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Fuel 87 (2008) 1789–1798


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Esterification of free fatty acids in waste cooking oils


(WCO): Role of ion-exchange resins
Nalan Özbay, Nuray Oktar *, N. Alper Tapan
Faculty of Engineering and Architecture, Department of Chemical Engineering, Gazi University, 06570 Maltepe, Ankara, Turkey

Received 3 October 2007; received in revised form 17 December 2007; accepted 19 December 2007
Available online 15 January 2008

Abstract

Although WCO plays a crucial role for the economical production of biodiesel, free fatty acid (FFA) level in the nature of WCO cause
saponification problems during transesterification. Acidic ion-exchange resins can be used to decrease WCO free fatty acid level. In this
study, activities of resins (Amberlyst-15 (A-15), Amberlyst-35 (A-35), Amberlyst-16 (A-16) and Dowex HCR-W2) in direct FFA ester-
ification were examined in the temperature range of 50–60 °C and the effect of catalyst amount (1–2 wt%) on FFA conversion was also
analyzed. FFA conversion increased with increasing reaction temperature and catalyst amount. Order of catalytic activities was found as
A-15 > A-35 > A-16 > Dowex HCR-W2. This was related to the size of average pore diameters and magnitude of BET surface area.
Ó 2007 Elsevier Ltd. All rights reserved.

Keywords: Biodiesel; Esterification; Ion-exchange resins

1. Introduction Biodiesel can be produced by transesterification,


whereby oil reacts with low molecular weight alcohols [4].
Since fossil fuels increase greenhouse gas emissions and Generally, alkaline catalysts (like sodium hydroxide), are
cause global warming, the use of alternative resources like used with low FFA content oils to catalyze transesterifica-
biofuels are more pronounced everyday. For example, tion reaction.
European Community has decided to replace at least Biodiesel can also be produced from waste cooking oils
5.75% of the yearly consumed fossil fuels by biofuels, by (WCO) [5–14]; it is being tested for diesel engine perfor-
the year 2010. The use of these biofuels does not contribute mance [15,16] and has similar performance with biodiesel
to the growth of greenhouse gases (2003/30/EC directive) produced from fresh vegetable oils. In spite of its low cost,
[1]. WCO pretreatment is still a problem [17] due to its high
As an alternative to fossil fuels, biofuels must be techni- free fatty acid level. Lately, Canakci and Van Gerpen
cally feasible, economically competitive, environmentally developed a two step pretreatment reaction that reduces
acceptable, and readily available [2]. Regarding these prop- the acid level of the high FFA feedstocks to <1% [18].
erties, biodiesel has been widely recognized as a promising Transesterification of WCO feedstocks with FFAs (lar-
biofuel. On the other hand, biodiesel is usually more expen- ger than 0.5%) cause an undesired saponification reaction.
sive than petroleum-based diesel fuel when it is produced In order to eliminate this problem, alternative acid
from vegetable oils or animal fats [3]. catalysts can be employed [19]. When strong liquid acid
catalysts (sulfuric acid, hydrofluoric acid, and p-toluenesul-
fonic acid) are used, they are less sensitive to FFA conver-
*
Corresponding author. Tel.: +90 312 2317400 2556; fax: +90 312
sion during transesterification. In addition, the rate of
2308434. reaction is slow and higher reaction temperatures are
E-mail address: nurayoktar@gazi.edu.tr (N. Oktar). required. On the other hand, if solid acid catalysts like

0016-2361/$ - see front matter Ó 2007 Elsevier Ltd. All rights reserved.
doi:10.1016/j.fuel.2007.12.010
1790 N. Özbay et al. / Fuel 87 (2008) 1789–1798

Nomenclature

A acidity (gOA/goil) MWOA molecular weight of oleic acid (g/mol)


