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Process Biochemistry 37 (2001) 65 – 71

www.elsevier.com/locate/procbio

Biodiesel production from crude palm oil and evaluation of


butanol extraction and fuel properties
Edward Crabbe, Cirilo Nolasco-Hipolito, Genta Kobayashi, Kenji Sonomoto,
Ayaaki Ishizaki *
Laboratory of Microbial Technology, Faculty of Agriculture Graduate School, Kyushu Uni6ersity, Hakozaki, Higashi-ku,
Fukuoka 812 -8581, Japan
Received 24 September 2000; received in revised form 28 February 2001; accepted 25 March 2001

Abstract

Three principal variables, molar ratio of methanol to oil, amount of catalyst, and reaction temperature, affecting the yield of
acid-catalyzed production of methyl ester (biodiesel) from crude palm oil were investigated. The biodiesel was then used as an
extractant in batch and continuous acetone–butanol–ethanol fermentation, and its fuel properties and that of the biodiesel–ABE
product mix extracted from the batch culture analyzed. The optimized variables, 40:1 methanol/oil (mol/mol) with 5% H2S04
(vol/wt) reacted at 95°C for 9 h, gave a maximum ester yield of 97%. Biodiesel preferentially extracted butanol, and enhanced its
production in the batch culture from 10 to 12 g l − 1. The fuel properties of biodiesel and the biodiesel– ABE mix were comparable
to that of No.2 diesel, but their cetane numbers and the boiling points of the 90% fractions were higher. Therefore, they could
serve as efficient No. 2 diesel substitutes. The biodiesel– ABE mixture had the highest cetane number. © 2001 Elsevier Science
Ltd. All rights reserved.

Keywords: Biodiesel; Diesohol; Palm oil; Methyl ester; Extractant; Transesterification

1. Introduction sustained interest in identifying and channeling renew-


able (biomass) raw materials into the manufacture of
For more than two centuries, the world’s energy liquid fuel alternatives because development of such
supply has relied heavily on non-renewable crude oil- biomass-based power would ensure that new technolo-
derived (fossil) liquid fuels out of which 90% is esti- gies are available to keep pace with society’s need for
mated to be consumed for energy generation and new renewable power alternatives for the future.
transportation. It is also known that emissions from the Oil-seed crops are by far the largest group of ex-
ploitable renewable biomass resource for liquid fuel and
combustion of these fuels such as carbon dioxide (CO2),
energy generation [2]. Their oils have long been consid-
carbon monoxide (CO), nitrogen oxides (NOx ) and
ered as alternative or emergency fuels for diesel engines
sulphur-containing residues are the principal causes of
because they have heat contents approximately 90% of
global warming and many countries have passed legis-
that of No. 2 diesel fuel, the transportation fuel [3].
lation to arrest their adverse environmental conse- However, their high viscosity, about 10 times that of
quences [1]. With populations increasing rapidly and No.2 diesel fuel [4,5] has limited their use in modern
many developing countries expanding their industrial direct-injection type diesel engines because it affects
base and output, worldwide energy demand is bound to engine performance and in some cases engine damage is
increase. On the other hand, known crude oil reserves inevitable. One main solution has been to transesterify
could be depleted in less than 50 years at the present these oils with simple alcohols to their respective fatty
rate of consumption. This situation initiated and has acid methyl esters (FAME) or ethyl esters (FAEE).
These products are collectively referred to as biodiesel
* Corresponding author. Tel.: 81-92-6423019; fax: 81-92-6423030. [6,7] because their fuel properties are comparable to
E-mail address: Ishizaki@agr.kyushu-u.ac.jp (A. Ishizaki). that of No. 2 diesel fuel.

