Description of the Patent of Invention for "PROCESS FOR EXTRACTION AND CATALYTIC ESTERIFICATION OF FATTY ACIDS FOUND IN SEWAGE SCUM". Field of the Invention This invention is related to the esterification process of the fatty acids found in the "sewage scum", namely the surface phase of sewage rich in fatty matter. By dry weight, this oily phase consists of over 80% carboxy acids with 2 - 24 carbon atoms deriving from the decomposition process of different triglycerides and soaps in sewage. Through this invention, these fatty acids are extracted from the scum and esterified with methanol or ethanol through the use of acid catalysts in this process. Background of the Invention Sewage may be defined as a dilute aqueous solution formed by organic and inorganic substances, either dissolved or in suspension. When reaching the sewage treatment stations, the formation of at least three important phases becomes quite clear: a) A lower level called sludge results from the decantation of the solid, dense matter in the sewage; b) An aqueous phase with high BOD and COD values that requires physical and chemical treatment before being discharged into rivers and seas;
c) A surface phase known as scum, consisting basically of organic matter that is not soluble in water, mainly greasy matter .
The total fats potential contained in Brazilian sewage may reach some 2.106 tons/year, on the basis that each person generates about 250 liters of sewage a day containing 30 - 80 grams of fat.
Although representing a relatively low percentage of sewage, the disposal of this scum is extremely harmful to the environment. As it covers the surface, the scum layer hampers the diffusion of oxygen into the water, with disastrous consequences for submerged eco-syste s . It should be noted that sewage treatment stations are stepping up their capacities - in the Greater Rio de Janeiro area, for instance, through the Guanabara Bay Clean-up Program
(PDBG) . This means that the amount of scum is increasing more significantly in absolute terms. Even in regions or countries already endowed with ample sewage treatment infrastructure, the usual disposal facilities for this scum consist of sanitary landfills, also with limited capacities.
Another problem caused by this scu is associated with its transportation, as it is a thick paste which is hard to pump.
An important by-product of fatty matter is bio- diesel, consisting of fatty acid esters, which is an alternative fuel obtained from renewable biological sources such as vegetable oils and animal fats. Compared to oil- based diesel (petro-diesel, biodiesel is an environmentally clean fuel as it reduces emissions of atmospheric pollutants and particulate matter, in addition to being bio-degradable and atoxic. With physical and chemical properties similar to those of petro-diesel, biodiesel may be used directly in engines with no major mechanical modifications or outlays on maintenance.
The pre-esterification of free fatty acids using homogenous acid catalysis has the disadvantage that it is difficult to remove the catalyst residues from the pre- esterified matter. The catalyst is normally removed through washing the mixture with methanol, which is separated from the oil phase through extraction by a solvent that does not blend with the oil, normally glycerin. However, this means that part of the esterified fatty acids is lost, lowering the yield from this process. In order to deal with this problem, bio-catalysts (enzymes) may be used or even solid acid catalysts. Foglia et al . (US patent 5,713,965) proposed the use of upases for esterifying the free fatty acids with normal or secondary alcohols. The reaction takes place at low temperatures (between 30°C and 60°C) with high
ester yield levels, but it is necessary to separate and recycle the solvent. Jeromin et al . (US patent 4,698,186) proposed the use of cation exchange resins as esterification catalysts. These resins contain sulfonic or carboxy acid groups linked to a polymer matrix, normally polystyrene. This reaction also takes place at low temperatures (55°C - 65°C) at a methanol : fatty acid mol ratio of 10:1 to 50:1, with the catalyst being hard to separate from the reaction products. HOOC-R + R'OH <> R-COO -R' + H20
Fatty acid alcohol ester water
Scheme 1 - Esterification Reaction Heterogeneous acid catalysts were used by Bradin (US patent 5,578,090) to esterify free fatty acids with alcohols or olefins. When esterification takes place with alcohols, water is formed as a by-product, which may dilute or destroy the acid catalyst. When using olefins, there is no water formation, but strict temperature control is required (under 70°C) in order to prevent excessive polymerization of the olefins. Lewis acids were used as catalysts, including aluminum chloride and iron chloride, with the latter being preferable for esterification with olefins, as it minimizes parallel dimerization and polymerization reactions.
