1. OLEOCHEMICAL METHYL ESTER FROM
RBD PALM KERNEL OIL
By :
SAJJAD KHUDHUR – P81540

2. Oleochemicals
The term ― oleochemicals refers to any chemical compounds derived from natural oils and fats of both plant and animal origins. Prior to 1980, almost 95% of natural oils and fats are used in food application while only a small percentage is applied in non-food purposes such as soap manufacturing and drying oils Oleochemicals are widely used to manufacture products such as soaps and detergents, cosmetics and personal care products, lubricants and greases, drying oil, surface coatings and polymers, and biofuels

3. The advantages of using oleochemicals over petrochemicals are:
Oleochemicals are derived from renewable resources .
Oleochemical production requires less energy and causes less pollution .
Oleochemicals are fully non-toxic .

4. What is palm oil? Palm oil is an edible vegetable oil derived from pulping the fruit of oil palms originally native to Africa. Palm oil is commonly used as a cooking oil in Africa, Southeast Asia and parts of Brazil and its consumption is on the rise worldwide. Palm oil is semi-solid at room temperatures .

5. Palm & Palm kernel oil

6. Productions from Palm oil

7. Methyl Esters
Methyl esters, often called fatty acid methyl esters (FAME) are a type of fatty acid ester that are derived from the transesterification .
Tranesterification is the displacement of alcohol from an ester by another alcohol in a process
homogeneous base catalysts such as sodium hydroxide (NaOH) or another strong base such as potassium hydroxide (KOH) is used in this transesterification process. These inexpensive catalysts shorten the reaction time and they are easy to handle in terms of transportation and storage
Some feedstocks require a pretreatment reaction before they can go through the transesterification process

8. Storage
Store in closed containers between 13°C and 49°C, in well ventilated areas protected from sunlight. Do not store close to flames or sparks. This material is NOT dangerous for air, ground or marine transport
Packaging : PE , DR , ISO ,

9. Feedstocks
These feedstocks include most vegetable oils (soybean oil, jatropha oil, rapeseed oil, palm oil, sunflower oil, corn oil, peanut oil, canola oil, and cottonseed oil) and animal fats .They can also be produced from other sources like waste cooking oil, greases
Waste Cooking Oils
This type of feedstocks is of low cost, making them attractive for FAME production . Using waste cooking oil, especially those that cannot be treated, will reduce the environment pollution. Waste cooking oil conversion into FAME through the transesterification process

10. Advantages of Methyl Esters
2. Animal Fats
Animal fats are received from chicken, and fish. Tallow and animal meats which are not allowed to be used as food can be used as methyl ester production feedstock.
Advantages of Methyl Esters
Lower Energy Consumption
Less Expensive Equipment
Easier to Distill-Fractionate
Easier to Transport

11. APPLICATION OF PRODUCTS
1. FAME as Biodiesel
The flow and combustion properties of biodiesel are almost similar to petroleum-based diesel. As a point of comparison, pure biodiesel (B100) releases about 90% of the energy that normal diesel does. Hence, it is expected that the engine performance is nearly the same
Biodiesel combustion is environmentally benign, offers good storage properties, bio-renewable
These characteristics of biodiesel reduce the noxious emissions in the exhaust gas compared to petro-diesel.

12. Values for the American Society for Testing and Materials (ASTM) Standards of Maximum Allowed Quantities in Diesel and Biodiesel

13. 2. FAME as Raw Materials for Other Products
these chemicals also have potential as intermediates to produce a number of oleochemical derivatives such as fatty alcohols, sucrose esters, alkanolamides, soaps, alpha-sulfonated methyl esters, and other fatty esters as shown below

14. 3. Methyl Octanoate/Decanoate (Light Cut: C8-10)
Crude methyl esters can be fractionated to separate the C8-C10 fraction, known as plasticizer range. The plasticizer range methyl ester is a liquid with good dissolving power. It can be used in a limited way as a solvent for printing inks
Methyl Laurate/Myristate (Middle Cut: C12-14)
Middle cut methyl esters are most preferred for detergent use . The C12-C14 methyl esters find special application as lubricant additives
Methyl Palmitate/Oleate (Heavy Cut: C16-18)
Most heavy-cut (C16-18) methyl ester is consumed as either biodiesel or in lubricant . It is also used as a solvent, as a plasticizer, solvent for solid active ingredients in products as diverse as body lotions, facial self-tanning creams, fade creams, hair conditioners and styling creams

15. Glycerine
Glycerine, also called glycerol, is a common by-product in the methyl esters manufacturing process . Glycerine is a nontoxic, edible, and biodegradable compound . It is widely used in the manufacture of drugs, plasticizers for medicine capsules , Besides, glycerine is an excellent solvent of iodine, bromine, phenol, tannins, alkaloids

