Moncat Fatty Acid Book

7/26/2019 Moncat Fatty Acid Book

1/10

Hydrogenation of Fatty Acids


2/10


3/10

1

Introduction

Oils and fats are essential nutrients in both human and animal diets. The principlesource of oils and fats are meats, poultry, fish, dairy products, fruits and nuts.Major components of oils and fats are triglycerides i.e. esters of glycerine andfatty acids (Fig 1). The properties of different triglycerides (oils and fats) aredictated by the chain length of the fatty acid (mostly C4 - C24) and as well as thepresence of number of double bonds per molecule.

H 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18|

H-C-O-OC-CH2-CH2-CH2-CH2-CH2-CH2-CH2-CH2- CH2-CH2-CH2- CH2-CH2-CH2-CH2-CH2-CH3

|

H-C-O-OC-CH2-CH2-CH2-CH2-CH2-CH2-CH2-CH = CH-CH2-CH2- CH2-CH2-CH2-CH2-CH2-CH3

|

H-C-O-OC-CH2-CH2-CH2-CH2-CH2-CH2-CH2-CH = CH-CH2-CH = CH-CH2-CH2-CH2-CH2-CH3|

H

Fig. 1 : Structure of triglyceride (oil) molecule i.e. an ester ofglycerine and 3 fatty acids (say C18)

Mainly, fatty acids are obtained from hydrolysis of triglyceride (oil) and glycerine isgenerated as byproduct. Distillation of free fatty acid from crude oil also generatesfatty acids, which are tough to hydrogenate. Unsaturated fatty acids arehydrogenated and used as raw material to manufacture large number of oleo

chemicals.

H 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18|

H-C-OH HO-OC-CH2-CH2-CH2-CH2-CH2-CH2-CH2-CH2-CH2-CH2-CH2-CH2-CH2-CH2-CH2-CH2-CH3 Stearic

|

H-C-OH HO-OC-CH2-CH2-CH2-CH2-CH2-CH2-CH2-CH = CH-CH2-CH2-CH2-CH2-CH2-CH2-CH2-CH3 Oleic

|

H-C-OH HO-OC-CH2-CH2-CH2-CH2-CH2-CH2-CH2-CH=CH-CH2-CH=CH-CH2-CH2-CH2-CH2-CH3 Linoleic|

H

Glycerine 3 Fatty Acid Molecules of C18 Chain

Fig. 2 : Glycerine and fatty acids obtained after hydrolysis oftriglyceride (oil) molecule


4/10

2

Hydrogenation of various feed stocks

Fatty acid part of triglycerides having double bonds is susceptible to attack byatmospheric oxygen, resulting in rancid odour, which is not acceptable to

consumers. Unsaturated fatty acid molecules having 2 - 4 double bonds(unsaturated) are hydrogenated fully to convert the double bonds into singlebonds (saturation).

Hydrogenation of C18 unsaturated fatty acids (oleic, linoleic or linolenic) givestearic acid which has large number of industrial applications. In todays world,fatty acids are hydrogenated using supported nickel metal as most appropriatecatalyst to remove the unsaturation. Though supported noble metal catalyst couldbe used for similar applications, nickel catalyst offers comparatively higherperformance / price ratio.

Stearic acid manufacturers use selective nickel catalyst for completehydrogenation of unsaturated fatty acids. The product with lower iodine value has

large number of industrial applications i.e. in the manufacture of tyres, fattyalcohols and cosmetics. If the product has negligible degree of unsaturation (I.V.< 0.5), it offers stability in products with high temperature applications. Largenumber of soap manufacturers use partially hydrogenated rice bran fatty acid (IV95 - 97 to 50 - 55) in their formulations. In case of fatty acids (palm fatty acid)which are naturally available with lower iodine value (50 -55), furtherhydrogenation might be less relevant.

