Efficient conversion of brown grease produced by municipal wastewater treatment plant into biofuel using aluminium chloride hexahydrate under very mild conditions

Life Cycle Assessment of a system for the extraction and transformation of Waste Water Treatment Sludge (WWTS)-derived lipids into biodiesel

In recent years, the demand for biofuels has been growing exponentially, as has the interest in biodiesel produced from organic matrices. Particularly interesting, due to its economic and environmental advantages, is the use of the lipids present in sewage sludge as a raw material for the synthesis of biodiesel. The possible processes of this biodiesel synthesis, starting from lipid matter, are represented by the conventional process with sulfuric acid, by the process with aluminium chloride hexahydrate and by processes that use solid catalysts such as those consisting of mixed metal oxides, functionalized halloysites, mesoporous perovskite and functionalized silicas. In literature there are numerous Life Cycle Assessment (LCA) studies concerning biodiesel production systems, but not many studies consider processes that start from sewage sludge and that use solid catalysts. In addition, no LCA studies were reported on solid acid catalysts nor on those based on mixed metal oxides which present some precious advantages, over the homogeneous analogous ones, such as higher recyclability, prevention of foams and corrosion phenomena, and an easier separation and purification of biodiesel product. This research work reports the results of a comparative LCA study applied to a system that uses a solvent free pilot plant for the extraction and transformation of lipids from sewage sludge via seven different scenarios that differ in the type of catalyst used. The biodiesel synthesis scenario using aluminium chloride hexahydrate as catalyst has the best environmental profile. Biodiesel synthesis scenarios using solid catalysts are worse due to higher methanol consumption which requires higher electricity consumption. The worst scenario is the one using functionalized halloysites. Further future developments of the research require the passage from the pilot scale to the industrial scale in order to obtain environmental results to be used for a more reliable comparison with the literature data.

A comprehensive review on nanocatalysts and nanobiocatalysts for biodiesel production in Indonesia, Malaysia, Brazil and USA

Biodiesel is an alternative to fossil-derived diesel with similar properties and several environmental benefits. Biodiesel production using conventional catalysts such as homogeneous, heterogeneous, or enzymatic catalysts faces a problem regarding catalysts deactivation after repeated reaction cycles. Heterogeneous nanocatalysts and nanobiocatalysts (enzymes) have shown better advantages due to higher activity, recyclability, larger surface area, and improved active sites. Despite a large number of studies on this subject, there are still challenges regarding its stability, recyclability, and scale-up processes for biodiesel production. Therefore, the purpose of this study is to review current modifications and role of nanocatalysts and nanobiocatalysts and also to observe effect of various parameters on biodiesel production. Nanocatalysts and nanobiocatalysts demonstrate long-term stability due to strong Brønsted-Lewis acidity, larger active spots and better accessibility leading to enhancethe biodiesel production. Incorporation of metal supporting positively contributes to shorten the reaction time and enhance the longer reusability. Furthermore, proper operating parameters play a vital role to optimize the biodiesel productivity in the commercial scale process due to higher conversion, yield and selectivity with the lower process cost. This article also analyses the relationship between different types of feedstocks towards the quality and quantity of biodiesel production. Crude palm oil is convinced as the most prospective and promising feedstock due to massive production, low cost, and easily available. It also evaluates key factors and technologies for biodiesel production in Indonesia, Malaysia, Brazil, and the USA as the biggest biodiesel production supply.