16. MARKET SURVEY
the global demand for the oleochemicals will exceed the global production capacity.
Global Supply & Demand for Oleochemicals
it is expected to grow at 6% per year over the next five years . The Asia-Pacific led by Malaysia, China, and Indonesia, accounts for 68% or around two-thirds of the global oleochemicals market and this is expected to grow at 8% per year over the next five years

17. Geographic breakdown of global oleochemicals market and projected growth 2013-2018

18. Major ASEAN oleochemical producers

19. methyl ester has started to gain world‘s attention and it has increasingly
Basic Oleochemicals exported from Malaysia (in tonnes)

20. Raw Material Supply in Malaysia
the uses of crude palm oil (CPO), processed palm oil (PPO), crude palm kernel oil (CPKO), and processed palm kernel oil (PPKO) in oleochemical industry has increased over the recent years and it is expected to rise for the following years due to the increasing demand of oleochemical products.
The usage of palm oil and palm kernel oil for oleochemical industry (tonnes)
The refined, bleached, and deodorized palm kernel oil (RBDPKO) is categorized as one of the processed palm kernel oil (PPKO).

21. List of RBD Palm Kernel Oil Supplier in Malaysia

22. Competitors
Methyl Ester Producers in Malaysia

23. Alkali/Base-catalyzed Transesterification :
SCREENING OF SYNTHESIS ROUTE
Alkali/Base-catalyzed Transesterification :
A base catalyst is a chemical with a pH value greater than 7.. Sodium hydroxide (NaOH), potassium hydroxide (KOH), and sodium methoxide (CH3ONa) are the most common homogeneous base catalysts employed during alkaline transesterification . The base catalyzed process is the most commonly used because of its relative ease. It can be performed at low temperature and pressure and yields high conversion (98%) within a short time Homogeneous catalysts have been used industrially for methyl ester production

24. Acid-catalyzed Transesterification
Most commonly used acids are strong acids like sulphuric, sulphonic, phosphoric, and hydrochloric acids Acid-catalyzed transesterification processes are not as popular as the base-catalyzed processes, mainly because strong acids are corrosive and the processes are too slow. Several reactions may be required in order to achieve high conversion. It has been stated that acid-catalyzed reaction may be 4000 times slower than the base catalyst process
3. Non-catalytic Transesterification
To avoid catalyst drawbacks transesterification process was suggested . As a result of catalyst absence, purification of the products of the transesterification reaction is much simpler and environmentally friendly compared to the previously mentioned processes.
They reported that conventional catalyst required 1 hr to convert palm oil to FAME,
Compared to catalytic reactions, SCM reactions are fast and can achieve high conversions in a very short time. However, the reaction requires higher temperatures, pressures, and alcohol to oil molar ratio in comparison to catalytic transesterification, which result in high production cost

25. 4. Enzymatic Transesterification
Has the advantage of having low operating conditions and high product purity. Enzymatic transesterification can be carried out at 35 to 45°C . On the other hand, the major disadvantages of the enzymatic transesterification are its slower reaction rate and possible enzyme inactivation by methanol .

26. Comparison of various catalysts for transesterification
Screening of Catalyst Types
The transesterification reaction can be catalyzed by acids, bases or enzymes. Besides, acid and base catalysts can be further categorised into homogeneneous and heterogeneous forms.
Comparison of various catalysts for transesterification

27. Catalyst Options 1. Sodium hydroxide (NaOH)
2. Potassium hydroxide (KOH)
3. Sodium methoxide (NaOCH3)
4. Potassium methoxide (KOCH3)
At present, NaOH and KOH are the mostly used industrial catalysts. The reasons that those two compounds are chosen, lie to the facts that they are widely available and economical and they cause high conversion to methyl ester in low temperature and pressure in a short reaction time

28. Comparison of different homogeneous alkali catalysts
NaOCH3 (18 scores) is selected to be the best homogeneous base catalyst.

29. OBJECTIVES The objectives of this plant design project are as follow:
To produce methyl esters (light cut, middle cut, heavy cut) from RBD palm kernel oil.
To achieve the production of methyl esters by using homogeneous base-catalyzed transesterification method with sodium methoxide (NaOCH3) as catalyst.

30. Block flow diagram

31. A COMPARISON OF DIFFERENT PURIFICATION METHODS
Hot distilled water, silica gel and phosphoric acid are common purification methods.
Hot distilled water is one of the most common and cheap method of purification. The biodiesel produced is washed with water for several times until clear layer of water is obtained. Biodiesel is then dried by heating to 110C.
Silica gel by column chromatography purification method is to introduce the produced and separated biodiesel into a column with a fixed bed of silica gel
Phosphoric acid solution, phosphoric acid 5% by weight with water, is purification method that purifies biodiesel by the means of liquid-liquid extraction