Efforts to transform free fatty acids are justified because their presence is generally associated with fatty raw materials with low commercial value, such as sewage scum, allowing fatty acid esters to be produced at costs competitive with those of petro-diesel and other feedstock used by the petrochemical industry. Moreover, the use of heterogeneous catalysts minimizes the separation and purification costs, making this process even more attractive. Sumary of the Invention
This invention covers the process of extracting fatty acids from sewage scum, using a catalytic esterification process and presenting the optimum reaction condition ranges in terms of temperature, pressure, space- time and reagent concentrations for the efficient transformation of the fatty acids in the sewage scum into methyl or ethyl esters.
This invention also covers the use of solid acid site-based catalysts in the alcohols esterification process for free fatty acids in sewage scum.
Brief Description of the Drawings
As an example, Figure 1 presents a flow sheet for the bio-diesel production process based on fatty acids extracted from scum. This sequence involves the following
items of equipment: 1-pump, 2-centrifuge, 3-press-filter, 4-extractor, 5-esterification reactor, and 6-distillation column to recycle surplus alcohol and solvents.
Figures 2 and 4 give the conversion graphs (%) x reaction time ( in) for the esterification reaction of the fatty acids extracted from scum.
Tables 1 through 4 give detailed descriptions of the reaction conditions used respectively in Examples 1 through 4.
As an example, Table 5 presents some physical and chemical properties of the methyl ester obtained through the procedure described in Example 1. The trials were carried out according to the ASTM standards described in the table .
Detailed Description of the Invention
The purposes of this invention include a process for extraction followed by the esterification of free fatty acids in sewage scum and the use of solid acid catalysts in this process. The scum collected at sewage treatment stations has a high water content level. The water dilutes the reagents, slowing the reaction speed. Moreover the water is a product of the esterification reaction, with thermodynamic effects on the chemical balance lowering the
process yield. Another negative aspect of the water is its interaction with the catalyst acid sites, minimizing this effect. Consequently, as much water as possible should be removed before the reaction. Conventional filtering ■ equipment such as a press filter may be used for this purpose. A centrifuge is also recommended to remove the water.
The fatty matter is then removed from the scum through extraction by an apolar solvent, either organic or not. In this case, organic apolar solvents may be used, such as pentane, hexane or heptane, or even solvents in super-critical conditions such as C02, ethane or propane. The use of polar solvents with the esters is not advisable, due to simultaneous interaction with the remaining water content.
Should organic solvents be used, an upper phase is attained, containing the fatty matter. The lower phase contains the waste waters. The surplus solvent should be recycled through a flash in a distillation unity. A certain amount of solvent is kept for carrying the solubilized fatty matter to the esterification reactor, boosting the reaction yield.
The esterification reaction may occur in the presence of a homogeneous or heterogeneous catalyst.
In this invention, acid catalysts are used for esterifying blends of fatty scum acids. These fatty acids may be esterified with methyl or ethyl alcohol.
The use of solid acid catalysts in this process to esterify the fatty acids requires the existence of acid sites that can promote the reaction.
In this invention, it is shown that the addition of alcohol in stoichiometric excess is of the utmost importance. At the current international ratification stage of bio-diesel, methanol and ethanol are the main alcohols used. However, other products may also be used for the formation of biodiesel, as well as additives to enhance its lubricity and ketone rating, or even as tenso-actives for blends of polar and apolar fuels (for instance, alcohol- diesel blends) . The esters formed in this manner may also be used as solvents, tenso-actives, intermediate tenso- actives or detergents .
In order to obtain high conversion and selectivity rates for the esters, alcohol/fatty acid mol ratios of 3 to 15 should be used, preferably working between 6 and 12.