High strength composites from low-value animal coproducts and industrial waste sulfur

Herein we report high strength composites prepared by reaction of sulfur, plant oils (either canola oil or sunflower oil) and brown grease. Brown grease is a high-volume, low value animal fat rendering coproduct that represents one of the most underutilized products of agricultural animal processing. Chemically, brown grease is primarily comprised of triglycerides and fatty acids. The inverse vulcanization of the unsaturated units in triglycerides/fatty acids upon their reaction with sulfur yields CanBG_x or SunBG_x (x = wt% sulfur, varied from 85–90%). These composites were characterized by infrared spectroscopy, dynamic mechanical analysis (DMA), mechanical test stand analysis, elemental analysis, and powder X-ray diffraction. CanBG_x and SunBG_x composites exhibit impressive compressive strengths (28.7–35.9 MPa) when compared to other materials such as Portland cement, for which a compressive strength of ≥17 MPa is required for residential building. Stress–strain analysis revealed high flexural strengths of 6.5–8.5 MPa for CanBG_x and SunBG_x composites as well, again exceeding the range of ∼2–5 MPa for ordinary Portland cements. The thermal properties of the composites were assessed by thermogravimetric analysis, revealing decomposition temperatures ranging from 223–226 °C, and by differential scanning calorimetry. These composites represent a promising new application for low value animal coproducts having limited value to be used as organic crosslinkers in the atom-efficient inverse vulcanization process to yield high sulfur-content materials that have impressive mechanical properties.

Herein we report high strength composites prepared by reaction of sulfur, plant oils (either canola oil or sunflower oil) and brown grease.

A review of sustainable biodiesel production using biomass derived heterogeneous catalysts

The production of biodiesel through chemical production processes of transesterification reaction depends on suitable catalysts to hasten the chemical reactions. Therefore, the initial selection of catalysts is critical although it is also dependent on the quantity of free fatty acids in a given sample of oil. Earlier forms of biodiesel production processes relied on homogeneous catalysts, which have undesirable effects such as toxicity, high flammability, corrosion, by-products such as soap and glycerol, and high wastewater. Heterogeneous catalysts overcome most of these problems. Recent developments involve novel approaches using biomass and bio-waste resource derived heterogeneous catalysts. These catalysts are renewable, non-toxic, reusable, offer high catalytic activity and stability in both acidic and base conditions, and show high tolerance properties to water. This review work critically reviews biomass-based heterogeneous catalysts, especially those utilized in sustainable production of biofuel and biodiesel. This review examines the sustainability of these catalysts in literature in terms of small-scale laboratory and industrial applications in large-scale biodiesel and biofuel production. Furthermore, this work will critically review natural heterogeneous biomass waste and bio-waste catalysts in relation to upcoming nanotechnologies. Finally, this work will review the gaps identified in the literature for heterogeneous catalysts derived from biomass and other biocatalysts with a view to identifying future prospects for heterogeneous catalysts.

A Novel and Efficient Method for the Synthesis of Methyl (R)-10-Hydroxystearate and FAMEs from Sewage Scum

In this work, the transesterification of methyl estolides (ME) extracted from the lipid component present in the sewage scum was investigated. Methyl 10-(R)-hydroxystearate (Me-10-HSA) and Fatty Acid Methyl Esters (FAMEs) were obtained in a single step. A three-level and four factorial Box–Behnken experimental design were used to study the effects of methanol amounts, catalyst, temperature, and reaction time on the transesterification reaction using aluminum chloride hexahydrate (AlCl3·6H2O) or hydrochloric acid (HCl) as catalysts. AlCl3·6H2O was found quite active as well as conventional homogeneous acid catalysts as HCl. In both cases, a complete conversion of ME into Me-10-HSA and FAMEs was observed. The products were isolated, quantified, and fully characterized. At the end of the process, Me-10-HSA (32.3%wt) was purified through a chromatographic separation and analyzed by NMR. The high enantiomeric excess (ee > 92%) of the R-enantiomer isomer opens a new scenario for the valorization of sewage scum.

