Enzymatic transesterification/esterification processing systems and processes employing lipases immobilzed on hydrophobic resins

Abstract

Disclosed are processing systems and processes for carrying out enzymatic batchwise or continuous process for the production of fatty acid alkyl esters for use in the biofuels, food, cosmetics, pharmaceuticals and detergents industries.

1 . A processing system for the transesterification/esterification of a fatty acid source with an alcohol, to form fatty acid alkyl esters, comprising:
 a reaction vessel configured for reacting a reaction medium comprising a fatty acid source and at least one of an alcohol and an alcohol donor in the presence of a lipase preparation, wherein the lipase preparation comprises at least one lipase immobilized on a hydrophobic porous support, wherein said reaction vessel comprises a stirring system for stirring said reaction medium comprising said fatty acid source and said at least one of an alcohol and an alcohol donor and said lipase preparation within the reaction vessel and wherein said processing system is configured for passing said reaction medium comprising said fatty acid source and said at least one of an alcohol and an alcohol donor through said lipase preparation in a gravity opposed direction.   
     
     
         2 . The processing system according to  claim 1 , wherein said reaction vessel is configured for providing an expanded or fluidized bed of said immobilized lipase preparation. 
     
     
         3 . The processing system according to  claim 1 , wherein said reaction vessel comprises a vessel inlet port and a vessel outlet port, and wherein said vessel inlet port is at a location lower than that of said vessel outlet port. 
     
     
         4 . (canceled) 
     
     
         5 . The processing system according to  claim 1 , wherein said reaction vessel comprises the lipase preparation, at least during operation of said processing system for the production of said fatty acid alkyl esters. 
     
     
         6 . The processing system according to  claim 1 , wherein said reaction vessel comprises said reaction medium comprising the fatty acid source and the at least one of an alcohol and an alcohol donor, at least during operation of said processing system for the production of said fatty acid alkyl esters. 
     
     
         7 . The processing system according to  claim 1 , wherein said reaction medium further comprises at least one of an aqueous alkaline buffer solution and water, said water being at least one of free water and mixed with a polyol or polyols, at least during operation of said processing system for the production of said fatty acid alkyl esters. 
     
     
         8 . The processing system according to  claim 1 , wherein said reaction medium comprises a mixture of at least a fatty acid source and at least one of an alcohol and an alcohol donor, said processing system comprising a pre-reaction vessel in selective fluid communication with said reaction vessel via said vessel inlet port, said pre-reaction vessel being configured for premixing at least the fatty acid source and the at least one of an alcohol and an alcohol donor to form said mixture, and for selectively delivering said mixture to said reaction vessel at least during operation of said processing system for the production of said fatty acid alkyl esters. 
     
     
         9 . The processing system according to  claim 8 , including at least one of the following:
 wherein the system comprises a supply of fatty acid source in selective fluid communication with said pre-reaction vessel and configured for selectively delivering the fatty acid source to said pre-reaction vessel at least during said operation of said processing system, and an alcohol and/or alcohol donor source in selective fluid communication with said pre-reaction vessel and configured for selectively delivering the at least one of an alcohol and an alcohol donor to said pre-reaction vessel at least during said operation of said processing system;   wherein the system comprises at least one of an aqueous buffer source and a water source in selective fluid communication with said pre-reaction vessel and configured for selectively delivering the at least one of an aqueous alkaline buffer solution and water, free or mixed with a polyol/polyols, to said pre-reaction vessel, to be comprised in said reaction mixture at least during said operation of said processing system;   wherein the system is configured for selectively delivering one or more of the fatty acid source and the at least one of an alcohol and an alcohol donor to said pre-reaction vessel in a continuous manner or in discrete batches at least during said operation of said processing system;   wherein the system is configured for selectively delivering the at least one of an aqueous alkaline buffer solution and water, free or mixed with a polyol/polyols, to said pre-reaction vessel in a continuous manner or in discrete batches at least during said operation of said processing system; and   wherein said pre-reaction vessel is configured for selectively delivering said mixture to said reaction vessel in a continuous manner or in discrete batches at least during said operation of said processing system.   
     
     
         10 - 13 . (canceled) 
     
     
         14 . The processing system according to  claim 1 , the processing system being configured for selectively and directly delivering to said reaction vessel at least one of the fatty acid source; and/or the at least one of an alcohol and an alcohol donor; and/or the at least one of an aqueous alkaline buffer solution and water, free or mixed with a polyol/polyols. 
     
