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Current Situation and Future Prospects of Oleochemical Industry
Ahmad Mustafa
R&D and Quality Manager, Oleo Misr
www.oleomisr.com
Focus Points
Current Situation of Oleochemicals
Specialty Oleochemicals (Production)
Specialty Oleochemicals (Definition)
Enzymatic Processes
Oleo Misr R&D
Conclusion
• Most of oleochemicals plants now are producingbasic oleochemicals.
• Few years ago, plants some plants started shiftingtheir production to specialty oleochemicals.
• Producing specialties need information and knowhow which is not fully commercialized now.
Basic Specialty
Oleochemicals
• Main processes
Fat Splitting Fractionation Transestrification Hydrogenation Saponification
• High-Value Processes
Esterification Amidation Quaternization Sulfonation Ethoxylation Epoxidation Alcoholyses of epoxidized
fats
Basic Oleochemicals
Fatty acid, Crude glycerin
Methylesters
Fractionated acids & methylesters
Fatty alcohols
Soap noodles
Specialty Oleochemicals
MCT, IPM, IPP, monoglycerides
amides, amido amines
Quats, amine oxides
Sulfates
Ethoxylates
Plasticizers, stabilizers,
Polyols
Specialty esters are considered as a high valueoleochemicals that are produced in low quantities butare highly priced with high profit margins.
5
With bioinnovation…
Basic Specialties
Specialty Oleochemicals
Profitability ProfileP
rofi
tab
ility
ConsumptionLow
Low
High
High
Pharmaceuticals
Cosmetics and personal care
Biolubricant & Grease
Soap & Detergent
Source: ZAINAB IDRIS, exploring the potential of downstream sector in the palm oil industry in Sabah. SEMINAR ON INVESTMENT OPPORTUNITIES IN HIGH GROWTH SECTORS IN SABAH 2012
• Non-Toxic/ non corrosive, Thus eliminating environmental risks.
• Eliminate side reactions.
• Plant using enzymatic technology has less investment.
• Less Energy Consumption.
• Less Processes Steps.
• Produces clean and pure product.
• Selective Reaction.
Glycerin Monolaurate
Feed additive
Emulsifier
Isopropyl Palmitate
Bio-solvent
Emollient
2-Ethylhexyl Oleate
Placticizer
Bio-lubricant
Glycerin Laurate has wide range of applications
FOOD COSMETICS Dietary
Supplements
Feed Additive
13
Experimental design
Design-Expert® SoftwareFactor Coding: ActualConversion (%)
Design points below predicted value93.23
43.2
X1 = A: Temp.X2 = B: Enzyme load
Actual FactorC: Molar ratio = 2.53634
1.05796
1.79715
2.53634
3.27554
4.01473
48
51
54
57
60
40
50
60
70
80
90
100
Co
nv
ers
ion
(%
)
A: Temp. (C)B: Enzyme load (%)
Design-Expert® SoftwareFactor Coding: ActualConversion (%)
Design points below predicted value93.23
43.2
X1 = A: Temp.X2 = C: Molar ratio
Actual FactorB: Enzyme load = 2.53634
1.05796
1.79715
2.53634
3.27554
4.01473
48
51
54
57
60
40
50
60
70
80
90
100
Co
nv
ers
ion
(%
)
A: Temp. (C)C: Molar ratio
Design-Expert® SoftwareFactor Coding: ActualConversion (%)
Design points below predicted value93.23
43.2
X1 = B: Enzyme loadX2 = C: Molar ratio
Actual FactorA: Temp. = 54
1.05796
1.79715
2.53634
3.27554
4.01473
1.05796
1.79715
2.53634
3.27554
4.01473
40
50
60
70
80
90
100
Co
nv
ers
ion
(%
)
B: Enzyme load (%)C: Molar ratio
14Interactive Effects of Different Variables on Glycerin Laurate Formation
1 0 . 0 0 1 5 . 0 0 2 0 . 0 0 2 5 . 0 0 3 0 . 0 0 3 5 . 0 0 4 0 . 0 0 4 5 . 0 0
1 0 0 0 0 0 0
2 0 0 0 0 0 0
3 0 0 0 0 0 0
4 0 0 0 0 0 0
5 0 0 0 0 0 0
6 0 0 0 0 0 0
7 0 0 0 0 0 0
8 0 0 0 0 0 0
9 0 0 0 0 0 0
T im e - - >
A b u n d a n c e
T I C : 0 2 0 1 0 0 2 . D \ d a t a . m s
1 1 . 6 0 7
1 5 . 9 7 6
1 6 . 8 5 8
1 7 . 1 5 6
2 3 . 6 7 3
2 3 . 8 8 5
3 4 . 9 4 3
15
GC Chromatogram for Glyceryl Laurate
Triester
MonoesterDiester
Lauric
0102030405060708090
100
1 2 3 4 5 6 7
Re
sid
ual
act
ivit
y
Number of cycles
16
17
0102030405060708090
100
0 30 60 90 120 150 180
Co
nve
rsio
n, %
Time, min
Without emulsifier
with emlsifier
Lipase reusabilityEmulsifier addition
Plasticizer is a substance that is added to other polymeric substances to aid processing of the polymer and to impart
flexibility, plasticity, softness, and reduce brittleness.