Intensification of Processes for the Production of Ethyl Levulinate Using AlCl3·6H2O

A process for obtaining ethyl levulinate through the direct esterification of levulinic acid and ethanol using AlCl3·6H2O as a catalyst was investigated. AlCl3·6H2O was very active in promoting the reaction and, the correspondent kinetic and thermodynamic data were determined. The reaction followed a homogeneous second-order reversible reaction model: in the temperature range of 318–348 K, Ea was 56.3 kJ·K−1·mol−1, whereas Keq was in the field 2.37–3.31. The activity of AlCl3·6H2O was comparable to that of conventional mineral acids. Besides, AlCl3·6H2O also induced a separation of phases in which ethyl levulinate resulted mainly (>98 wt%) dissolved into the organic upper layer, well separated by most of the co-formed water, which decanted in the bottom. The catalyst resulted wholly dissolved into the aqueous phase (>95 wt%), allowing at the end of a reaction cycle, complete recovery, and possible reuse for several runs. With the increase of the AlCl3·6H2O content (from 1 to 5 mol%), the reaction proceeded fast, and the phases’ separation improved. Such a behavior eventually results in an intensification of processes of reaction and separation of products and catalyst in a single step. The use of AlCl3·6H2O leads to a significant reduction of energy consumed for the final achievement of ethyl levulinate, and a simplification of line-processes can be achieved.

Production of Biodiesel from Brown Grease

Among the renewable energy sources is biodiesel. This fuel is usually produced by catalytic transesterification of vegetable oils and animal fats under heating and pressure. Brown grease is a mixture of oils, fats, solids and detergents from food industry wastes that is captured in grease traps. Brown grease is classified as waste and must be treated and disposed of appropriately. It contains oils and fats that can be converted into biodiesel. However, the high concentration of free fatty acids in brown grease does not enable the use of conventional biodiesel production schemes. This study proposes a new scheme for biodiesel production from brown grease. In addition, conditions for the effective separation of a fat phase from brown grease were tested, and the composition of a fatty phase was determined for several grease traps. Esterification and transesterification of brown grease lipids were carried out with methanol, where the Lewis acids BF3 and AlCl3 were used as catalysts and the reaction was activated by ultrasound. The results show that biodiesel can be obtained from brown grease by esterification and transesterification within several minutes under ultrasonic activation at room temperature. These results open prospects for the development of efficient, low-cost and environmentally friendly biodiesel production.

Biodiesel Production by Acid Methanolysis of Slaughterhouse Sludge Cake

Simple Summary

Excessive sludge in the wastewater treatment basins has to be removed periodically to ensure good water quality of the effluent. This study aims to evaluate the feasibility of biodiesel production by acid methanolysis of slaughterhouse sludge cake. Experimental and analytical results showed that acid methanolysis of sludge cake was one of the feasible and practical options to recycle sludge waste and produce renewable energy.

Abstract

Biosludge is a normal form of accumulating microbial populations inside the sewage or wastewater treatment facilities. Excessive sludge in the wastewater treatment basins has to be removed periodically to ensure good water quality of the effluent. This study aims to evaluate the feasibility of biodiesel production by transesterification of slaughterhouse sludge cake. The sludge cake was collected from a selected commercial slaughterhouse and transesterified with methanol, n-hexane, and acids (e.g., sulfuric acid or hydrochloric acid) at 55 °C. Three acid concentrations (2%, 4%, and 8%, v/v) in methanol under four reaction time periods (4, 8, 16, and 24 h) were applied. Results showed that the highest accumulated fatty acid methyl ester (FAME) yields of 2.51 ± 0.08% and 2.27 ± 0.09% were achieved when 8% (v/v) of H₂SO₄ or HCl were added in a 4 h reaction time, respectively. Methyl esters of palmitic acid (C16:0), palmitoleic acid (C16:1), stearic acid (C18:0), and oleic acid (C18:1n9c) were the major components of biodiesel from acid methanolysis of slaughterhouse sludge cake. Experimental and analytical results of acid methanolysis of slaughterhouse sludge cake showed that acid methanolysis of sludge cake was one of the feasible and practical options to recycle sludge waste and produce renewable energy.

