efficiently, and safely. Both batch and continuous-flow
because it can be left in the reactor if the reactive flow is kept. The technologies have been used to set-up and scale-up the reaction [98-

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use of enzymes in reactors allows use of high concentration of them 100]. Although in general biodiesel is produced by the batch-type

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and that makes for a longer activation of the lipases. Additionally, process, the disadvantages of the batch-type process are time
the immobilization of lipase could protect it from the solvent that consuming for the process, the unreliable production quality and the

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could be used in the reaction and that will prevent all the enzyme high labor cost. Alternatively the preferred method is known as the
particles getting together. Finally, the separation of products is Connemann process [101]. In contrast to batch reaction methods
easier using these biocatalysts. Nevertheless further research needs [47], the Connemann process utilizes continuous flow of the
to be made in order to reduce the high cost for biotechnological reaction mixture through reactor columns, in which the flow rate is
production of biodiesel fuel, specially the use of lipase, lower than the sinking rate of glycerol as shown in Fig. (2). This
immobilized cells or algae cultivation. Further discussion will be results in the continuous separation of glycerol from the biodiesel.
made in this respect on the current and future developments section. The reaction mixture may be processed through further reactor
columns to complete the transesterification process. Residual
2.4. The Supercritical Method alcohol, glycerol, free fatty acids and catalyst may be removed by
Chemically catalyzed triglyceride transesterification requires a aqueous extraction.
multiple step process with one or more batch reactors. Initially, the In 1996, Krawczyk presented a flow diagram for producing
triglycerides and alcohol form two immiscible liquid phases, and as biodiesel via transesterification on the industrial scale. The process
the reaction proceeds, two separate liquid phases are formed. One mainly consisted of a transesterification reactor, an alcohol/glycerol
contains the newly formed alkyl esters of the triglyceride and the distillation column and a methyl/ethyl ester distillation column. A
other contains the glycerol, with the excess alcohol, catalyst and continuous deglycerolization process to produce biodiesel from
feed oil being dispersed into both phases. The reaction time for refined rapeseed oil by alkali-catalyzed transesterification at
each step takes at least several hours and once completed, the liquid ambient pressure and 65-70 °C was introduced by Connemann and
products must be allowed sufficient time to separate phases before Fischer [102]. In this process, a distillation column was also used to
additional processing and separation steps can occur to produce the separate methanol from biodiesel and glycerol. The alcohol was
final products. It is important to recycle the excess of alcohol and recycled to the transesterification reactor and multi-stage water
the unused catalyst must be neutralized. washing was employed to purify the biodiesel product. The above
Even the most efficient of the traditional chemically catalyzed industrial manufacturing information on biodiesel production
processes require multiple hours to process each batch of feed. formed the principle basis for the design of the alkali-catalyzed
Additionally, significant problems arise in the separation steps. processes.
Significant quantities of glycerol left in the alkyl esters diminish the More recently, researchers have put forward several continuous
quality of the diesel fuel and likewise contaminated glycerol also production processes using catalytic methods, which can increase
loses much of its value compared to pure uncontaminated glycerol. the production efficiency and quality of biodiesel [103-107].
30 Recent Patents on Biotechnology 2008, Vol. 2, No. 1 Manzanera et al.

Table 1. Comparison of the Different Technologies to Produce Biodiesel (from Marchetti et al., [96])

Variable Alkali catalysis Lipase catalysis Supercritical Acid catalysis


Alcohol.

Reaction temperature (oC) 60-70 30-40 239-385 55-80

Free fatty acid in raw materials Saponified products Methyl esters Esters Esters

Water in raw materials Interference with reaction No influence Interference with reaction

Yield of methyl esters Normal Higher Good Normal

Recovery of glycerol Difficult Easy Difficult

Purification of methyl esters Repeated washing None Repeated washing

Production cost of catalyst Cheap Relatively expensive Medium Cheap

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Both methods, batch and continuous-flow require an efficient

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blending of triglycerides with the alcohol and catalyst together at
the transesterification reactor. Mixing efficiency of the reagents is
of crucial importance and is considered as one of the most