Within this reaction environment, a catalyst is required that triggers the esterification reaction of the fatty acids at the lowest possible temperatures, in order to ensure that the reaction is economically feasible with
no heat breakdown of the reagents. This process involves temperatures in a range of 40°C - 200°C, preferably using a range of 60°C - 170°C.
High pressure promotes the reaction, although it is not vital. For more volatile alcohols such as methanol and ethanol, the reaction temperature range described above means that in some cases the process pressure is necessarily larger than atmospheric pressure.
The reactions involve liquid phase components and possibly active sites located inside the solid catalyst particles and consequently subject to mass-transfer constraints. High-speed stirring is required at levels sufficient to minimize this problem. Stirring speeds ranging between 400 and 1,500 RPM are appropriate for this purpose.
Whether solid or not, any catalyst with heat stability and Brδnsted and/or Lewis acidity under the reaction conditions may be used. Preferably, the catalysts listed below are used: Sulfated zirconia (sulfur content of 3% - 6%) with a surface area of 30 - 200 m2/g, pre-calcined between 300°C and 800°C;
Zirconia promoted with tungsten (tungsten level of 5% - 15%) , with a surface area of 70 - 200 m2/g, pre-calcined at 300°C - 800"C;
H-Zeolites, with a silica/alumina mol ratio of 4 - 75 and a surface area of 200 - 800 m2/g;
Aluminum chloride, super-anhydrous or chemically supported; Concentrated sulfuric acid; Methane-sulphonic acid; Toluenesulfonic acid; Concentrated hydrochloric acid; Concentrated phosphoric acid. The fatty acid esterification process using heterogeneous catalysts may be run on a batch basis, in a continuous reactor, as well as in fixed bed reactors. For the continuous systems, in order to reach balance conversions, the spatial time in terms of the fatty acids is 1 - 30 minutes, preferably limited to 3 - 20 minutes.
For both the batch and continuous processes, new reaction steps may be required in order to ensure better global yield. Ideally, the water produced during the initial esterification stage should be removed in order to promote the shift in the chemical balance in the right direction.
When using heterogeneous catalysts, the catalysts are removed after the reaction through simple filtering, or maintained through a fixed bed. When using homogeneous catalysts, neutralization of the medium is required after
the reaction. This neutralization produces a salt that should be removed by washing. Preferably, calcium carbonate and sodium carbonate solutions are used, with the possibility of also using controlled amounts of sodium hydroxide or potassium hydroxide, or even ammonia bubbled directly into the solution.
After neutralization followed by filtering, the solvent used for extraction in the reaction medium is recovered, in addition to retrieving surplus alcohol. The sequence depends on the solvent vapor pressures and the alcohols used. Vacuum evaporation is recommended, in order to minimize heat decomposition or parallel reactions.
Finally, the esters formed should be dried through heating (vacuum or not) . Esters with high purity levels may then be obtained through vacuum distillation. This stage may be skipped, depending on the bio-diesel specifications . As an example, Figure 1 gives a schematic process flow sheet. The items of equipment listed are: 1-pump, 2-extractor, 3-press filter, 4-flash vessel, 5-reactor, 6-distillation column.
Figure 1 - Flow Sheet giving an Example of the Process.
As an example, Figure 2 presents a chromatogram of the methyl esters obtained through the esterification of fatty acids contained in sewage scum. Cχ6 refers to the
palmitic acid ester, Cι refers to the heptadecanoic acid ester, Ciβ refers to the stearic, oleic, linoleic and linolenic acid esters, Cn-OH refers to the hydroxy fattyesters. This chromatogram was obtained as described in Example 1 and the Figure 2 - Typical Chromatogram - Chromatographic Method: Column: Carbowax, Length: 25 m, internal diameter: 0.32 mm, oven temperature: 200°C (isotherm), FID temperature: 250°C, injection temperature: 250°C, flow gas (He): 1.9 mL/min, Split: 1:20. Example 1
* Mol Ratio SiO2/Al2O3.
Example 2