STTR Phase II: Ultra-High Efficiency Biodiesel Manufacturing

该奖项是根据2009年美国复苏和再投资法案（公法111-5）资助的。这个小型企业技术转让二期项目将改变两相化学反应必须使用机械混合才能取得商业效益的模式。创新的纤维反应器（TM）为化学和生化制造的效率提供了两个数量级的变化。本项目将重点研究生物柴油的酯交换反应。生物柴油工厂通过多个反应器阶段和离心机阶段将脂肪/油转化为生物柴油。复杂性是由于差的传质，差的反应转化，和差的相分离由于副产物肥皂。改善传质和消除肥皂分散体将降低生产生物柴油的成本。在一期实验中，纤维反应器的转化率比商业生物柴油工艺快3-100倍。先进材料与工艺找到了一种非常规的方法来改善传质，同时解决生物柴油过程中的相分离问题。使用光纤反应器将通过显著改善传质和消除分散来减少复杂性、尺寸、资金、能源消耗和水污染。第一阶段验证了生物柴油生产中节能和工艺强化的可行性。第二阶段将使用第一阶段模型和CHEMCAD模型来设计和运行一个使用高通量连续静态纤维反应器和洗涤工艺的中试反应器。到2015年，生物柴油的产能将增加10倍，从而改善美国的能源安全。仍然存在两个障碍——生产所需的甘油三酯，并与石油经济相匹配。一个新的工业和网络正在发展，以提供足够的藻类油。纤维反应器将使生产生物柴油的资本和运营成本降低50%，并使用低成本的原油/脂肪。第一阶段发展纤维反应器的基础酯交换化学。第二阶段将开发化学/工程数据以扩大规模。纤维技术将以类似的优势应用于制药和特种化学品制造。该项目将通过培训学生在有机化学、纤维、材料、工艺、试验操作、分馏、分析、有机合成和质量控制方面的研究和教育相结合。学生使用湿化学，GPC， HPLC和LC/MS对原料和反应产物进行鉴定/定量。德克萨斯州立大学2008年有46名化学/生物化学专业毕业生。2009年入学的化学/生物化学专业学生有329人。37名研究生中35%是少数民族，48%是女性。国际经济研究所向100多名学生提供了研究助学金/就业机会，其中62%是妇女或少数民族。本项目将对学术部门和研究所的研究能力产生积极影响；并帮助妇女和少数民族改善他们在工业化学方面的培训。

This award is funded under the American Recovery and Reinvestment Act of 2009 (Public Law 111-5).This Small Business Technology Transfer Phase II project will change the paradigm that two-phase chemical reactions must use mechanical mixing to be commercially effective. The innovative Fiber Reactor (TM) offers two orders of magnitude change in efficiency for chemical and biochemical manufacturing. This project will focus on biodiesel transesterification reactions. Biodiesel plants convert fats/oils to biodiesel with multiple reactor stages and centrifuge stages. Complexity is due to poor mass transfer, poor reaction conversion, and poor phase separations due to by-product soap. Improving mass transfer and eliminating soap dispersions will reduce the cost of manufacturing biodiesel. In Phase I experiments, the Fiber Reactor was 3-100 times faster than commercial biodiesel processes with superior conversion. Advanced Materials and Processes has found an unconventional way to improve mass transfer and simultaneously solve phase separation problems in biodiesel processes. Use of a Fiber Reactor will reduce complexity, size, capital, energy consumption, and water pollution by dramatically improving mass transfer and eliminating dispersions. Phase I proved feasibility of energy savings and process intensification in biodiesel manufacturing. Phase II will use Phase I models and CHEMCAD models to design and operate a pilot reactor using the high throughput continuous static Fiber Reactor and wash processes. Biodiesel capacity could increase 10 times by 2015 and improve U.S. energy security. Two hurdles remain - produce the triglyceride needed and match petroleum economics. A new industry and networks are being developed to supply enough algae oil. Fiber Reactors will reduce capital and operating cost for producing biodiesel by 50% and use low cost crude oils/fats. Phase I developed basic transesterification chemistry for Fiber Reactors. Phase II will develop chemistry/engineering data for scale up. Fiber technology will apply to pharmaceutical and specialty chemical manufacturing with similar benefits. This project will integrate research and education by training students in organic chemistry, fibers, materials, processes, pilot operations, fractionation, analysis, organic synthesis, and quality control. Students use wet chemistry, GPC, HPLC and LC/MS for identification/quantification of raw materials and reaction products. Texas State University graduated 46 chemistry/biochemistry majors in 2008. Enrollment in 2009 included 329 chemistry/biochemistry majors. The 37 graduate students were 35% minority and 48% women. IEIS has provided research assistantships/employment to over 100 students of whom 62% were women or minorities. This project will have a positive impact on the research capabilities of academic departments and IEIS; and help women and minorities to improve their training in industrial chemistry.