CNaOH concentration of NaOH (mol/L) msample weight of sample (g)
VNaOH volume of solution consumed during titration
(mL)

ion-exchange resins, zeolites and superacids like sulphated 2. Experimental


zirconia and niobium acid [20] are used, they could prevent
corrosion [21], their separation is easy, and also high FFA 2.1. Materials
conversions can be achieved [22].
Ion-exchange resins are commonly used for esterifica- Three WCO batches were obtained from university caf-
tion [23–26] and transesterification reactions [27]. They eterias in ANKARA and filtered to remove impurities. The
have a gel type structure of microspheres that form a mac- acidities of the feedstocks were 0.47, 0.42 and 0.41 wt%.
roporous polymer [28]. Conventional ion-exchange resins Analytic grade methanol was purchased from Merck
are composed of copolymers of divinylbenzene (DVB), sty- Chemicals for esterification reaction. Commercial strong
rene and sulfonic acid groups [being the active site acidic ion-exchange resins (A-15 (Merck), A-35 (Rohm
(Brønsted acidity)]. Polymer structure of resin is character- and Haas), A-16 (Fluka) and Dowex HCR-W2 (Merck))
ized by the content of the crosslinking component (DVB),
which determines surface area and pore size distribution of
the resin [29]. 60
The aim of this study is to compare activities of different A-15
50 A-35
strong acidic ion-exchange resins like Amberlyst-15,
A-16
Amberlyst-35, Amberlyst-16 and Dowex HCR-W2 for 40
Dowex HCR-W2
FFA esterification in WCO and examine the effect of cata-
lyst amount, reaction temperature and reaction time on the 30
esterification.
20

10

0
Table 1 Surface area Porosity (%) Average pore Ion exchange Particle
Characteristics of ion-exchange resins m2/g diameter (nm) capacity diameter
Property A-15 A-35 A-16 Dowex (meq/g) (nmx10)
HCR-W2
Fig. 1. Properties of ion exchange resins.
Structure MR MR MR G
Matrix Styrene– Styrene– Styrene– Styrene–
divinyl- divinyl- divinyl- divinyl-
benzene benzene benzene benzene 0.45
Form H+ H+ H+ H+
0.4 STM
Crosslinking level H H L L
Exchange capacity 5.2d 5.2c 4.8c 4.8e ITM
0.35
(meq/g)
Surface area (m2/g) 53c 50c 30c – 0.3
Acidity (wt%)

Porosity (%) 33a 29a 25b –


0.25
Average pore 30c 30c 25c –
diameter (nm) 0.2
Particle diameter 0.74f 0.15–0.25g 0.38–0.45g >1.2 (%2)e
(mm) <0.42h 0.15
(%1)e
0.1
MR: macroreticular structure, G: gel type polymer, H: high, L: low.
a 0.05
[27].
b
[29].
c 0
[30]. 0 50 100
d
[31]. Reaction Time (min)
e
[32].
f
[33]. Fig. 2. Comparison of different acidity test methods with Dowex HCR-
g
[34]. W2 (at 60 °C and 2 wt% catalyst amount). STM: standard titration
h
[35]. method, ITM: indirect titration Method.
N. Özbay et al. / Fuel 87 (2008) 1789–1798 1791

100 Table 2
Comparison of strong acid ion-exchange resins for FFA esterification at
90
A-15 50 and 60 °C
80 A-35 T (°C) Catalyst XFFA (%)
A-16
70 amount (wt%)
A-15 A-35 A-16 Dowex HCR-W2
Swelling (%)

Dowex HCR-W2
60
50 1 25.4 23.0 22.1 20.8
50 2 32.6 30.6 29.9 24.2
60 1 37.2 36.5 34.1 30.4
40
2 45.7 41.9 40.1 34.7
30
Reaction time = 3 h. XFFA: conversion of FFAs in WCO.
20

10
that A-15 has superior physical properties with respect to
0 others.
45 50 55 60 65

Temperature ( oC)

