酶法制备生物柴油新工艺及其高值化技术探索
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摘要
生物柴油是新型绿色可再生燃料,主要以动植物油脂为原料,通过酯交换工艺制备而成,可代替石化柴油。相对于化学法制备生物柴油的诸多缺陷,酶法制备工艺因反应条件温和、甲醇用量少、无污染等优点成为当前生物柴油开发的主流发展方向。
乌桕是我国特有的木本油料植物,因油脂含量高而有“中国植物牛油”、“石油树”等美称。该油脂中因含有毒酚类物质而不宜食用,但其十八碳脂肪酸的含量近90%,为制备生物柴油的理想原料。本文以乌桕梓油为对象,以脂肪酶为催化剂,研究生物柴油制备新方法,并尝试基于生物柴油的高值化技术探索。主要研究工作和创新点摘要如下：
(1)对乌桕梓油理化性质和成分进行了测定和分析。油脂成分和理化性质可以反映油脂品质,进而影响生物柴油产品性能。检测结果显示,该油脂含有7种脂肪酸,以十八碳脂肪酸为主,碳链长度和结构非常适合作为制备生物柴油的原料；其酸值适中,含微量磷脂,但皂化值偏大。该结果为酶法制备乌桕梓油生物柴油提供了可行性分析。
(2)对自行固定化洋葱伯克霍尔德菌G63脂肪酶在微水相体系中催化乌桕梓油制备生物柴油的工艺参数进行了优化。获得最佳工艺参数：醇油摩尔比4：1,脂肪酶用量2.7%,反应温度41℃。在此条件下,生物柴油得率为96.22%。R2(0.9819)显示该回归模型可准确预测乌桕梓油生物柴油的得率。在最优反应条件下重复使用20批次后,生物柴油得率仍然保持在90%以上,表明该固定化酶具有良好的操作稳定性。
(3)以“乒乓反应机理”为基础,首次构建了G63脂肪酶催化转酯动力学模型,实验验证该模型能较好地预测G63脂肪酶的转酯反应速度。抑制常数Ki=0.21mol/L,表明甲醇对该反应存在一定的抑制作用；反应常数k3=0.0549 L/mol·min,显示该酶对甘油三酯的二位酯键存在选择性。以上数据和分析表明该酶对底物存在一定程度的位置特异性。
(4)系统研究了Novozym 435/Lipozyme TL IM复合酶催化转酯制备生物柴油的工艺及动力学特征。通过改变介质种类和配比,确定能较好维持脂肪酶活性及稳定性的最佳溶剂组合———6:4(v/v)的乙腈与叔丁醇组合。进而通过响应面法优化反应条件,获得最佳参数：醇油摩尔比为6.4：1,复合酶用量为4.32%,分子筛用量为5.5%,反应20h后甲酯得率达96.38%。重复使用360h后酶活依旧稳定,显示该反应体系具有很好的操作稳定性、耐醇性及底物适应性。
(5)构建并比较了复合酶体系与单酶体系的催化转酯动力学模型。复合酶体系的Vmax(3.67 mol/L·min)大于单酶体系Vmax(3.25 mol/L·min),而KmTG和KmCH3OH均小于单酶体系的；复合酶体系抑制常数Ki(0.013mol/L)则略低于单酶体系的(0.019mol/L)。由此推论,在底物与酶的结合方面,复合酶体系要优于单酶体系,而复合酶体系转酯反应的抑制效应要小于单酶体系,首次从动力学角度证实Novozym 435/Lipozyme TL IM复合酶作用酯键存在一定的正协同效应。
(6)初步探索了基于生物柴油的高附加值精细化工品的合成工艺,以期扩大生物柴油的利润空间。以自制的乌桕梓油生物柴油为原料,膨润土为催化剂,催化制备二聚酸甲酯。优化获得的最佳二聚酸甲酯合成工艺条件：催化剂用量为9.9%,助剂用量为0.8%,在221℃下反应6.1h,二聚酸甲酯的得率为63.2%,与预测值65.26%非常接近。由于二聚酸甲酯是多能中间体,因此该工艺为生物柴油进一步高值化提供了前期工艺准备。
(7)对生物柴油和二聚酸甲酯的生产进行了初步经济效益分析。以年加工规模2.5万吨生物柴油为例,通过对其前期投入、生产成本和销售总额的估算,分析得出酶法制备生物柴油具有良好的市场前景,其深加工产品二聚酸甲酯更是具有诱人的经济效益。由此可见,大力发展生物柴油是一项利国利民的战略举措。
Biodiesel is one of the newly green bio-fuels with non-edible oils as raw material, and preparation through transesterification. It is an ideal substitution for fossil diesel. Compared with chemical preparation method, enzymatic catalyzed method, owing to mild reaction conditions, less methanol consumption and non-pollution to environment, has been become the mainstream direction of the research and development of biodiesel. However, enzymatic production of biodiesel also has some drawbacks, such as high price of lipase, being easily inactivated of lipase, etc.
