Biodiesel production is the process of producing the biofuel, biodiesel, through the chemical reactions transesterification and esterification. This involves vegetable or animal fats and oils being reacted with short-chain alcohols (typically methanol or ethanol).
Process steps 
The major steps required to synthesize biodiesel are as follows:
Feedstock pretreatment 
Common feedstock used in biodiesel production include yellow grease (recycled vegetable oil), "virgin" vegetable oil, and tallow. Recycled oil is processed to remove impurities from cooking, storage, and handling, such as dirt, charred food, and water. Virgin oils are refined, but not to a food-grade level. Degumming to remove phospholipids and other plant matter is common, though refinement processes vary.
Regardless of the feedstock, water is removed as its presence during base-catalyzed transesterification causes the triglycerides to hydrolyze, giving salts of the fatty acids (soaps) instead of producing biodiesel.
Determination and treatment of free fatty acids 
A sample of the cleaned feedstock oil is titrated with a standardized base solution in order to determine the concentration of free fatty acids (carboxylic acids) present in the vegetable oil sample. These acids are then either esterified into biodiesel, esterified into glycerides, or removed, typically through neutralization.
Base-catalyzed transesterification reacts lipids (fats and oils) with alcohol (typically methanol or ethanol) to produce biodiesel and an impure coproduct, glycerol. If the feedstock oil is used or has a high acid content, acid-catalyzed esterification can be used to react fatty acids with alcohol to produce biodiesel. Other methods, such as fixed-bed reactors, supercritical reactors, and ultrasonic reactors, forgo or decrease the use of chemical catalysts.
Product purification 
Products of the reaction include not only biodiesel, but also byproducts, soap, glycerol, excess alcohol, and trace amounts of water. All of these byproducts must be removed to meet the standards, but the order of removal is process-dependent.
The density of glycerol is greater than that of biodiesel, and this property difference is exploited to separate the bulk of the glycerol coproduct. Residual methanol is typically recovered by distillation and reused. Soaps can be removed or converted into acids. Residual water is also removed from the fuel.
Animal and plant fats and oils are composed of triglycerides, which are esters containing three free fatty acids and the trihydric alcohol, glycerol. In the transesterification process, the alcohol is deprotonated with a base to make it a stronger nucleophile. Commonly, ethanol or methanol are used. As can be seen, the reaction has no other inputs than the triglyceride and the alcohol. Under normal conditions, this reaction will proceed either exceedingly slowly or not at all, so heat, as well as catalysts (acid and/or base) are used to speed the reaction. It is important to note that the acid or base are not consumed by the transesterification reaction, thus they are not reactants, but catalysts. Common catalysts for transesterification include sodium hydroxide, potassium hydroxide, and sodium methoxide.
Almost all biodiesel is produced from virgin vegetable oils using the base-catalyzed technique as it is the most economical process for treating virgin vegetable oils, requiring only low temperatures and pressures and producing over 98% conversion yield (provided the starting oil is low in moisture and free fatty acids). However, biodiesel produced from other sources or by other methods may require acid catalysis, which is much slower. Since it is the predominant method for commercial-scale production, only the base-catalyzed transesterification process will be described below.
Triglycerides (1) are reacted with an alcohol such as ethanol (2) to give ethyl esters of fatty acids (3) and glycerol (4):
- R1, R2, R3 : Alkyl group
The alcohol reacts with the fatty acids to form the mono-alkyl ester (biodiesel) and crude glycerol. The reaction between the biolipid (fat or oil) and the alcohol is a reversible reaction so excess alcohol must be added to ensure complete conversion.
Base-catalysed transesterification mechanism 
The transesterification reaction is base catalyzed. Any strong base capable of deprotonating the alcohol will do (e.g. NaOH, KOH, sodium methoxide, etc.), but the sodium and potassium hydroxides are often chosen for their cost. The presence of water causes undesirable base hydrolysis, so the reaction must be kept dry.
In the transesterification mechanism, the carbonyl carbon of the starting ester (RCOOR1) undergoes nucleophilic attack by the incoming alkoxide (R2O−) to give a tetrahedral intermediate, which either reverts to the starting material, or proceeds to the transesterified product (RCOOR2). The various species exist in equilibrium, and the product distribution depends on the relative energies of the reactant and product.