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important parameters affecting the transesterification reaction. In

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order to guarantee a proper mixing several devices can be used,
such as oscillatory baffled reactors [108-110], where a pulsed
stream of a heterogenous multiphase mixture is passed through a

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flow tube. Alternatively, instead of the baffles described above, a

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metal helix can be present in the flow tube, obtaining in this way a

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much more thorough mixing of the heterogeneous mixture,

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increasing in this way the biodiesel yield during the transes-
terification process [111]. Intensive mixing can also be achieved

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using centrifugal pumps, high shear mixers, or motionless mixers
[55,112]. The disadvantage of high intensity mixing is that the

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presence of soap materials, partially reacted triglycerides, or excess

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alcohol can lead to stable emulsions and very slow separation of the
ester and glycerol phases.

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Ultrasonic reactors have been described for chemical activation

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via sonochemistry, where reaction is induced by ultrasonic sound
waves. These waves are provided through the energy derived from

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the collapse of cavitation bubbles generated within the ultrasonic
reactor. Such energy is derived when the cavitation bubbles
collapse rapidly and violently and, in doing so, generate apparent
temperatures of many thousands of degrees Kelvin and apparent
pressures of several thousand atmospheres within the individual
bubbles. Thus, the bubbles that are formed serve as individual
microreactors operating at high temperature and high pressure
while the liquid region immediately adjacent to the bubbles is at
temperatures ranging generally from about 70oC to 80oC and at
between 1.0 and 5.0 atmospheres of pressure. Through asymmetric
collapse of the bubbles, micro jets are created, leading to intensive
mixing of the liquids [113]. Microwaves are reported to greatly
speed up the hydrolysis and esterification processes, reducing the
reaction time to around one quarter of the time required by the
Fig. (2). Simplified flow scheme of biodiesel production plant as described conventional process and reducing the quantity of required alcohol
by Connemann et al. in [101]. to just over the stoichiometric quantity. In order to use microwaves
Triglycerides are supplied from the oil tank at a rate of 57 l/h through a heat Pyrex bioreactors can be used [114]. Additionally the reactor can be
exchanger, together with the alcohol (1.4-1.6 times) and catalyst (0.24- preceded by different devices to precondition the reagents in order
0.36% w/w) into a mixer at a rate of 10 l/h. Reaction mixture is passed into to improve the reaction, from vacuum chambers to introduce the
the top of the first reactor, set up as a standing column at a lower rate of alcohol in gaseous form in the reaction mixture and to keep the
flow than the glycerol sinking rate, being separated off in the direction of reaction vessel under vacuum (i.e. 15-50 mm Hg) and at
flow. Transesterification of 85-90% already takes place in this column. temperatures of 180-200oC [115], or an atomiser (atomization
Reaction product is then passed into a second stirring reactor, where further apparatus) to produce the vaporization of the alcohol with the
transesterification -up to 95-97%- takes place. Aqueous extraction solution chemical catalyst in a mixing chamber prior to entry into the
and separator are used to extract biodiesel. Further purification steps are reaction vessel [116].
repeated in order to improve reaction efficiency and to remove, traces of
Sometimes pretreatment of the feedstock is needed. In order to
soap, alcohol, water and glycerol.
pretreat the oil feedstock before it is added to the reactor different
Biodiesel Recent Patents on Biotechnology 2008, Vol. 2, No. 1 31

