An Integrated Process Analysis for Producing Glycerol Carbonate from CO2 and Glycerol

Glycerol carbonate (GC) is one of the most attractive green chemicals involved in several applications such as polymer synthesis, e. g., the production of polyurethanes and polycarbonates. This relevant chemical can be produced, in a green way, using CO2 (from carbon capture) and glycerol (a byproduct from biodiesel manufacturing). Therefore, in this work, a comprehensive analysis of the GC production process is conducted based on the following synthesis route: urea-dimethyl carbonate-GC using carbon dioxide and glycerol as the main raw materials where the synthesis pathway was efficiently integrated using Aspen Plus. A techno-economic analysis was performed in order to estimate the required capital investment and operating cost for the whole GC process, providing insights on individual capital cost requirements for the urea, dimethyl carbonate, and GC production sections. A total capital cost of $192.1 MM, and a total operating cost of $225.7 MM/y were estimated for the process. The total annualized cost was estimated as $1,558 USD/t of GC produced, competitive with current market price.

E-waste derived silica-alumina for eco-friendly and inexpensive Mg-Al-Ti photocatalyst towards glycerol carbonate (electrolyte) synthesis: Process optimization and LCA

Valorization ofe-waste, i.e. waste printed circuit board (WPCB) through mechano-chemical activation to obtain silica as the catalyst support and alumina as the catalyst precursor for eco-friendly synthesis of inexpensive highly proficient photocatalyst has been explored. The WPCB derived silica-supported layered double oxide photocatalyst (MATLS_W) and its counterpart (MATLS_C) involving commercial silica and alumina precursors were synthesized through the wet-impregnation method under energy-efficient solar simulated quartz halogen lamp (SSQHL) irradiations to improve its photocatalytic properties compared to conventional methods. The prepared MATLS_Wpossessed a significantly low band-gap-energy (1.58 eV) that rendered efficient photocatalysis in the green-synthesis of glycerol carbonate (GC) (an effective electrolyte). The catalytic performance of the optimal MATLS_Wresulted in a superior yield of GC (98.68%) compared to that rendered by MATLS_Ccatalyst (GC yield: 96.56%) at optimal process conditions. Detailed life cycle assessment (LCA) of the entire process (deploying Ecoinvent 3.5 database) dictated conducive environmental impacts concerning 1 kg GC synthesis alongside a scale-up study for 1 MT GC synthesis encompassing silica-alumina extraction from WPCB, MATLS_W preparation, and employment of SSQHL-radiated batch reactor (SSQHLBR) (56.64% less energy consumption than conventional). The overall process deploying the novel MATLS_Win conjunction with the effectual reactor demonstrated superiority over the conventional GC synthesis process through appreciable reductions of environmental impact parameters, namely GWP, FDP, and HTP by 5.78%, 3.60%, and 5.72% respectively. The developed green process for e-waste utilization can procreate an effective waste management protocol towards a cleaner world.

Highly active and efficient Cu-based hydrotalcite-like structured materials as reusable heterogeneous catalysts used for transcarbonation reaction

A series of robust and efficient Cu-Al hydrotalcite-like compounds (HTLc) as catalysts were prepared by the simple precipitation method with different Cu/Al molar ratios and investigated for the transcarbonation of glycerol with dimethyl carbonate (DMC) for glycerol carbonate (GC) synthesis in a batch reactor. The structural and textural properties of the Cu-Al (HTLc) catalysts were analyzed by several methods like N₂-sorption, SEM-EDX/TEM, XRD, FTIR, CO₂-TPD, TGA/DTA and ICP-OES. It was found that the transcarbonation of glycerol is directly dependent on the strong basic sites of the catalysts. The Cu/Al molar ratio has easily tuned the glycerol conversion and the GC yield. Among all synthesized catalysts, the Copper-Aluminum (3Cu-Al@500) catalyst showed excellent catalytic activity for a glycerol conversion (96%) and a GC yield (86%) with reaction rate (irrespective to glycerol) of approximately 0.106 mol L^-1 h^-1. Furthermore, the optimization of the reaction conditions (i.e. molar ratio of the reactants, catalyst mass, reaction time and temperature) and the reusability of the 3Cu-Al@500 catalyst for glycerol conversion and GC yield with TOF value were studied. In addition, the effect of stirring speed and particle size on the minimization of external and internal mass transfer resistance, respectively, was investigated.