Influence of plasticizer
Lower hardnessHigher elongation
Better low Temperature
On Processing
Lower ViscosityFaster filler incorporation
Lower power demand
On Physical properties
i.e. Green Non Phthalate Plasticizer
FirstPlasticizer
1860 1930
Phthalates Introduced
1980’s
DEHP Declared Carcinogenic
2001
IARCRe-classifies
DEHP as non-carcinogenic
1998
European Parliament calls for alternatives to phthalates
Timeline (history) for Plasticizers
2005
Green Plasticizer
Safety Data SheetFor DOP
Replacing Plasticizer derived from petroleum with plasticizer based oleochemicals is Urgent
Oleomisr pays attention to produce a green replacer of DEHP and DOP Utilizing Palm Oil
• Utilizing Palm FA to produceGreen Polymer Additivescombines functionality withinnovation using renewable andcheap feedstock.
• Producing epoxized palm oil isnot only used as a placticizer,however it can be used also as astarting material for producingpolyurethane which has a largepotential market.
Palm Based Placticizer(Oleo Misr R&D)
23
0
20
40
60
80
100
0 30 60 90 120 150 180
Co
nve
rsio
n, %
Time, min
As isopropyl palmitate is a non-greasy emollient that is has good
spreading characteristics, it finds a numerous applications in
cosmetics industry such as: bath oils, creams, lotions, make-up,
hair care products, deodorants, and pressed powders. Also it has
other versatile applications in different areas such as a solvent or
co-solvent in ink and paint industries.
Design-Expert® SoftwareFactor Coding: ActualConversion (%)
Design points above predicted valueDesign points below predicted value90
45
X1 = A: Molar RatioX2 = B: Enzyme Load
Actual FactorC: Molecular sieves conc. = 5.5
1
1.6
2.2
2.8
3.4
4
3
6
9
12
15
40
50
60
70
80
90
100
Co
nv
ers
ion
(%
)
A: Molar ratio (mmol)B: Enzyme amount (w/w, %)
Design-Expert® SoftwareFactor Coding: ActualConversion (%)
Design points above predicted valueDesign points below predicted value90
45
X1 = A: Molar RatioX2 = C: Molecular sieves conc.
Actual FactorB: Enzyme Load = 2.5
1 2
3 4
5 6
7 8
9 10
3
6
9
12
15
40
50
60
70
80
90
100
Co
nv
ers
ion
(%
)
A: Molar ratio (mmol)C: Molecular sieves amount (w/w, %)Design-Expert® SoftwareFactor Coding: ActualConversion (%)
Design points above predicted valueDesign points below predicted value90
45
X1 = B: Enzyme LoadX2 = C: Molecular sieves conc.
Actual FactorA: Molar Ratio = 9
1 2
3 4
5 6
7 8
9 10
1
1.6
2.2
2.8
3.4
4
40
50
60
70
80
90
100
Co
nv
ers
ion
(%
)
B: Enzyme amount (w/w, %)C: Molecular sieves amount (w/w, %)
Experimental design
Interactive Effects of Different Variables on Isopropyl palmitate Formation
25
Comparison between Chemical and Enzymatic Methods.
Pretreatment
Reaction
Washing
Bleaching
Filtration
Distillation
Catalyst
Acid/water
Bleaching earth
Filter aid &Bleaching earth
Soaps
Unreactedfatty acids
By-products,color, etc.
> 200 °C
> 100 °C
50−60 °C
Spent Bleaching earth
Chemical
FFA
Pretreatment
Reaction
Distillation
Enzyme reuse
Enzymatic
Soaps, etc.
By-products
FiltrationSeparationGlycerin
Glycerine laurate Glycerine laurate
26
1. Specificity.
2. Low Energy Consumption.
3. Green & SustainableProducts.
4. Environmental Friendly.
Enzymes have a Great Leap to Make
27
1. Enzyme cost.
• Reusability.
2. Reaction time.
• Media emulsification
But there are some Challenges along the Path to Commercialization
Lauric acid
Glycerin
Environmental Footprint
29
83%Reduction
30
Environmental Footprint
88%Reduction
31
Environmental Footprint
100%Reduction
32