0032-9592/01/$ - see front matter © 2001 Elsevier Science Ltd. All rights reserved.
PII: S 0 0 3 2 - 9 5 9 2 ( 0 1 ) 0 0 1 7 8 - 9
66 E. Crabbe et al. / Process Biochemistry 37 (2001) 65–71

Studies to date based on biodiesel produced from In a preceding investigation we reported that CPO–
rapeseed or canola [8], sunflower [9], safflower [10] and FAME or crude palm oil methyl ester (CPOE) is bio-
soybean oils [11], have shown that biodiesel is environ- compatible with the process organism, selectively
mentally friendly because there is substantial reduction extracted butanol and in so doing increased both bu-
of unburned hydrocarbons, CO and particulate matter tanol productivity and production in ABE fermentation
emission when it is used in conventional diesel engine [15]. Therefore, the objective of this study was to
[12]. Moreover, biodiesel contains no sulphur, so the optimize the parameters that affect transesterification
sulphate fraction in the fuel is eliminated; and since the of CPO to its corresponding methyl ester (CPOE) and
oil originates from vegetable matter, the CO2 produced to evaluate its solvent extraction and fuel properties. In
is sequestered and the net CO2 released into the atmo- addition, we report on the performance of CPOE as an
sphere would be greatly reduced. Biodiesel blends effi- online butanol extractant in continuous ABE
ciently with petroleum diesel, and this results in less fermentation.
offensive exhaust odours which is a real benefit when
machinery or vehicles are used in confined environ-
ments. Additionally, it operates in modern combustion 2. Methods and materials
engines just like petroleum diesel; therefore, no engine
modifications are required. Biodiesel is less flammable 2.1. Chemicals
than No. 2 diesel fuel, which makes it useful in mining
operations where the risk of fire outbreak in under- Crude palm oil (CPO) was obtained from the Palm
ground shafts must be reduced to the minimum. Since it Oil Research Institute of Malaysia (PORIM, Serdang,
can be produced domestically it would boost many Malaysia) and stored at 4°C. Its quality characteristics
domestic economies and conserve foreign expenditure were determined according to the official methods of
fats and oils published by the Association of Oil
on crude oil imports by providing an impetus for the
Chemists. The fatty acid composition was determined
production of high yielding oil-seed crop varieties to
by gas chromatography (GC) as described later.
sustain a domestic biodiesel industry.
Methanol, hexane, petroleum ether and sulphuric acid,
In addition to their fuel properties, FAMEs of veg-
all of commercial grade quality, were purchased from
etable oil origin are known to extract butanol [13,15],
Nacalai Tesque Inc. (Kyoto, Japan). Fatty acid methyl
an excellent fuel extender, which efficiently blends with
esters, methyl laurate, methyl myristate, methyl palmi-
petroleum diesel to form diesohol [14]. Butanol is pre-
tate, methyl palmitoleate, methyl oleate, methyl
ferred to ethanol in diesohol formulation because un-
linoleate, methyl linoleneate and methyl arachidate ob-
like the latter it has a lower vapour pressure and mixes
tained from Sigma Chemical Co. (St. Louis, MO) and
with petroleum diesel at all temperatures. Diesohol
methyl stearate purchased from Wako Chemical Co.
production can also be achieved using FAME of veg- (Osaka, Japan) were used as the reference standards for
etable oil origin as butanol extractant in the acetone– GC analyses while methyl heptadecanoate purchased
butanol –ethanol (ABE) fermentation since the from Sigma Chemical Co. was used as the internal
composite product (FAME – butanol mix) would have standard.
fuel properties comparable to diesohol obtained by
blending petroleum diesel and commercial butanol. 2.2. Transesterification 6ariables (biodiesel preparation)
This process eliminates the need for further recovery of
butanol and would reduce the running cost of an ABE Methylation was carried out in ordinary 250-ml
fermentation industry. screw-capped bottles. Approximately 25 g of the melted
However, unlike fossil reserves, different regions of oil (at 400°C) was used in each experiment. All molar
the world have their own vegetable oil resources that ratios (mol/mol) are by convention written as methanol
could be exploited for biodiesel production. Biodiesel to CPO. The reaction catalyst used was concentrated
has been produced from a variety of sources including H2SO4 which was added as volume by weight of the oil
refined and crude vegetable oils, residues from veg- (vol/wt%). The fatty acid composition of the oil was
etable oil extraction, used cooking oils, and animal determined using a large excess of methanol (167:1
grease or tallow. In Southeast Asia, Malaysia has a rich mol/mol), in 3% H2SO4 and reacted at 95°C for 24 h.
oil palm industry that generates excess crude palm oil This product was then used as the standard of compari-
(CPO), in vast quantities for consumption. CPO is one son for subsequent ester yield. The effect of molar ratio
of the four leading vegetable oils traded on the world of methanol to oil was determined as 3:1 to 40:1
market. It is also cheaper than canola, rapeseed or mol/mol in 3% H2SO4; and the effect of the amount of
soybean oil and would reduce the overhead cost of acid was determined as 1 to 5% H2SO4 (vol/wt%) using
biodiesel production and generate a ready supply of 23:1. methanol to oil (mol/mol). Both reactions were
diesel fuel substitute or blend. carried out at 95°C for 24 h. The effect of the reaction
E. Crabbe et al. / Process Biochemistry 37 (2001) 65–71 67