Sapium sebiferum is a unique woody oil plant in China. Its seed has high oil content. Thus, it has the reputations of "China margarine" or "oil tree". However, its oil is not edible and unfit for human consumption because of toxic polyphenols. Its oil contains18-carbon fatty acid as high as 89% and is an ideal substrate for biodiesel production. In this study, several new techniques for biodiesel preparation catalyzed by immobilized Burkholderia cepacia lipase and compound lipases (Novozym 435/Lipozyme TL IM) were developed, and the innovative technology for synthesis of high value-added chemicals from biodiesel was further explored. Main results and innovations are listed as follows:
1. Physio-chemical properties and components of stillingia oil were analyzed. Oil components and physico-chemical properties represent oil quality, and determine the characteristics of biodiesel product. The analysis data showed that the oil contained seven fatty acids, among which 18-carbon fatty acid occupied the most, and their carbon chain length and structures were suitable for biodiesel production. It had modest acid value and a small quantity of phospholipids, but the saponification value and iodine value was fairly high. These provide feasibility for biodiesel production with stillingia oil catalyzed by lipase.
2. Experiments were conducted to optimize the conditions of biodiesel production catalyzed by immobilized B. cepacia G63 lipase from stillingia oil in solvent-free system. The obtained optimal conditions were:molar ratio of methanol to oil 4:1, loading of lipase 2.7%(based on oil weight), reaction temperature 41℃, content of moisture 7%, the rate of stirring speed 200rpm, and reaction 12h. Under these conditions, the biodiesel yield was up through the kinetic study, we have validated that the compound-enzyme system has positive synergetism.
6. On consideration of the fluctuation of market price of oil materials and commercial profit of biodiesel product, an innovative technique for synthesis of high value-added chemicals based on biodiesel was further explored. We prepared dimmer acid methyl ester from biodiesel and employed bentonite as catalyst. The optimum reaction conditions were optimized, and they are:catalyst loading 9.9%, additives quantity 0.8%, at a temperature of 221℃, reaction 6.1h. Under the optimal conditions, the dimmer acid methyl ester yield was up to 63.2%, which coincided with the predicted value (65.26%). The technique provides a pre-processing process for further development of high value-added chemicals based on dimmer acid methyl ester.
7. Herein, the economic benefits of biodiesel and dimmer acid methyl ester were preliminarily analysed, respectively. For example, a factory producing 25,000 tons of biodiesel annually, we estimated its total producution cost on the basis of its initial investment, production and sale costs, and we found that the deep processing product-dimmer acid methyl ester had a better economic benefit than biodiesel. Therefore, development of biodiesel and its high value-added chemicals has a potential prospect.
乌桕是我国特有的木本油料植物,因油脂含量高而有“中国植物牛油”、“石油树”等美称。该油脂中因含有毒酚类物质而不宜食用,但其十八碳脂肪酸的含量近90%,为制备生物柴油的理想原料。本文以乌桕梓油为对象,以脂肪酶为催化剂,研究生物柴油制备新方法,并尝试基于生物柴油的高值化技术探索。主要研究工作和创新点摘要如下：
(1)对乌桕梓油理化性质和成分进行了测定和分析。油脂成分和理化性质可以反映油脂品质,进而影响生物柴油产品性能。检测结果显示,该油脂含有7种脂肪酸,以十八碳脂肪酸为主,碳链长度和结构非常适合作为制备生物柴油的原料；其酸值适中,含微量磷脂,但皂化值偏大。该结果为酶法制备乌桕梓油生物柴油提供了可行性分析。
(2)对自行固定化洋葱伯克霍尔德菌G63脂肪酶在微水相体系中催化乌桕梓油制备生物柴油的工艺参数进行了优化。获得最佳工艺参数：醇油摩尔比4：1,脂肪酶用量2.7%,反应温度41℃。在此条件下,生物柴油得率为96.22%。R2(0.9819)显示该回归模型可准确预测乌桕梓油生物柴油的得率。在最优反应条件下重复使用20批次后,生物柴油得率仍然保持在90%以上,表明该固定化酶具有良好的操作稳定性。
(3)以“乒乓反应机理”为基础,首次构建了G63脂肪酶催化转酯动力学模型,实验验证该模型能较好地预测G63脂肪酶的转酯反应速度。抑制常数Ki=0.21mol/L,表明甲醇对该反应存在一定的抑制作用；反应常数k3=0.0549 L/mol·min,显示该酶对甘油三酯的二位酯键存在选择性。以上数据和分析表明该酶对底物存在一定程度的位置特异性。
(4)系统研究了Novozym 435/Lipozyme TL IM复合酶催化转酯制备生物柴油的工艺及动力学特征。通过改变介质种类和配比,确定能较好维持脂肪酶活性及稳定性的最佳溶剂组合———6:4(v/v)的乙腈与叔丁醇组合。进而通过响应面法优化反应条件,获得最佳参数：醇油摩尔比为6.4：1,复合酶用量为4.32%,分子筛用量为5.5%,反应20h后甲酯得率达96.38%。重复使用360h后酶活依旧稳定,显示该反应体系具有很好的操作稳定性、耐醇性及底物适应性。
(5)构建并比较了复合酶体系与单酶体系的催化转酯动力学模型。复合酶体系的Vmax(3.67 mol/L·min)大于单酶体系Vmax(3.25 mol/L·min),而KmTG和KmCH3OH均小于单酶体系的；复合酶体系抑制常数Ki(0.013mol/L)则略低于单酶体系的(0.019mol/L)。由此推论,在底物与酶的结合方面,复合酶体系要优于单酶体系,而复合酶体系转酯反应的抑制效应要小于单酶体系,首次从动力学角度证实Novozym 435/Lipozyme TL IM复合酶作用酯键存在一定的正协同效应。