apparatus have been developed. The design of the apparatus 4. AVOIDING DRAWBACKS
depends on the type and quality of feedstock. In the case of algae
feedstock, there are apparatus for separating algae cells from liquid 4.1. NOx (Nitrogen Oxide) Emissions
medium, for example based on a tangential flow filter device, [117], If biodiesel improves engine emissions in most categories when
or based on a multi-stage loop-flow flotation column where bubbles compared to petroleum based diesel fuel, however it is also
are used to adsorb the algal cells that can be separated from the responsible for an increase in nitrous oxide emissions. Blends
aqueous medium [118] or based on whirlpool circulation using containing higher concentrations of biodiesel, show a proportional
special bags [22]. Modified cylindrical screening can be used as increase in emissions of nitrogen oxides (NOx). Presently, NOx
filters when waste oils and fats are used as feedstock [119], or the emissions could be a significant limitation to the widespread
above mentioned filtering devices for waste fryer oils based on adoption of biodiesel fuels. NOx is a generic term for mono-
vacuuming and heating passing the heated fluid via a strainer nitrogen oxides. These oxides are produced during combustion, and
[36,37]. Devices containing particles or polymers that include are of interest as air pollution. They are believed to aggravate
amine or imine moieties for filtering contaminants formed upon breathing conditions, to produce ozone at surface heights, which is
heating or cooking with oil are also used [120]. Tysinger et al. also an irritant, and to react with the oxygen present in the air, and
described a process in which free fatty acids and other impurities eventually can form nitric acid when dissolved in water [130].
may be removed from mechanically extracted soybean oil by When NOx is dissolved in atmospheric moisture it can result in acid
physical refining. In physical refining, the oil is vacuum distilled at rain that potentially can damage entire forests. Some researchers
high temperatures to separate more volatile components from the have sought to address the NOx issue by the addition of certain fuel
oil. However, this physical refining is of limited value in refining additives to the biodiesel. For example, Bradin described a fuel

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solvent extracted soybean oil, due to the higher levels on elemental additive composition including fatty acid alkyl esters and glyceryl
phosphorous content, of non-hydratable phospholipids, and the high ethers. The additive-containing fuel is made by a multi-step process

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temperatures required for physical refining, may suppose an that includes separation of glycerol from biodiesel, conversion of
increase in production cost non affordable for the prerequisites of glycerol to glycerol ether, and then addition of the glycerol ether
this product [121]. In order to reduce the production cost a compact back into the biodiesel fuel [52]. Other researchers describe

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processor including a vapor recovery system for removing excess controlling engine emission NOx by producing a blending of a

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alcohols from the fuel has been developed as well. This vapor synthetic middle distillate derived from Fischer-Tropsch produced
recovery system includes a system for conserving and storing the synthesis gas (syngas) and biodiesel, which generate very low

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excess alcohol for further use in the processing of biodiesel fuel so levels of NOx and sulfur emissions when used in diesel engines
the process can be scaled down as well for small refineries [122]. [131]. Addition of water to the fuel, to cool down the combustion

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For industrial scale, different technologies are also applied in order process reduces the formation of NOx as well. However, that
to recover the methanol and methoxide vapor from the reaction process undesirably lowers fuel BTU (British Thermal Units) value

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vessel by condensing it [123]. This selectively continuous process by replacing fuel with water. A large number of materials have
of separating the reaction products eliminates the costly washing been found to be catalytically active for selective catalytic reduction

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step, and those further steps associated with such processing, of NOx. By far, the most widely reported in the open literature are

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because continuous separation is more efficient than batch metal-exchanged zeolites, such as Cu-ZSM-5, Co-ZSM-5, and Fe-
decantation, yielding reaction products of greater purity. No ZSM-5. However, the zeolite-based materials lose much of their

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additional water is introduced into the system since water washing activity when water (common in exhaust streams) is added to the

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has been eliminated and because the vacuum system used to exhaust stream. While other catalysts that possess greater water
recover the methanol from the FAME and glycerol products is also stability have been found, such as metal-supported oxides, these

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dry. This permits the use of a molecular sieve column to eliminate tend to lack the desired activity shown by the metal zeolites, and
the minute amounts of water present in the excess methanol, produce large amounts of N2O (also a major pollutant). Baacke et