Lewis-Brønsted acid catalysed ethanolysis of the organic fraction of municipal solid waste for efficient production of biofuels

A combined Lewis-Brønsted acid ethanolysis of sugars was thoroughly investigated with the aim of producing ethyl levulinate (EL) in a single step. Ethanolysis carried out at 453 K for 4 h using H₂SO₄ (1 wt%) and AlCl₃·6H₂O (30 mol % with respect to sugars) produced a yield of 60 mol % of EL respect to glucose and starch. Such optimised conditions were positively applied directly on different food waste, preliminarily characterised and found to be mainly composed by simple (10-15%) and relatively complex sugars (20-60%), besides proteins (6-10%) and lipids (4-10%), even in their wet form. The catalytic system resulted robust enough to the point that the copresence of proteins, lignin, lipids and mineral salts not only did not negatively affect the overall reactivity, but resulted efficiently converted into soluble species, and specifically, into other liquid biofuels of different nature.

A solvent-free approach to extract the lipid fraction from sewer grease for biodiesel production

Fats, oils and greases (FOG) are the number one cause of sewer pipe blockage and have been mostly disposed of as a waste until recently. This study investigated a low cost and environmentally friendly approach to extract the lipid fraction (fatty acids and glycerides for biodiesel production) from sewer grease (SG), i.e., FOGs obtained from wastewater treatment plants (WWTPs). The lipid fraction of the sewer grease was primarily in the form of free fatty acid (FFA), at 20.7wt%. An innovative solvent-free extraction approach was developed using waste cooking oil (WCO) to overcome the challenges of emulsion, impurities and high moisture content of the sewer grease. A 95% extraction yield of sewer grease was achieved under the optimum operating condition of 3.2:1 WCO-SG ratio (wt/wt), 70°C and 240min. In addition, the reusability of the WCO was also investigated. WCO can be used two to three times for sewer grease extraction with more than 90% extraction efficiency.

Scum sludge as a potential feedstock for biodiesel production from wastewater treatment plants

The main goal of this study was to compare the component and yield of biodiesel obtained by different methods from different sludge in a wastewater treatment plant. Biodiesel was produced by ex-situ and in-situ transesterification of scum, primary and secondary sludge respectively. Results showed that scum sludge had a higher calorific value and neutral lipid than that of primary and secondary sludge. The lipid yield accounted for one-third of the dried scum sludge and the maximum yield attained 22.7% under in-situ transesterification. Furthermore the gas chromatography analysis of fatty acid methyl esters (FAMEs) revealed that all sludge contained a significant amount of palmitic acid (C16:0) and oleic acid (C18:1) regardless of extraction solvents and sludge types used. However, the difference lay in that oleic acid methyl ester was the dominant component in FAMEs produced from scum sludge while palmitic acid methyl ester was the dominant component in FAMEs from primary and secondary sludge. In addition, the percentage of unsaturated fatty acid ester in FAMEs from scum sludge accounted for 57.5-64.1% of the total esters, which was higher than the equivalent derived from primary and secondary sludge. In brief, scum sludge is a potential feedstock for the production of biodiesel and more work is needed in the future.

Fat, oil and grease waste from municipal wastewater: characterization, activation and sustainable conversion into biofuel

Fat, oil and grease (FOG) recovered by the oil/water separator of a wastewater treatment plant (WWTP) were sampled, characterized, activated and converted into biofuel. Free acids (50-55%) and fatty soaps (26-32%) not only composed the main components, but they were also easily separable from the starting waste. The respective free fatty acid profiles were gas-chromatographically evaluated, interestingly verifying that free acids had a different profile (mainly oleic acid) with respect to the soapy fraction (saturated fatty acids were dominant). The inorganic composition was also determined for soaps, confirming that calcium is the most commonly present metal. The chemical activation of this fatty waste was made possible by converting the starting soaps into the respective free fatty acids by using formic acid as activator, coproducing the relevant formates. The activated fatty matter was then converted into biofuel through direct esterification under very mild conditions (345 K, atmospheric pressure) and obtaining thermodynamic conversion in less than 2 h. The process was easily scaled up, isolating at the end pure biodiesel (purity > 96%) through distillation under vacuum, providing a final product conformed to commercial purposes.