Hydrocarbon fuels from brown grease: Moving from the research laboratory toward an industrial process

Abstract

Brown grease is a generic term for the oily solids and semi-solids that accumulate in the sewer system and in sewage treatment plants. It has previously been shown that brown grease undergoes pyrolysis to form a homologous series of alkanes and 1-alkenes between 7 and 17 carbon atoms, with smaller amounts of higher hydrocarbons and ketones up to about 30 carbon atoms. The initial study was performed in batch mode on a scale of up to 50 grams of starting material. However, continuous processes are usually more efficient for large scale production of fuels and commodity chemicals. This work describes the research and development of a continuous process. The first step was to determine the required reactor temperature. Brown grease consists largely of saturated and unsaturated fatty acids, and they react at different rates, and produce different products and intermediates. Intermediates include ketones, alcohols, and aldehydes, and Fe(III) ion catalyzes at least some of the reactions. By monitoring the pyrolysis of brown grease, its individual components, and intermediates, it was determined that a reactor temperature of at least 340 °C is required. A small scale (1 L) continuous stirred tank reactor was built and its performance is described.