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whether water comes from air leaks into the system or from al. described a zeolite catalyst and a method for reduction of
moisture in the natural oil feed etc., rather than rectification of the nitrogen oxides by mixing the waste gas with ammonia [132].
excess methanol from the wash water using distillation as in the However, the use of ammonia in the reduction of nitrogen oxide is
batch approach. Desiccant columns equipped with molecular sieves less desirable, especially in transportation systems, due to the toxic
are used to dry the recovered excess methanol. Bam and coworker nature of the ammonia that must be stored locally, presenting a
designed the technology to not only recover the excess alcohol but hazard.
to recover unspent catalyst. Since unspent catalyst is contained in On the other hand, Green et al. described a single phase catalyst
the by-product alcohol, the recycle of the by-product alcohol also obtained by intimately mixing the powders of the oxide binder and
recycles unspent catalyst, which reduces the amount of fresh the metal salts. This patent describes the mixing of particles of a
catalyst required. Vapors comprising unreacted alcohol from the metal exchanged zeolite with an oxide [133,134]. Also Sachtler and
extractive distillation are condensed in condenser located just after Chen described that the metal can be introduced into the zeolite in
the reactor [124]. an entirely different way, such as by metal vapor deposition [135].
Once the reaction has occurred, separation of the alkyl esters is Recently advances in the use of cerium-oxide, have been described
needed. Stidham et al. [125], Hayafuji [126] and Wimmer [127] to hold the potential to nearly eliminate NOx emissions from both
disclosed the processes to wash impurities such as soap particles petrodiesel and biodiesel, and diesel fuel additives based on cerium
from the product alkyl ester. A more recent approach is based on oxide that can improve fuel consumption by 11% in unmodified
bringing unpurified biodiesel in contact with cellulose-containing diesel engines [136]. Recently, a catalyst for reducing nitrogen
material by mixing the latter in order to eliminate the glycerol and oxide has been developed to remove NOx and particulate matter
catalyst residues, such as potassium soaps, accumulated during the using platinum as activating element [137].
production of the biodiesel. The system includes an agitated
sedimentation tank with a conduit for delivering purified biodiesel 4.3. Oxidation Stability
into de agitated sedimentation tank [128]. A different problem in using biodiesel is that since biodiesel has
Once the reaction has taken place in the reactor an alcohol/ a higher content of unsaturated fatty acid esters, it easily oxidizes in
glycerol distillation device has to be included. Alasti has recently the presence of oxygen, UV light, heat, or trace metals, such as iron
described a refinery for the separation of alcohol, glycerol, esters or copper. The products formed from this oxidation give rise to
and salts performed by volatility [129]. sediment and gum formation within the fuel and lead to corrosion
32 Recent Patents on Biotechnology 2008, Vol. 2, No. 1 Manzanera et al.

and plugging in injection pumps and fuel lines in engines, heaters, petroleum-based diesel. However, different and combined proto-
and machines which utilize this fuel source. Consequently, there is cols, apparatus and feedstock would be needed in order to produce
a need for a biodiesel fuel composition with improved oxidation biodiesel in large quantities.
stability. Asbahr and Bomba described the use of phenyl The most promising alternatives in order to obtain an
compound, and derivatives as an antioxidant for biodiesel [138]. environmentally friendly product are based on technology with
The list of possible antioxidants was extended by Abou-Nemeh biological origin especially those methods catalyzed by lipases.
Ibrahim, mainly consisting in aromatic derivatives such as 3,4,5- This technology works at the lowest reaction temperature; it is not
trihydroxybenzoic acid n-propyl ester, 1,2,3-trihydroxybenzene, influenced by the presence of water or free fatty acid in the
butylated hydroxyanisole, 2,6-di-tert-butyl-1-hydroxy-4-methyl- feedstock, hence reducing the production cost, and produces the
benzene, alpha-tocopherol acetate, alpha-tocopherol, gamma- highest yields of biodiesel. In addition, the lipase technology allows
tocopherol, delta-tocopherol, propyl gallate, dodecyl gallate, gallic an easy recovery of glycerol, without the need of purifying the
acid, octyl gallate, ascorbyl palmitate, pyrogallol, alpha naphthol, methyl esters. It is of paramount importance to reduce the
natural tocopherol, eugenol, or 6-ethoxy-1,2-dihydro-2,2,4- production cost derived from the protein purification though.
trimethylquinoline, although non aromatic compounds are included Therefore, the use of whole microorganisms, as biodiesel cell
as well such as dilauryl thiodipropionate, isopropyl 2-hydroxy-4- factories, with the ability to synthesize alcohol esters could save
methylthio butanoate, lecithin, stearyl citrate, palmityl citrate, this enzyme purification cost.
chlorophyll, ascorbic acid, citric acid, etc [139]. The use of
aromatic derivatives along with N- and S-containing antioxidants Steinbüchel and coworkers have created a fuel-refining
can undermine the environmentally friendly nature of biodiesel as a Escherichia coli bacterial strain by modifying it with genes taken
from two other microorganisms, Zymomonas mobilis and