Fig. 3. Swelling (%) of different types of catalysts at 50–60 °C. 2.2. FFA esterification

were used as solid acidic catalysts. Amberlyst and Dowex Esterification reactions were performed in a three-necked
HCR-W2 resins (in wet form) were dried in an oven for batch reactor (total volume 1000 ml) equipped with a reflux
12 h after washing with methanol at 110 °C and 105 °C, condenser to avoid alcohol vaporization. The three-necked
respectively. Physical properties of ion-exchange resin cat- reactor was immersed in a constant temperature water bath
alysts are summarized in Table 1. It is clearly seen in Fig. 1 equipped with a temperature controller. A plate type

50 50

45 45

40 40

35 35
FFA Conversion, (%)

FFA Conversion, (%)

30 30

25 25

20 20

15 A-15 15 A-15
A-35 A-35
10 10
A-16 A-16
5 Dowex HCR-W2 5 Dowex HCR-W2

0 0
0 50 100 150 200 0 50 100 150 200
Reaction Time (min) Reaction Time (min)

c 50 d 50

45 45

40 40
FFA Conversion, (%)

35 35
FFA Conversion, (%)

30 30

25 25

20 20

15 A-15 15 A-15
A-35 10 A-35
10
A-16 A-16
5 5
Dowex HCR-W2 Dowex HCR-W2
0 0
0 50 100 150 200 0 50 100 150 200
Reaction Time (min) Reaction Time (min)

Fig. 4. Comparison of different types of catalysts (Initial FFA levels are 0.47 (at A-15 and A-16) and 0.41 (at A-35 and Dowex HCR-W2), 20 vol%
methanol, (a) 50 °C, 1 wt% catalyst, (b) 60 °C, 1 wt% catalyst, (c) 50 °C, 2 wt% catalyst, (d) 60 °C, 2 wt% catalyst.
1792 N. Özbay et al. / Fuel 87 (2008) 1789–1798

magnetic stirrer was used to control the stirring rate of the 99.9% (Merck)). Phenolphthalein indicator was used to
reaction mixture. In order to eliminate external mass trans- determine pH change during esterification reaction. Aque-
fer effects, the stirring speed was adjusted to 1500 rpm ous solution of 0.01 N NaOH were used as a titrant. Acid-
which was much higher than values indicated in the litera- ity (A) was determined according to the equation given
ture [36]. Esterification reactions were carried out in the below:
temperature range of 50–60 °C. Resin catalysts (1 and C NaOH V NaOH MWOA
2 wt%) and 20 vol.% methanol were used in the reaction A¼ 100ðwt%Þ ð1Þ
msample 1000
mixture [37]. Sampling were done manually at reaction
times of 3, 5, 10 min and every 20 min after that. In Eq. (1) the subscript ‘‘OA” refers to oleic acid which is a
In our esterification experiments, after each sampling of type of FFA.
the reaction mixture (10 g) the new FFA concentration The conversion of FFA can be determined from the
value was evaluated based on the remaining part of the equation given below:
reaction mixture. A i  At
FFA conversion ð%Þ ¼  100 ð2Þ
Ai
2.3. Titration analysis In Eq. (2) the subscript ‘‘i” refers to initial acidity level
and ‘‘t” refers to the acidity at certain reaction time.
Reactant (WCO) and reaction mixture were analyzed by In addition to the standard analysis method, indirect
standard titration method for the evaluation of free fatty titration method in aqueous-alcohol media (described else-
acid level [1]. Before titration, a certain amount of sample where [38]) was also used (with Dowex HCR-W2 (60 °C,
(10 g) was dissolved in diethyl ether (with a purity of 2 wt%)) in order to double check the validity of acidity lev-
99.9% (Merck)) and ethanol mixture (with a purity of els during reaction.