     
         15 . The processing system according to  claim 1 , wherein said reaction vessel comprises a thermal regulation processing system configured for maintaining the reaction medium comprising said at least fatty acid source and said at least one of an alcohol or alcohol donor in said reaction vessel within a selected temperature range. 
     
     
         16 . The processing system according to  claim 1 , further comprising a retaining arrangement configured for retaining the lipase preparation within said reaction vessel at least during operation of said processing system. 
     
     
         17 . The processing system according to  claim 16 , wherein said retaining arrangement is at one or both of said reaction vessel outlet and said reaction vessel inlet. 
     
     
         18 . The processing system according to  claim 1 , further comprising a product separation vessel in selective fluid communication with said reaction vessel, said processing system being configured for selectively delivering a reaction mixture including reaction products from said reaction vessel to said product separation vessel, and wherein said product separation vessel is configured for selectively separating a yield of the fatty acid alkyl esters from the reaction mixture delivered thereto. 
     
     
         19 . The processing system according to  claim 18 , including at least one of the following:
 wherein said product separation vessel comprises one of a centrifuge, coalescer and gravity separation processing system;   wherein said reaction vessel is configured for selectively delivering said reaction mixture to said product separation vessel in a continuous manner or in discrete batches at least during said operation of said processing system;   wherein the system is configured for selectively dispensing said yield of fatty acid alkyl esters from said product separation vessel;   wherein the system is configured for selectively dispensing said yield of fatty acid alkyl esters from said product separation vessel, and the system is further configured for selectively delivering said yield of fatty acid alkyl esters from said product separation vessel in a continuous manner or in discrete batches;   wherein said processing system is configured for increasing said yield of the fatty acid alkyl esters from the reaction mixture delivered to said product separation vessel;   wherein said processing system is configured for increasing said yield of the fatty acid alkyl esters from the reaction mixture delivered to said product separation vessel, and wherein said processing system is configured for selectively rerouting said yield of the fatty acid alkyl esters to said reaction vessel to further increase said yield of the fatty acid alkyl esters from the reaction mixture subsequently delivered to said product separation vessel; and   wherein said processing system is configured for selectively rerouting said yield of the fatty acid alkyl esters to one or more auxiliary reactor modules, wherein each said auxiliary reactor module comprises an auxiliary reactor vessel and an auxiliary product separation vessel, wherein said further increased yield of the fatty acid alkyl esters is selectively subsequently delivered via a respective said auxiliary product separation vessel.   
     
     
         20 - 25 . (canceled) 
     
     
         26 . The processing system according to  claim 18 , wherein:
 said processing system is configured for increasing said yield of the fatty acid alkyl esters from the reaction mixture delivered to said product separation vessel;   said processing system is configured for selectively rerouting said yield of the fatty acid alkyl esters to said reaction vessel to further increase said yield of the fatty acid alkyl esters from the reaction mixture subsequently delivered to said product separation vessel.   said processing system is configured for selectively rerouting said yield of the fatty acid alkyl esters to one or more auxiliary reactor modules, wherein each said auxiliary reactor module comprises an auxiliary reactor vessel and an auxiliary product separation vessel, wherein said further increased yield of the fatty acid alkyl esters is selectively subsequently delivered via a respective said auxiliary product separation vessel; and   wherein each said auxiliary reaction vessel is configured for reacting said yield of the fatty acid alkyl esters in the presence of an immobilized lipase preparation, wherein the immobilized lipase preparation comprises at least one lipase immobilized on a hydrophobic porous support and wherein said processing system is configured for passing the reaction medium through said immobilized lipase preparation in the respective said auxiliary reaction vessel in a direction at least partially opposed to gravity.   
     
     
         27 . The processing system according to  claim 1 , wherein said processing system is configured for selectively outputting and rerouting a reaction mixture including said reaction products back to said reaction vessel for further processing therein for enhancing yield of said fatty acid alkyl esters. 
     
     
         28 . The processing system according to  claim 18 , wherein said processing system is configured for selectively outputting and rerouting a reaction mixture including said reaction products back to said reaction vessel and for selectively subsequently outputting and delivering a modified reaction mixture including reaction products to said product separation vessel, and wherein said product separation vessel is configured for selectively separating a yield of the fatty acid alkyl esters from the reaction mixture delivered thereto. 
     
     
         29 . The processing system according to  claim 27 , wherein said processing system is configured for rerouting the reaction mixture through said reaction vessel in a gravity opposed direction. 
     