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clean fuel by polluting the environment, an important reason for
focusing on the non aromatic and the non N- and S-containing Acinetobacter baylyi [143]. The modified E. coli were cultured in

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compounds as antioxidants. growth medium containing glucose and oleic acid, which the
bacteria processed into fatty acid ethyl esters, a diesel-substitute
4.3. Glycerol Production named as "microdiesel". This was achieved by heterologous

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expression in E. coli of the Zymomonas mobilis pyruvate
The transesterification of oils and fats results in the generation
decarboxylase and alcohol dehydrogenase and the unspecific

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of glycerol as a byproduct of biodiesel. The free glycerol formed
acyltransferase from Acinetobacter baylyi strain ADP1. By this
must be removed from the mixture of esters, since glycerol can
approach Steinbüchel et al., managed to obtain ethanol formation

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cause damage to the engine [140]. Free and bonded glycerol, are the
and to combine it with a subsequent esterification of the ethanol
main parameters for defining the quality of biodiesel. During the

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with the acyl moieties of coenzyme A thioesters of fatty acids.

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transesterification process, free glycerol can easily be removed by
Using this transgenic microorganism the obtained concentration of
washing steps, whereas a low content of glycerides can only be
FAEE was of 1.28 g/L and the FAEE content of the cells was of 26

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achieved by the use of specific catalysts and reaction conditions or
% of the cellular dry mass, that were achieved by fed-batch
by further distillation of the product. A higher content of free

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fermentation using renewable carbon sources.
glycerol may cause problems during storage or in the fuel system,

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due to separation of glycerol, or can lead to injector fouling or the This novel approach might pave the way for industrial
formation of higher aldehyde emissions. A higher content of production of biodiesel equivalents from renewable resources by

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glycerides, especially triglycerides, may cause formation of employing engineered microorganisms, enabling a broader use of

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deposits at the injection nozzles, at the piston and at the valves biodiesel-like fuels in the future.
[141]. A simple method for the almost complete removal of Unlike regular biofuel, microdiesel is produced without toxic

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glycerol from methanol-free biodiesel streams coming out from chemicals. Waste oils could allegedly be used as source of fatty
industrial transesterification reactors has recently been described by acids, reducing the need to grow crops specifically for biodiesel

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Yori et al. The method is posed as a "dry" alternative to the production and therefore reducing the production cost of this fuel.
conventional "wet" methods involving water washing. It is based on
the use of silica beds and relies on the adsorption at room ABBREVIATIONS
temperature to retain the small amounts of glycerol dissolved in the IEA = International energy agency
solutions of fatty acid methyl esters and adjust their content to the
NYMEX = New York mercantile exchange
quality standards for biodiesel fuel [142]. Nevertheless, the
difficulty for the removal of glycerol as by-product is mainly IPCC = Intergovernmental panel on climate change
depending on the technical process of transesterification (see Table NREL = US National renewable energy laboratory
1). Once glycerol surplus is removed it can be used in different FAMEs = Fatty acid methyl esters
ways as described previously.
FAEEs = Fatty acid ethyl esters
5. CURRENT & FUTURE DEVELOPMENTS DAF = Dissolved air flotation
Energy and climate change are the now main subjects among SCF = Super critical fluid
the scientific community, and modern society. And there is broad
BTU = British termal units
agreement that there is no single solution to these problems of
meeting future demands for energy and managing the ACKNOWLEDGEMENTS
environmental consequences of energy production. The future
developments will consist of set of many different technologies. Maximino Manzanera was granted by Programa Ramón y Cajal
Recent scientific advances focus on basic biology and technology (MEC, Spain and ERDF, Euopean Union).
that can be applied to metabolic engineering in order to comply REFERENCES
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