35 35

30 30

25
FFA Conversion, (%)

FFA Conversion, (%)

25

20 20

15 15
1 wt% catalyst 1 wt% catalyst

10 2 wt% catalyst 10 2 wt% catalyst

non-catalyzed non-catalyzed
5 5

0 0
0 50 100 150 200 0 50 100 150 200
Reaction Time (min) Reaction Time (min)

c 35
d 35

30 30
FFA Conversion, (%)

FFA Conversion, (%)

25 25

20 20

15 15
1 wt% catalyst 1 wt% catalyst
10 10
2 wt% catalyst 2 wt% catalyst

5 non-catalyzed 5 non-catalyzed

0 0
0 50 100 150 200 0 50 100 150 200
Reaction Time (min) Reaction Time (min)

Fig. 5. Effect of amount of catalyst at 50 °C (A-15 (a), A-35 (b), A-16 (c), Dowex HCR-W2 (d)). Initial FFA levels are 0.47 (at A-15 and A-16), 0.41 (at A-
35, Dowex HCR-W2 and non-catalyzed), 20 vol% methanol.
N. Özbay et al. / Fuel 87 (2008) 1789–1798 1793

2.4. Swelling experiments ined and to see the reproducibility of the results FFA acid-
ity during reaction was confirmed by two different test
Before analyzing the effect of swelling on activities of methods. And also the relation between some physical
catalysts, the swelling capacities were determined as properties like crosslinking level and swelling capacity
described below: was confirmed.
Amberlysts (A-15, A-35, A-16) and Dowex HCR-W2
catalysts were dried in an oven at 110 °C and 105 °C,
respectively. Then 0.5 cm3 of treated resin was placed into 3.1. Validation of two different WCO acidity test methods
a measured tube. Methanol was added into the tube and
tempered at 50–60 °C in temperature controlled water bath The FFA acidity of WCO (during esterification with
for 2 h. The change of the ion-exchange resin volume was Dowex HCR-W2 (60 °C, 2 wt%) acidic resin) was con-
recorded. Percentage of swelling at room temperature firmed by indirect titration method in aqueous-alcohol
was calculated according to the following equation: media [38] and standard titration method [1]. The agree-
ment between these two test methods can be seen in Fig. 2.
swollen volume ðcm3 Þ
Swelling ð%Þ ¼ 3
 100 ð3Þ
initial volume ðcmÞ
3.2. Swelling capacity of ion-exchange resins

3. Results and discussion The degree of crosslinking determines the rigidity of the
resin and the extent of swelling in the presence of a polar
In this part of the study, the effect of reaction parame- component. Resins with lower crosslinking have higher
ters (the amount and type of acidic ion exchange resin swelling capacity [30]. Fig. 3 indicates the swelling capacity
and reaction temperatures) on FFA conversion were exam- of resins at 50 and 60 °C in pure methanol. The literature

50 50

45 45

40 40
FFA Conversion, (%)

FFA Conversion, (%)

35 35

30 30

25 25

20 1 wt% catalyst 20 1 wt% catalyst


15 2 wt% catalyst 15 2 wt% catalyst
10 non-catalyzed 10 non-catalyzed
5 5

0 0
0 50 100 150 200 0 50 100 150 200
Reaction Time (min) Reaction Time (min)

c 50 d 50
45 45
40 40
FFA Conversion, (%)

FFA Conversion, (%)

35 35
30 30

25 25

20 20
1 wt% catalyst 1 wt% catalyst
15 15
2 wt% catalyst 2 wt% catalyst
10 10
non-catalyzed non-catalyzed
5 5

0 0
0 50 100 150 200 0 50 100 150 200
Reaction Time (min) Reaction Time (min)

Fig. 6. Effect of amount of catalyst at 60 °C. (A-15 (a), A-35 (b), A-16 (c), Dowex HCR-W2 (d)) Initial FFA levels are 0.47 (at A-15 and A-16), 0.41 (at A-
35, Dowex HCR-W2 and non-catalyzed reaction), 20 vol% methanol.
1794 N. Özbay et al. / Fuel 87 (2008) 1789–1798