temperature was determined at 70, 80 and 95°C over a 2.4. Medium


24-h period. In this experiment, the reaction mixtures
contained 40:1 methanol to oil (mol/mol) in 5% H2SO4 The medium used in all the investigations was Tryp-
in a number of screw-capped bottles. The course of tone–yeast extract– ammonium acetate (TYA) with the
transesterification was followed at 3, 6, 9, 12, and 24 h. following composition per litre of deionized water: 2 g
Reactions were quenched in a beaker filled with iced yeast extract (Difco, Detroit, MI), 6 g Bactotryptone
water, and the ester yield determined. Controlled reac- (Difco, Detroit, MI), 3 g ammonium acetate, 0.3 g
tion temperatures were made possible by incubation in MgSO4·7H2O, 10 mg FeSO4·7H2O. Unless otherwise
ordinary electric hot water pots. In all experiments, the indicated, batch fermentation was carried out using an
excess methanol was recovered by rotary evaporation initial glucose concentration of 40 g l − 1. The initial
under reduced pressure and confirmed by GC, because medium pH was adjusted to 6.5 and sterilized at 115°C
methanol inhibited the growth of the process organism. for 15 min.
The product was then extracted into hexane or
petroleum ether, and the glycerol was washed off with 2.5. CPOE as an extractant in an integrated extracti6e
deionized water. The hexane extract was then dried ABE fermentation
over anhydrous sodium sulphate, and hexane removed
by rotary evaporation under reduced pressure. The Initially, a stirred batch fermentation was carried out
fatty acid composition of the refined product was then in 40 g l − 1 glucose in TYA medium, with and without
determined by GC as described later. CPOE extraction, at a working volume of 400 ml in
1-litre fermentors at 30°C without pH control and
2.3. Microorganism and growth conditions agitated at 130 rpm. The media were inoculated with
10% inoculum and the culture headspace briefly
Clostridium saccharoperbutylacetonicum N1-4 (ATCC sparged with purified N2 gas (99.9%) to ensure anaero-
13564) was maintained as spores in sterilized sand as a biosis. Where CPOE was added, an equal volume was
long-term stock. For short-term storage, the organism pumped onto the surface of the culture medium at the
was maintained in 15% potato– glucose in [150 g start of the experiment. The concentration of products
potato, 10 g glucose, 0.5 g ammonium sulphate, 3 g and fuel properties of the CPOE–ABE mixture ob-
calcium carbonate] medium at 4°C. Of this stock, 1 ml tained as the organic phase were analyzed.
was transferred into 9 ml of fresh potato– glucose The experimental set-up used to evaluate the perfor-
medium, heat-shocked in boiling water for 60 s, cooled mance of CPOE as an online extractant in continuous
in iced water and subcultured at 30°C for 30 h. It was fermentation with cell–recycle system is shown in Fig.
transferred into fresh medium, subcultured for 18 h and 1. The cultivation was carried out in a 1-litre fermentor
used as inoculum, which formed 10% of the total at a working volume of 400 ml at 30°C and agitated at
volume of the culture. 130 rpm. The pH was regulated between pH 5.4 and 5.5
by automatic addition of 2.5 M of H2SO4 or NaOH.
After inoculation, purified N2 gas (99.9%) was sparged
through the culture headspace to ensure anaerobiosis.
The culture was operated in batch mode and switched
to continuous feeding with biomass recycling when the
residual glucose concentration was approximately 5 g
l − 1. The dilution rate was 0.14 h − 1 and the feed
medium contained 60 g l − 1 glucose. An extraction unit
containing 150 ml of CPOE was incorporated at the
permeate outlet of the microfiltration membrane. Sam-
ples were periodically withdrawn from the fermentor
and both phases of the extraction unit starting from the
4th residence time.