     
         30 . The processing system according to  claim 26 , wherein said processing system is configured for selectively outputting and rerouting a reaction mixture provided by each said auxiliary reaction vessel back to the respective said auxiliary reaction vessel for enhancing yield of said fatty acid alkyl esters. 
     
     
         31 . The processing system according to  claim 26 , wherein said processing system is configured for selectively outputting and rerouting a reaction mixture including said reaction products provided by the respective said auxiliary reaction vessel back to the respective said auxiliary reaction vessel and for selectively subsequently outputting and delivering a modified reaction mixture including reaction products from the respective said auxiliary reaction vessel to the respective said auxiliary product separation vessel, and wherein the respective said auxiliary product separation vessel is configured for selectively separating a yield of the fatty acid alkyl esters from the reaction mixture delivered thereto. 
     
     
         32 . The processing system according to  claim 30 , wherein said processing system is configured for passing the reaction products through each said auxiliary reaction vessel in a gravity opposed direction. 
     
     
         33 - 53 . (canceled) 
     
     
         54 . A processing system for the transesterification/esterification of a fatty acid source with an alcohol to form fatty acid alkyl esters, comprising:
 a reaction vessel configured for reacting a reaction medium comprising a fatty acid source and at least one of an alcohol and an alcohol donor in the presence of a lipase preparation, wherein the lipase preparation comprises at least one lipase immobilized on a hydrophobic porous support, wherein said reaction vessel comprises a stirring system for stirring said reaction medium comprising said fatty acid source and said at least one of an alcohol and an alcohol donor and said lipase preparation within the reaction vessel and wherein said processing system is configured for passing said reaction medium comprising said fatty acid source and said at least one of an alcohol and an alcohol donor through said lipase preparation in a gravity opposed direction, and further comprising a product separation vessel in selective fluid communication with said reaction vessel, said processing system being configured for selectively delivering a reaction mixture including reaction products from said reaction vessel to said product separation vessel, and wherein said product separation vessel is configured for selectively separating a yield of the fatty acid alkyl esters from the reaction mixture delivered thereto.   
     
     
         55 . A processing system for the transesterification/esterification of a fatty acid source with an alcohol, to form fatty acid alkyl esters, comprising:
 a reaction vessel configured for reacting a reaction medium comprising a fatty acid source and at least one of an alcohol and an alcohol donor in the presence of a lipase preparation, wherein the lipase preparation comprises at least one lipase immobilized on a hydrophobic porous support, wherein said reaction vessel comprises a stirring system for stirring said reaction medium comprising said fatty acid source and said at least one of an alcohol and an alcohol donor and said lipase preparation within the reaction vessel and wherein said processing system is configured for passing said reaction medium comprising said fatty acid source and said at least one of an alcohol and an alcohol donor through said lipase preparation in a gravity opposed direction, and further comprising a product separation vessel in selective fluid communication with said reaction vessel, said processing system being configured for selectively delivering a reaction mixture including reaction products from said reaction vessel to said product separation vessel, and wherein said product separation vessel is configured for selectively separating a yield of the fatty acid alkyl esters from the reaction mixture delivered thereto, and further having at least one of the following: said product separation vessel comprises one of a centrifuge, coalescer and gravity separation processing system;
 said reaction vessel is configured for selectively delivering said reaction mixture to said product separation vessel in a continuous manner or in discrete batches at least during said operation of said processing system; 
 the system is configured for selectively dispensing said yield of fatty acid alkyl esters from said product separation vessel; 
 the system is configured for selectively dispensing said yield of fatty acid alkyl esters from said product separation vessel, and the system is further configured for selectively delivering said yield of fatty acid alkyl esters from said product separation vessel in a continuous manner or in discrete batches; 
 said processing system is configured for increasing said yield of the fatty acid alkyl esters from the reaction mixture delivered to said product separation vessel; 
 said processing system is configured for increasing said yield of the fatty acid alkyl esters from the reaction mixture delivered to said product separation vessel, and wherein said processing system is configured for selectively rerouting said yield of the fatty acid alkyl esters to said reaction vessel to further increase said yield of the fatty acid alkyl esters from the reaction mixture subsequently delivered to said product separation vessel; 
 wherein said processing system is configured for selectively rerouting said yield of the fatty acid alkyl esters to one or more auxiliary reactor modules, wherein each said auxiliary reactor module comprises an auxiliary reactor vessel and an auxiliary product separation vessel, wherein said further increased yield of the fatty acid alkyl esters is selectively subsequently delivered via a respective said auxiliary product separation vessel.