Fig. 1 : Stearic acid used in tyres Fig. 2 : Fatty acid used in soaps

Monarch Catalyst Pvt. Ltd. has developed indigenous technology for theproduction of dry reduced nickel catalyst for hydrogenation of edible oils and fattyacids. Now, it is a market leader in manufacture of different grades of suchspecialty nickel catalysts in India. Nickel catalysts available in internationalmarket were frequently collected and their performance was compared withMonarch catalysts in the laboratory on different oils and fatty acids. Though thehydrogenation conditions viz., reactor size, stirring efficiency, temperature and

pressure varies from plant to plant, the catalyst consumption and reactionselectivity follow the trend observed in the laboratory test methods.


5/10

3

Palm Fatty Acid Distillate (PFAD)

The free fatty acid present in crude palm oil (not linked to glycerine) is removed

either by alkali treatment or by vacuum distillation. The fatty acid removed fromdistillation is obtained as light brown solid at room temperature and it melts tobrown liquid on heating. Some of the volatile impurities present in crude palm oilare transferred to fatty acid during distillation. Therefore, hydrogenation of palmfatty acid distillate (PFAD) to stearic acid gives a product with a final I.V. of 6 - 7with relatively higher concentration of nickel catalyst dosage. Further lowering ofI.V. (to around 4 - 5) is achieved by carrying out distillation of the fullyhydrogenated product.

MONCAT

1991is selective catalysts for hydrogenation of PFAD with initial I.V. of

55 57 to a desired lower iodine value of 5 -6.

Fig. 3 : Hydrogenation of Palm Fatty Acid Distillate Degummed (P = 14 bar, T = 180 195 C, time =80 min)

During fatty acid hydrogenation, a side reaction between nickel / nickel oxide andcarboxylic group of fatty acid results in formation of undesired nickel soap. Lossin nickel as nickel soap could be minimized by carrying out hydrogenation reactionat higher hydrogen pressure.

MONCAT

1991 = Catalyst for complete hydrogenation of fatty acid

MONCAT

2991 = Catalyst for partial hydrogenation of fatty acid

4

6

8

10

12

14

16

1.4 1.8 2.2 2.6Cat (kg/T)

I.V. PFAD

Intl Ref-1

MONCAT 1991

Intl Ref-2


6/10

4

Palm Stearine Fatty Acid (PSFA)

Splitting of a) crude palm oil or b) curde palm stearine (CPS) or c) refined,bleached, and deodorized palm stearine (RBDPS) gives glycerine and palmstearine fatty acid (CPSFA or RBDPSFA) as the main product. The palm stearinefatty acid obtained free from impurities is hydrogenated from initial iodine value ofabout 32 to a very low iodine values of 0.5 - 0.8. Further distillation of such lowI.V. product results in achieving a very low I.V. i.e., 0.3 - 0.4, which is a premium

product. The nickel catalyst MONCAT

1991 is selective for hydrogenation of

palm stearine fatty aid (PSFA) into stearic aid.

Fig. 4 : Hydrogenation of Palm stearin fatty acid(P = 20 bar, T = 180 195 C, Time = 70min.)

During hydrogenation of softer substrate (RBDPSFA), iodine value less than 1.0 isachieved at catalyst dosage of 1.0 kg/MT itself. Therefore, it is important to refinepalm stearine effectively before splitting it into palm stearine fatty acid to lower thecatalyst requirement for hydrogenation.

0

1

2

3

4

5

6

7

0.5 1.0 1.5 2.0

CPSFA

Cat (Kg/T)

I.V.

MONCAT 1991

Intl Ref-1

Intl Ref-2


7/10

5

Rice Bran Fatty Acid

Rice bran oil (RBO) is extracted from the bran and it is known to contain higherconcentration (> 20%) of free fatty acid / phophatides. During physical refining ofRBO, free fatty acid (FFA) is distilled out to get rice bran fatty acid (RBFA).However, splitting of RBO and vacuum distillation of fatty acid gives comparativelywhitish or light pinkish RBFA with minimum impurities. Hydrogenation of RBFA is

carried out to get lower iodine values (3 - 5) using MONCAT

1991. Distillation of

hydrogenated product (stearic acid) results in further lowering of I.V. to 1 2.