2.6. Analysis

Fig. 1. Experimental setup of the continuous extractive fermentation 2.6.1. Fatty acid composition and ester yield
with cell recycle. The components are designated as follows: A, feed A mixture of the fatty acids (10 g l − 1 each in hexane)
reservoir; B, acid pump; C, acid reservoir; D, alkali reservoir; E,
served as the standard for gas chromatographic analysis
alkali pump; F, pH controller; G, feed pump; H, fermentor; I, pH
electrode; J, hollow fibre pump; K, hollow fibre module; L, permeate with methyl heptadecanoate as the internal standard.
pump; M, sparger; N, extractant; 0, filtrate; P, filtrate pump; Q, The fatty acids were quantified by injecting 2 ml of each
product reservoir; and R, stirrer. sample into the Shimadzu GC 8A chromatograph (Shi-
68 E. Crabbe et al. / Process Biochemistry 37 (2001) 65–71

Table 1 determined using reference methods published by


Quality characteristics of crude palm oil
American Society for Testing and Materials (ASTM):
Parameters PORIMa Present study
density (D 1298), distillation characteristics (D 86),
specification flash point (D 93), cetane number (D 2622), and ele-
mental composition. The results were compared to that
Moisture (% w/w) ND 0.02 of No. 2 diesel fuel.
Acid value (mg KOH/g) ND 6.9
Fatty acid composition
Lauric 0–0.4 0.46
Myristic 0.6–1.6 1.22 3. Results and discussion
Palmitic 41–47 47.9
Palmitoleic 0–0.6 0.04 3.1. Quality characteristics of crude palm oil
Stearic 3.7–5.6 4.23
Oleic 38.2–43.5 37.0
Linoleic 6.6–11.9 9.07 Table 1 shows that the fatty acid composition of
Linolenic 0–0.5 0.26 CPO determined in this study was within the range
Arachidic 0–0.8 0.31 specified by the Palm Oil Research Institute of
Mean molecular weight (g) 847.3 Malaysia (PORIM). Based on this result, the calculated
Unsaturated fatty acids (%) 44.8–57.3 45.9
mean molecular weight of CPO was 847.3. The esti-
Saturated fatty acids (%) 45.3–55.4 54.1
mated acid value was 6.9%. This value confirmed that
a
PORIM — Palm Oil Research Institute of Malaysia. CPO is a crude vegetable oil which contains a large
portion of free fatty acids (FFA). For this reason, a
large excess of methanol would be required and acid-
catalyzed transesterification would be the preferred
madzu Co., Tokyo) fitted with a flame ionization detec- method of methylation to ensure a high yield of the
tor (FID) employing Shinchrom E71 on 80/100 Shi- methyl ester.
malite® (AW 201) (Chromato Packings, Fukuoka)
packed into a glass column 3-m long by 3 mm in 3.2. Influence of transesterification parameters
internal diameter. The injector and detector tempera-
tures were set at 250°C and the column temperature The three most important parameters affecting
was 230°C. Nitrogen was used as the carrier gas at a triglyceride transesterification are the molar ratio of the
pressure 1.5 kg cm2. The concentrations of the individ- methanol to the triglyceride, the nature and the amount
ual esters were recorded with a Chromatopac C-R6A of catalyst, and the reaction temperature [16]. Stoichio-
integrator (Shimadzu Co., Kyoto). The percentage of metrically, complete transesterification should occur at
methyl ester yield was calculated by comparing the a molar ratio of 3:1 (methanol to triglyceride) yielding
fatty acid composition of the sample to that of the 3 mol of ester and 1 mol of glycerol. However, other
control. reports have shown that at this stoichiometry, the
reaction rate is slow and rarely proceeds to completion
2.6.2. Fermentation products necessitating the use of excess methanol. As shown in
The samples withdrawn from the broth were cen- Fig. 2, ester yield increased as the molar ratio of
trifuged (12 000× g, 10 min) and the supernatant methanol to palm oil increased although the reaction