data for crosslinking level in Table 1 and the order of swell- HCR-W2. As described above, this order of catalytic activ-
ing capacities in Fig. 3 confirms the relation given above. ities is related with the size of average pore diameters and
magnitude of BET surface area (Table 1).
3.3. Comparison of different ion-exchange resins
3.4. The effect of catalyst amount
It is generally known that lower crosslinking levels will
cause higher swelling of ion-exchange resins [39]. Besides At constant reaction temperature, acidity (increase in
in spite of lower swelling capacity, if the ion-exchange resin FFA conversion) decreased with increasing catalyst
has high pore diameter it will let FFA molecules enter into amount. In the case of non-catalyzed reaction, almost no
the inner surface of the catalyst and will increase esterifica- esterification was observed (Figs. 5 and 6). In the previous
tion rate [39]. In Table 1, the structural characteristics of A- studies [5,6,13,40,41] similar behaviour was also reported.
15, A-35, A-16, Dowex HCR-W2 are given. Although A-15
has the highest crosslinking level and the lowest swelling 3.5. The effect of temperature
capacity as expected (Fig. 3.) since it has a high pore diam-
eter and superior physical properties (surface area) than When esterification reactions were carried out at tem-
others, it would exhibit highest FFA conversions as seen peratures less than the boiling point of methanol (50–
in Table 2. Finally it can be said that, high average pore 60 °C) and at atmospheric pressure, the FFA conversions
diameters (with high BET surface area) has more dominant were 46% maximum. The advantage of this process may
effect than low crosslinking level in esterification reaction. be that lower operating temperatures and pressures are
FFA conversion for different catalysts are shown in required unlike previous works [42,43].
Fig. 4. It is seen from this figure the catalytic activities of The effect of temperature on the FFA conversion at dif-
resins can be arranged as A-15 > A-35 > A-16 > Dowex ferent catalyst amounts (1 and 2 wt%) is presented in Figs.

40 40

35 35

30 30
FFA Conversion, (%)
FFA Conversion, (%)

25 25

20 20

15 15

10 10
50 °C 60 °C 50 °C 60 °C
5 5

0 0
0 50 100 150 200 0 50 100 150 200
Reaction Time (min) Reaction Time (min)

c 40
d 40

35 35

30 30
FFA Conversion, (%)
FFA Conversion, (%)

25 25

20 20

15 15

10 50 °C 60 °C 10 50 °C 60 °C

5 5

0 0
0 50 100 150 200 0 50 100 150 200
Reaction Time (min) Reaction Time (min)

Fig. 7. Effect of reaction temperature on conversion of FFA (1 wt% of A-15 (a), A-35 (b), A-16 (c), Dowex HCR-W2 (d)). Initial FFA levels are 0.47 (at
A-15 and A-16), 0.41 (at A-35, Dowex HCR-W2), 20 vol% methanol.
N. Özbay et al. / Fuel 87 (2008) 1789–1798 1795

7 and 8. Because of the increase in reaction rate and equi- 60 °C for 2 wt% A-15 catalyst. In the literature, Sendziki-
librium constant for an endothermic reaction, it was seen ene et al. [44] have achieved nearly 50% conversion for
that FFA levels decreased with increasing reaction temper- 1% homogenous acidic catalyst (H2SO4) at 50 °C, so it is
ature. This behaviour was independent of the type and clearly seen that A-15 heterogenous catalyst can take place
amount of catalyst [5,40]. of conventional homogenous catalyst. Since the perfor-
mance levels of the two types of catalysts mentioned above
3.6. Effect of catalyst type on reaction rate are comparable, it is believed that they will show resem-
blance at higher FFA levels.
The rate of change of FFA conversion can be seen in
Figs. 9 and 10, it was seen that the reaction rate drops to 3.8. The role of internal diffusion on reaction rate
zero after 40 min for all type of catalysts. In the literature,
the FFA esterification reaction is completed in 15 min for In order to understand the effect of internal diffusion, an
homogenous catalyst (H2SO4) [44] and 100 min for Relite additional run was performed on finely powdered (<6 lm)
CFS (acidic ion exchange polymeric resin) [41]. A-15, A-16, A-35, Dowex HCR-W2 catalysts (2 wt%) at
60 °C reaction temperature. In Fig. 11 it can be seen that
3.7. Maximum performance level comparison with there is no significant difference (<10%) in FFA conver-
conventional catalyst sions between powdered and particle catalysts. In addition,
as we have mentioned before (in Fig. 1) A-15 has better
All the experiments were conducted with an initial FFA physical properties (particle diameter, surface area etc.)
concentration of 2.54 mol/L. After the esterification reac- than the other type of resins which may decrease the inter-
tion FFA conversions were observed as 45% maximum at nal mass transfer resistance.