Production methods 
Supercritical process 
An alternative, catalyst-free method for transesterification uses supercritical methanol at high temperatures and pressures in a continuous process. In the supercritical state, the oil and methanol are in a single phase, and reaction occurs spontaneously and rapidly. The process can tolerate water in the feedstock, free fatty acids are converted to methyl esters instead of soap, so a wide variety of feedstocks can be used. Also the catalyst removal step is eliminated. High temperatures and pressures are required, but energy costs of production are similar or less than catalytic production routes.
Ultra- and high-shear in-line and batch reactors 
Ultra- and High Shear in-line or batch reactors allow production of biodiesel continuously, semi- continuously, and in batch-mode. This drastically reduces production time and increases production volume.
The reaction takes place in the high-energetic shear zone of the Ultra- and High Shear mixer by reducing the droplet size of the immiscible liquids such as oil or fats and methanol. Therefore, the smaller the droplet size the larger the surface area the faster the catalyst can react.
Ultrasonic reactor method 
In the ultrasonic reactor method, the ultrasonic waves cause the reaction mixture to produce and collapse bubbles constantly. This cavitation provides simultaneously the mixing and heating required to carry out the transesterification process. Thus using an ultrasonic reactor for biodiesel production drastically reduces the reaction time, reaction temperatures, and energy input. Hence the process of transesterification can run inline rather than using the time consuming batch processing. Industrial scale ultrasonic devices allow for the industrial scale processing of several thousand barrels per day.
Lipase-catalyzed method 
Large amounts of research have focused recently on the use of enzymes as a catalyst for the transesterification. Researchers have found that very good yields could be obtained from crude and used oils using lipases. The use of lipases makes the reaction less sensitive to high FFA content, which is a problem with the standard biodiesel process. One problem with the lipase reaction is that methanol cannot be used because it inactivates the lipase catalyst after one batch. However, if methyl acetate is used instead of methanol, the lipase is not in-activated and can be used for several batches, making the lipase system much more cost effective.
See also 
- "Biodiesel Magazine | biodieselmagazine.com". biodieselmagazine.com. 2012 [last update]. Retrieved May 3, 2012.
- "Pre-Treatment For Oil Biodiesel Processors & Biodiesel Equipment by Biodiesel Experts International, LLC". biodieselexpertsintl.com. 2012 [last update]. Retrieved May 3, 2012.
- Dubé, Marc A, et al. (2007). "Acid-Catalyzed Transesterification of Canola Oil to Biodiesel under Single- and Two-Phase Reaction Conditions". Energy & Fuels 21: 2450–2459. American Chemical Society. Retrieved on 2007-11-01.
- Bunkyakiat, Kunchana; et al. (2006). "Continuous Production of Biodiesel via Transesterification from Vegetable Oils in Supercritical Methanol". Energy and Fuels (American Chemical Society) 20 (2): 812–817. doi:10.1021/ef050329b.
- Vera, C.R.; S.A. D'Ippolito, C.L. Pieck, J.M.Parera (2005-08-14). "Production of biodiesel by a two-step supercritical reaction process with adsorption refining" (PDF). 2nd Mercosur Congress on Chemical Engineering, 4th Mercosur Congress on Process Systems Engineering. Rio de Janeiro. http://www.enpromer2005.eq.ufrj.br/nukleo/pdfs/0818_paper_818.pdf. Retrieved 2007-12-20.
- Kusdiana, Dadan; Saka, Shiro. "Biodiesel fuel for diesel fuel substitute prepared by a catalyst free supercritical methanol" (PDF). Retrieved 2007-12-20.
- Du, Wei; et al. (2004). "Comparative study on lipase-catalyzed transformation of soybean oil for biodiesel production with different acyl acceptors". Journal of Molecular Catalysis B: Enzymatic 30 (3–4): 125–129. doi:10.1016/j.molcatb.2004.04.004.
Further reading 
- Gerpen, J.V., "Biodiesel processing and production", Fuel Processing Technology, 2005, 86, 1097–1107. doi:10.1016/j.fuproc.2004.11.005
- Ma, F. & Hanna, M.A., "Biodiesel production: a review", Bioresource Technology, 1999, 70, 1–15. doi:10.1016/S0960-8524(99)00025-5
- Fast-Transesterification of Soybean Oil Using Ultrasonication
- Current State of Ultrasonic Processing for Fast Biodiesel Production
- Biodiesel Production Technology August 2002 – January 2004
- UNL Chemical and Biomolecular Engineering Research and Publications
- Continuous Process for the Conversion of Vegetable Oils into Methyl Esters of Fatty Acids
- Biodiesel Safety and Best Management Practices for Small-Scale Noncommercial Use and Production