acidified using 2 M HCl. The solvents and acids were did not proceed to completion. The highest yield of
quantified a using a Shimadzu GC 8A gas chro- 78% using 3% H2SO4 as the reaction catalyst was
matograph (Shimadzu Co., Kyoto) equipped with a 3 obtained at 23:1 mol/mol. By extrapolation, the highest
m-glass column (i.d. 1.2 mm) packed with Chromo- molar ratio needed to achieve complete methylation
sorb® 101 and fitted with a FID. Injector and detector was found to be between 35:1 and 45:1 mol/mol.
temperatures were held at 250°C and the column tem- Although alkali-catalyzed transesterification proceeds
perature was 200°C. Nitrogen was used as the carrier faster than acid catalysis, the type of oil used deter-
gas at a pressure of 1.2 kg cm2 and isobutanol was the mines the mode of chemical catalysis. Alkali-catalyzed
internal standard. For the quantification of products in reactions are one-step reactions and proceed faster
the extractant, the same GC conditions were used with- when the acid value is low (i.e. in refined oils) whereas
out an internal standard and any pre-treatment. acid catalysis favours vegetable oils with high acid
value (i.e. in crude oils). A high FFA also deactivates
2.6.3. Fuel properties alkali catalysts, and the addition of excess amount of
Samples of the purified methyl ester (CPOE) and the alkali as compensation gives rise to the formation of
CPOE –ABE mixture obtained from the batch culture emulsion, which increases viscosity, leads to the forma-
experiment were sent to Tonen Co. Ltd (Saitama, tion of gels and to problems associated with glycerol
Japan) for analysis. The following fuel parameters were separation and loss in ester yield. To confirm this
E. Crabbe et al. / Process Biochemistry 37 (2001) 65–71 69

assumption, preliminary reactions carried out using 1%


by weight of NaOH and KOH as the reaction catalyst
at a molar ratio of 8:1 resulted in emulsion formation
that led to losses in yield during glycerol separation.
Therefore, acid-catalyzed methylation was the adopted
procedure. Fig. 3 shows the effect of the catalyst con-
centration on the ester yield using a 23:1 (mol/mol)
ratio of methanol to oil. Ester yield increased as the
acid concentration increased; the highest yield of 82%
was obtained using an acid concentration of 5%. At this
acid concentration, the ester yield increased to 96.7% at
40:1 mol/mol when methylation was carried out be-
tween 35:1 and 45:1 mol/mol, which compared to the
methyl ester yield of the control as indicated in Fig. 2.

Fig. 4. Effect of reaction temperature on ester yield. The reaction mix


contained 40:1 mol/mol methanol to oil and 5% acid. The study was
carried out at 70°C, ; 80°C, ; and 95°C, .

Acid-catalyzed methylation is energy-intensive be-


cause it is usually conducted at high temperature. Since
this could affect the economy of the whole biodiesel
process, the effect of reaction temperature was investi-
gated at 75, 80 and 95°C using 5% H2SO4 as catalyst
and a 40:1 molar ratio of methanol to oil over a 24-h
period. As shown in Fig. 4, the rate of the reaction
increased as the reaction temperature increased; 99.7%
yield was obtained after 9 h at 95°C while a similar
yield was obtained at 80°C after 24 h. Methylation at
70°C was slow and incomplete after 24 h. Therefore,
Fig. 2. Effect of increasing molar ratio of methanol to triglyceride on the optimized variables for the acid-catalyzed transes-
methyl ester yield. The arrow indicates transesterification carried out terification of CPO were 40:1 mol/mol, 5% H2SO4
under optimized conditions (methanol to oil, 40:1; acid concentration, (vol/wt%) at 95°C for 9 h.
5%; and reaction temperature, 95°C).
3.3. Performance of CPOE as an online extraction
sol6ent