50 50

45 45

40 40
FFA Conversion, (%)
FFA Conversion, (%)

35 35

30 30

25 25

20 20

15 15

10 50 °C 60 °C 10 50 °C 60 °C

5 5

0 0
0 50 100 150 200 0 50 100 150 200
Reaction Time (min) Reaction Time (min)

c 50
d 50

45 45

40 40

35 35
FFA Conversion, (%)

FFA Conversion, (%)

30 30

25 25

20 20

15 15

10 50 °C 60 °C 10 50 °C 60 °C

5 5

0 0
0 50 100 150 200 0 50 100 150 200
Reaction Time (min) Reaction Time (min)

Fig. 8. Effect of reaction temperature on conversion of FFA (2 wt% of A-15 (a), A-35 (b), A-16 (c), Dowex HCR-W2 (d)). Initial FFA levels are 0.47 (at
A-15 and A-16), 0.41 (at A-35, Dowex HCR-W2 and non-catalyzed reaction), 20 vol% methanol.
1796 N. Özbay et al. / Fuel 87 (2008) 1789–1798

0,035 0,035

0,03 0,03

0,025 0,025
50 °C 60 °C 50 °C 60 °C

(wt%/min)

(wt%/min)
Δ(FFA)/Δ t

Δ(FFA)/Δ t
0,02 0,02

0,015 0,015

0,01 0,01

0,005 0,005

0 0
0 50 100 150 200 0 50 100 150 200
t (min) t (min)

c 0,035
d 0,035

0,03 0,03

0,025 0,025
50 °C 60 °C 50 °C 60 °C
(wt%/min)

(wt%/min)
Δ(FFA)/Δ t

Δ(FFA)/Δ t
0,02 0,02

0,015 0,015

0,01 0,01

0,005 0,005

0 0
0 50 100 150 200 0 50 100 150 200
t (min) t (min)

Fig. 9. The rate of change of FFA conversion (1 wt% catalyst; A-15 (a), A-35 (b), A-16 (c), Dowex HCR-W2 (d)).

0,045 0,035

0,04
0,03
0,035
0,025
0,03 50 °C 60°C 50 °C 60°C
(wt%/min)

(wt%/min)
Δ(FFA)/Δt

Δ(FFA)/Δt

0,025 0,02

0,02 0,015

0,015
0,01
0,01
0,005
0,005

0 0
0 50 100 150 200 0 50 100 150 200
t (min) t (min)

0,035 d 0,035

0,03 0,03
50 °C 60°C 50 °C 60°C
0,025 0,025
(wt%/min)

(wt%/min)

0,02
Δ(FFA)/Δt
Δ(FFA)/Δt

0,02

0,015 0,015

0,01 0,01

0,005 0,005

0 0
0 50 100 150 200 0 50 100 150 200
t (min) t (min)

Fig. 10. The rate of change of FFA conversion (2 wt% catalyst; A-15 (a), A-35 (b), A-16 (c), Dowex HCR-W2 (d)).
N. Özbay et al. / Fuel 87 (2008) 1789–1798 1797

80 80

70 70

60 60

FFA Conversion, (%)

FFA Conversion, (%)


50 50

40 40

30 30
Powder Particle Powder Particle
20 20

10 10

0 0
0 50 100 150 200 0 50 100 150 200
Reaction Time (min) Reaction Time (min)

c 80

70

60
FFA Conversion, (%)

50

40

30

20
Powder Particle

10

0
0 50 100 150 200

Reaction Time (min)

Fig. 11. Evolution of FFA conversion as a function of time for different runs ( powder, j particle).

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