A review on recent trends in reactor systems and azeotrope separation strategies for catalytic conversion of biodiesel-derived glycerol

The increasing demand for biodiesel (BD) as a renewable and sustainable energy source has impelled the generation of abundant and low-cost byproduct glycerol, which accounts for 10 wt% of total BD production and requires urgent utilization. The transesterification reaction, which utilizes glycerol and dimethyl carbonate (DMC) to synthesize valuable glycerol carbonate (GC) is an established reaction pathway to valorize oversupplied glycerol. Commercialization of inexpensive GC is constrained by the nature, stability, and basicity of applied catalyst, reaction conditions, types of the reactor system and separation methods of reaction products. This study presents a review and diversity of recent reports on reactor systems and DMC-methanol azeotrope separation strategies explored in GC synthesis from biodiesel-derived glycerol. Also, recent trends on heterogeneous catalysts, their performance, and the effects of reaction conditions were presented. Conducted studies revealed that the choice for reactor systems is constrained by factors such as energy consumption and operational safety and a significant mild reaction conditions could be realized using a microwave reactor. Furthermore, the reactive-extractive distillation and pervaporation processes showed high energy-efficiency and appreciable separation of DMC-methanol azeotrope. Thus, the development of stable catalyst and process intensification to fabricate an integrated reactor-separation system with high energy efficiency are fundamental and must be explored. This study portrays the recent research effort made in this direction and the limitations that require urgent attention.

Esterification of glycerol from biodiesel production to glycerol carbonate in non-catalytic supercritical dimethyl carbonate

Conversion of glycerol from biodiesel production to glycerol carbonate was studied by esterification with dimethyl carbonate in a non-catalytic supercritical condition. It was found that in a non-catalytic supercritical condition, glycerol at higher purity gave higher yield of glycerol carbonate at 98 wt% after reaction at 300 °C/20–40 MPa/15 min. The yield of glycerol carbonate was observed to increase with molar ratio, temperature, pressure and time until a certain equilibrium limit. The existence of impurities such as water and remnants of alkaline catalyst in crude glycerol will direct the reaction to produce glycidol. Although impurities might not be desirable, the non-catalytic supercritical dimethyl carbonate could be an alternative method for conversion of glycerol from biodiesel production to value-added glycerol carbonate.Graphical abstract

Ultrasound assisted enzyme catalyzed synthesis of glycerol carbonate from glycerol and dimethyl carbonate

The present work illustrates the transesterification of glycerol to glycerol carbonate (GlyC) from dimethyl carbonate (DMC) using commercial immobilized lipase (Novozym 435) under ultrasonic irradiation. The experiments were performed in a batch reactor placed in an ultrasonic water bath using a sequence of experimental protocol to evaluate the effects of temperature, molar ratios of substrates, enzyme loading, duty cycle and ultrasound power on the conversion of glycerol to GlyC. It has been found that ultrasound-assisted lipase-catalyzed transesterification of glycerol would be a potential alternative to conventional alkali-catalyzed method, as high conversion (99.75%) was obtained at mild operating conditions: molar ratio of DMC to glycerol 3:1, catalyst amount of 13% (w/w), lower power input (100W), duty cycle 50% and temperature (60°C) in a relatively short reaction time (4h) using Novozym 435 as catalyst. Ultrasound reduces the reaction time up to 4h as compared to conventional stirring method (14h) catalyzed by Novozym 435. The repeated use of the catalyst under the optimum experimental condition resulted in decay in both enzyme activity and product conversion.

Boosting the value of biodiesel byproduct by the non-catalytic transesterification of dimethyl carbonate via a continuous flow system under ambient pressure

Transformation of coconut oil into biodiesel by using dimethyl carbonate (DMC) via a non-catalytic transesterification reaction under ambient pressure was investigated in this study. The non-catalytic transformation to biodiesel was achieved by means of a heterogeneous reaction between liquid triglycerides and gas phase DMC. The reaction was enhanced in the presence of porous material due to its intrinsic physical properties such as tortuosity and absorption/adsorption. The numerous pores in the material served as micro reaction chambers and ensured that there was enough contact time between the liquid triglycerides and the gaseous DMC, which enabled the completion of the transesterification. The highest fatty acid methyl esters (FAMEs) yield achieved was 98±0.5% within 1-2min at a temperature of 360-450°C under ambient pressure. The fast reaction rates made it possible to convert the lipid feedstock into biodiesel via a continuous flow system without the application of increased pressure. This suggested that the commonly used supercritical conditions could be avoided, resulting in huge cost benefits for biodiesel production. In addition, the high value of the byproduct from the transesterification of the lipid feedstock with DMC suggested that the production biodiesel using this method could be more economically competitive. Finally, the basic properties of biodiesel derived from the non-catalytic conversion of rapeseed oil with DMC were summarised.

KR-1 biomass

Fatty acid methyl esters (FAMEs) and glycerol carbonate were simultaneously prepared from Chlorella sp. KR-1 containing 40.9% (w/w) lipid using a reactive extraction method with dimethyl carbonate (DMC). DMC was used as lipid extraction agent, acyl acceptor for transesterification of the extracted triglycerides, substrate for glycerol carbonate synthesis from glycerol, and reaction medium for the solvent-free reaction system. For 1g of biomass, 367.31 mg of FAMEs and 16.73 mg of glycerol carbonate were obtained under the optimized conditions: DMC to biomass ratio of 10:1 (v/w), water content of 0.5% (v/v), and Novozyme 435 to biomass ratio of 20% (w/w) at 70°C for 24h. The amount of residual glycerol was only in the range of 1-2.5mg. Compared to conventional method, the cost of FAME production with the proposed technique could be reduced by combining lipid extraction with transesterification and omitting the extraction solvent recovery process.