In a previous report [15], it was demonstrated that


CPOE was non-metabolizable and biocompatible with
Table 2
Comparison of product concentrations between extractive and non-
extractive ABE fermentation in glucose medium

Fermentation Product concentration (g l−1)

ABE
Butanol Acetone Ethanol (g l−1)

Non-extractive 10.55 4.26 0.68 15.49


Extracti6e
CPOE 5.74 0.65 0.14
Broth 5.86 3.09 0.70
Total 11.60 3.74 0.84 16.18

Fig. 3. Effect of acid concentration on methyl ester yield. Initial glucose 40 g l−1.
70 E. Crabbe et al. / Process Biochemistry 37 (2001) 65–71

Table 3
Performance of CPOE as an online extractant

Products (g l−1) Total


Fermentation stage ABE
Butanol Acetone Ethanol Acetate Butyrate (g l−1)

Fermentor 8.07 6.73 0.84 1.65 0.00 15.64


Permeatea 7.65 6.69 0.54 1.13 0.00 14.88
Extractant 10.51 6.69 0.80 0.00 0.00 18.00

a
Permeate values reported are product concentrations after solvent extraction.

this microorganism. Furthermore, CPOE remained produced while enhancing its production (Table 2).
thermally and chemically stable even after autoclave Therefore, to further enhance solvent extraction during
sterilization at high temperature (121°C) and pressure continuous fermentation, a 3:2 (vol/vol) ratio of CPOE/
and as an extractant during in situ batch fermentation. cell-free permeate was used. Fig. 5 shows the profile of
In the present batch culture experiment, CPOE selec- ABE products in the fermentor and in the two phases
tively extracted about 40–50% of the total butanol of the extraction unit at steady state. Butanol was
preferentially extracted into the CPOE layer. About
10.5 g l − 1 of butanol and 18 g l − 1 of total ABE
solvents accumulated in the extractant, which also in-
cluded a high concentration of acetone (Table 3).

3.4. Fuel properties of CPOE and CPOE–ABE


mixture

In Table 4 the fuel properties of CPOE and the


CPOE –ABE mixture obtained from batch extractive
Table 4
Fuel properties of CPOE, CPOE+ABE mixturea and No. 2 Diesel
fuel

Property ASTMb No. CPOE only CPOE+ABE


2-D

Density (g 0.8383c 0.8587 0.8548


cm−3), 15°C
Cetane number, 40 49 52
minimum
Flash Point, 52 27 26
°C, minimum
Elemental composition (wt%)
Carbon, max 74.3 74.16
Hydrogen 13.0 12.4
Oxygen 12.7 13.0
Sulphur, max 0.01 6 1.0
Nitrogen 3 1.0
Distillation range, °C
IBFd 179 63 54
10% 211 71 69
50% 264 335 339
90% 282–338 360 360
FBPd 610 597

a
From batch extractive ABE fermentationusing 40 g l−1 sago
glucose in TYA medium. CPOE contained 5.74 g l−1 butanol ex-
Fig. 5. Concentration of ABE solvents, at the various stages of the tracted from the broth during cultivation.
continuous extractive fermentation with cell recycle experiment. The b
Annual Book of ASTM Standards, American Society for Testing
graphs are (A) butanol; (B) total ABE solvent. Key to symbols: and Materials Philadelphia, 2000.
Product concentration in the first fermentor,
; in permeate after c
From ASTM 1994.
solvent extraction, ; in CPOE, . d
IBP, FBP — Initial and final boiling point, respectively.
E. Crabbe et al. / Process Biochemistry 37 (2001) 65–71 71

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