(6)初步探索了基于生物柴油的高附加值精细化工品的合成工艺,以期扩大生物柴油的利润空间。以自制的乌桕梓油生物柴油为原料,膨润土为催化剂,催化制备二聚酸甲酯。优化获得的最佳二聚酸甲酯合成工艺条件：催化剂用量为9.9%,助剂用量为0.8%,在221℃下反应6.1h,二聚酸甲酯的得率为63.2%,与预测值65.26%非常接近。由于二聚酸甲酯是多能中间体,因此该工艺为生物柴油进一步高值化提供了前期工艺准备。
(7)对生物柴油和二聚酸甲酯的生产进行了初步经济效益分析。以年加工规模2.5万吨生物柴油为例,通过对其前期投入、生产成本和销售总额的估算,分析得出酶法制备生物柴油具有良好的市场前景,其深加工产品二聚酸甲酯更是具有诱人的经济效益。由此可见,大力发展生物柴油是一项利国利民的战略举措。
Biodiesel is one of the newly green bio-fuels with non-edible oils as raw material, and preparation through transesterification. It is an ideal substitution for fossil diesel. Compared with chemical preparation method, enzymatic catalyzed method, owing to mild reaction conditions, less methanol consumption and non-pollution to environment, has been become the mainstream direction of the research and development of biodiesel. However, enzymatic production of biodiesel also has some drawbacks, such as high price of lipase, being easily inactivated of lipase, etc.
Sapium sebiferum is a unique woody oil plant in China. Its seed has high oil content. Thus, it has the reputations of "China margarine" or "oil tree". However, its oil is not edible and unfit for human consumption because of toxic polyphenols. Its oil contains18-carbon fatty acid as high as 89% and is an ideal substrate for biodiesel production. In this study, several new techniques for biodiesel preparation catalyzed by immobilized Burkholderia cepacia lipase and compound lipases (Novozym 435/Lipozyme TL IM) were developed, and the innovative technology for synthesis of high value-added chemicals from biodiesel was further explored. Main results and innovations are listed as follows:
1. Physio-chemical properties and components of stillingia oil were analyzed. Oil components and physico-chemical properties represent oil quality, and determine the characteristics of biodiesel product. The analysis data showed that the oil contained seven fatty acids, among which 18-carbon fatty acid occupied the most, and their carbon chain length and structures were suitable for biodiesel production. It had modest acid value and a small quantity of phospholipids, but the saponification value and iodine value was fairly high. These provide feasibility for biodiesel production with stillingia oil catalyzed by lipase.
2. Experiments were conducted to optimize the conditions of biodiesel production catalyzed by immobilized B. cepacia G63 lipase from stillingia oil in solvent-free system. The obtained optimal conditions were:molar ratio of methanol to oil 4:1, loading of lipase 2.7%(based on oil weight), reaction temperature 41℃, content of moisture 7%, the rate of stirring speed 200rpm, and reaction 12h. Under these conditions, the biodiesel yield was up through the kinetic study, we have validated that the compound-enzyme system has positive synergetism.
6. On consideration of the fluctuation of market price of oil materials and commercial profit of biodiesel product, an innovative technique for synthesis of high value-added chemicals based on biodiesel was further explored. We prepared dimmer acid methyl ester from biodiesel and employed bentonite as catalyst. The optimum reaction conditions were optimized, and they are:catalyst loading 9.9%, additives quantity 0.8%, at a temperature of 221℃, reaction 6.1h. Under the optimal conditions, the dimmer acid methyl ester yield was up to 63.2%, which coincided with the predicted value (65.26%). The technique provides a pre-processing process for further development of high value-added chemicals based on dimmer acid methyl ester.
7. Herein, the economic benefits of biodiesel and dimmer acid methyl ester were preliminarily analysed, respectively. For example, a factory producing 25,000 tons of biodiesel annually, we estimated its total producution cost on the basis of its initial investment, production and sale costs, and we found that the deep processing product-dimmer acid methyl ester had a better economic benefit than biodiesel. Therefore, development of biodiesel and its high value-added chemicals has a potential prospect.
引文
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