Fig. 5 : Hydrogenation of Rice Bran fatty acid (P = 14or 20 Bar, T = 180 -190 C, time = 120 min)

Post Hydrogenation Filterability

When compared with competitors catalysts for filterability after hydrogenation

MONCAT

catalysts gives quite comparable results when tested under identical

conditions (i.e. using same filtration equipment & other parameters).

5

10

15

20

25

0.6 0.8 1 1.2 1.4

I.V.

Cat k /T

RBFA

MONCAT

1991

Intl Ref-1

Intl Ref-2

0

5

10

15

20

25

30

0 40 80 120 160

Oil Filtered (ml)

Filtration Time (min)

MONCAT

Std Cat


8/10

6

Study of Nickel Soap Formation

During fatty acid hydrogenation, nickel or nickel oxide species of the catalystreacts with carboxylic group of fatty acid which results in formation of undesirablenickel soap. Though the nickel content as nickel soap in the final product is foundto be in the range of 80 - 90 ppm, it is much less in the freshly hydrogenated fattyacid.

A) During storage of hydrogenated productHolding time of product in hot condition before filtration should be as low aspossible to bring down nickel ppm in the final product. The effect of holding timeon soap formation is shown below:

Product storage time Ni soap (Ni ppm) in productImmediately after hydrogenation 44.1

10 minutes 50.6

15 minutes 54.8

20 minutes 59.0

25 minutes 63.4

After completion of filtration (& cooling) 91.2

B) Due to Hydrogenation at varying reaction conditionsComparatively lower reaction temperature and high pressure restrict nickel soapformation. In case of inevitable longer holding or transfer time, it is important to

cool the product rapidly (~ 100 C) to minimise the nickel soap formation.

Substrate = Fatty Acid, Ni Dosage = 500 ppm and Reaction Time = 80 min

Varying reaction Ni ppm at different hydrogenation pressure

Temp (OC) Atm 5 Bars 10 Bars 25 Bars

100 38 ppm 24 ppm 9 ppm < 2 ppm

135 98 ppm 76 ppm 52 ppm 29 ppm

185 311 ppm 204 ppm 112 ppm 63 ppm


9/10

7

MONCAT

catalysts handling InformationPhysical form:

MONCAT

catalysts are manufactured in pastil form. The pastils are nothing but

small droplets made up of dispersion of active metal species in hydrogenatedvegetable oil (solid at room temperature). Catalyst pastils are not only easy tohandle but also give no dusting while transferring or charging the catalyst. Also,coating of metal with vegetable fat renders active nickel metal less prone toexposure to air and thereby minimizes loss in activity during storage.

Packaging:

Catalyst pastils are packed in standard metal and HDPE bags / drums. Also, theyare packed in customer specific packaging materials (Small bags, Jumbo bags &Paper bags) to match the handling facility / practices at the customer end.

Shelf Life:

Catalyst stored in closed container retains performance for minimum oneyear.

Store catalyst in cool and dry place.

Refer our MSDS for safety instructions.

Catalyst is Kosher Certified


10/10

Our Global Sales Partners

South East Asia & China:Greenwell Global Chemicals Sdn. Bhd.18 Jalan Bulan H U5/H Seksyen U5,Sungai Buloh Batu 3,40150 Shah Alam, Selangor, Malaysia.

Contact Person: Mr K H TanPh: + 60 3 7846 8625 / 7846 9387Fax: + 60 3 7846 8867E-mail: [email protected]

Europe:H B International SAS26 bis rue de l'Ermitage - BP 31,95160 Montmorency, France.Contact Person: Mr Valery Desroches

Ph: +33 1 3934 6614Fax: +33 1 3412 4960E-mail: [email protected]

North America:Mega Sourcing IncIL USA & KL MalaysiaContact Person: Mr Dale MolinePh: +60 12 326 7763E-mail: [email protected]

Factory & Head Office:Monarch Catalyst Pvt.Ltd

A-94 MIDC Phase I, Dombivli (East),Thane 421 203, Maharashtra, India.Contact Person: Mr.Krishnan MuthukumarPh: +91 251 2471716Fax: +91 251 2470269E-mail: [email protected]

Moncat Fatty Acid Book

Documents

Transcript of Moncat Fatty Acid Book