豆油脱臭馏出物酶法甲酯化纯化V_E的研究
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摘要
本文以豆油脱臭馏出物为原料,以Novoyme 435酶为催化剂,对馏出物的间歇式和连续式酶法甲酯化工艺进行了研究,并对该反应的动力学规律进行了探索。对甲酯化产物进行了转酯化反应、甾醇分离和分子蒸馏研究,富集了高纯度的维生素E;对分离精制植物甾醇的工艺进行了摸索,同时对维生素E在鱼油中的抗氧化效果进行了考查。
     首先对豆油脱臭馏出物的组成和基本性质进行了测定并对其进行了刮膜式蒸发器脱水试验。水分含量由1.3g/kg降低至0.3g/kg。在Novoyme 435酶的作用下,对影响馏出物中脂肪酸甲酯化酯化率的因素:时间、酶用量、温度和底物比进行了单因素试验,并通过正交优化试验,发现影响酯化率的主要因素是反应时间和酶用量,其次为反应温度和底物比。经极差分析并综合各因素,确定四因素的最佳组合条件为酸醇摩尔比1:1.5,酶用量60plu/g,反应温度55℃,反应时间8h,该条件下酯化率为95.86%。薄层分析证实了豆油脱臭馏出物中的游离脂肪酸酶法甲酯化后转化为脂肪酸甲酯,其中的甘油酯并未甲酯化。甲酯化产物经20℃结晶,过滤分离,得粗甾醇,其纯度质量分数为54.01%,保留率为74.32%,分离甾醇后的甲酯化产物中维生素E含量质量分数为10.07%,保留率为98.35%。经甲酯化处理并脱除甲醇、水和甾醇后,维生素E的总保留率为95.86%。
     对脂肪酶催化豆油脱臭馏出物中的游离脂肪酸与甲醇的酯合成反应动力学进行了研究。从不同加酶量条件下反应初速度的变化研究,表明反应初速度随加酶量的增加而线性增加,酯化反应受动力学控制。并对反应的机理进行了初步推断,分析表明该甲酯化反应符合乒乓反应机制,并对其初速度动力学方程进行了推导,方程参数拟合表明实验值与计算值的趋势基本一致,反应机理推断和模型推导所作的假设合理。
     采用填充床反应器对连续式酶法甲酯化工艺进行了研究,考察了反应温度、底物比、进料速度、酶柱高、进料速度比值和分子筛用量对甲酯化酯化率的影响,对底物比、反应温度、进料速度比值进行三因素三水平正交实验,发现影响酯化率大小的因素依次是底物比、反应温度、进料速度比值。经极差分析,确定最佳反应条件为酸醇摩尔比1:2,进料速度比值0.075ml/min·cm,反应温度55℃,该条件下酯化率可达90.87%。该反应体系下,Novoyme 435酶的半衰期为45h。
     其次,对初步分离甾醇后的酶甲酯化产物利用甲醇钠催化其中甘油酯与甲醇发生转酯化反应,反应条件为0.5%(W/W油基)甲醇钠,0.7:1(V/W)甲醇,温度70℃,反应时间1h,经甘油分析表明原料体系中的甘油酯成分得到了较好的转化。此时维生素E含量质量分数10.14%,保留率96.27%。
     同时对不同冷析温度分离甾醇后的转酯化产物的脂肪酸组成和运动粘度进行了测定,并对滤饼中甾醇的纯度和保留率进行了分析,确定采用5℃冷析转酯化产物分离甾醇。
     对转酯化产物经分子蒸馏富集维生素E的工艺进行了研究。考察了一次蒸馏温度、二次蒸馏温度、进料速率、蒸馏压力以及刮膜器转速对产品维生素E含量和得率的影响。通过响应面分析,确定了二次蒸馏温度、进料速率、刮膜器转速对维生素E含量影响的回归方程,确定了最佳工艺:进料速度98.0~99.0ml/h,刮膜器转速156.0~157.0r/min,一次蒸馏温度110℃,二次蒸馏温度151~152℃,压力0.1Pa,维生素E含量可达质量分数50.98%,得率60.21%。对分子蒸馏的次数进行了研究,3次蒸馏后,维生素E含量质量分数为73.31%,得率为50.25%;4次蒸馏后,维生素E含量质量分数为85.35%,得率为45.62%。
     对冷析分离得到的粗甾醇进行了溶剂萃取洗脱的精制工艺研究,通过甾醇纯度和得率及经济性分析,选择正己烷作为粗甾醇洗脱剂;通过单因素实验和响应面分析,建立了甾醇纯度和得率回归方程,并进行了方差分析和显著性检验,确定了最佳工艺条件:液料比16.7:1,温度30℃,时间10min;该条件下,验证试验结果:甾醇纯度质量分数为85.10%,得率77.51%。产品经三次洗涤,纯度达到质量分数95.34%,得率为49.47%。
     天然维生素E为鱼油的特定抗氧化剂。以甘三酯型鱼油及乙酯型鱼油为原料,通过烘箱法耐热试验发现维生素E确实能够阻止鱼油的自动氧化。试验同时发现EPA,DHA含量质量分数30%鱼油中添加质量分数0.1%的天然V_E,比添加质量分数为0.12%V_E的抗氧化效果要好,可使鱼油的保质期延长144天。在EPA和DHA含量质量分数80%的鱼油中添加质量分数0.12%的天然V_E时,其抗氧化效果较好。
In this paper,intermittent and continuous enzymatic processes of methyl esterification on soybean oil deodorized distillate(SODD)as raw materials,using lipase Novoyme 435 as a catalyst were studied,and the mechanism of the the reaction kinetics was also investigated.After methyl esterification and molecular distillation,we enriched and refined high-purity vitamin E, and studied the process of separating and refining plants sterol from the methyl esterifing production.We also test the antioxidant effect of the vitamin E in the fish oil.
     Firstly,on the composition of raw materials(SODD) were determined,and the dehydration test was done.The moisture content decreased from 1.3g/kg to 0.3g/kg.The single factors test which impact the conversion of fatty acids to methyl ester was carried out.Through orthogonal process optimization experiments,we found that the main factors affecting the conversion were the enzyme dosage and reaction time,and that temperature and substrate ratio were of secondary interest.Using the extreme analysis and comprehensive analysis,we obtained the best combination of four factors.They are the acid conditions of methanol molar ratio of 1:1.5;the enzyme dosage 60 plu/g;the reaction temperature 55℃;and the reaction time 8 hours.The conversion rate under the conditions was 95.86%.The TLC analysis verified that most of the fatty acids from the SODD converted into fatty acid methyl ester,but that triglyceride did not change.The purity of sterol which was crystallized at 20℃,from the product of methyl esterification and separated by filtration was 54.01%,the preserving rate was 74.32%.The content of V_E in SODD was 10.07%and the preserving rate of vitamin E was 98.35%after removing sterols.After the methanol,sterols and moisture were removed,the total preserving rate of vitamin E was 95.86%.
     The reaction kinetics of lipase catalysis of SODD and methanol synthesis was studied.First of all,the studies of the influence of different enzyme dosage to the initial velocity showed that the initial velocity of the reaction linearly increased with the enzyme dosage increase,and esterification reaction was controlled by its kinetic.Secondly,with the inference of the reaction mechanism,the analysis showed that the reaction of methyl esterification conformed to accord with ping pong response mechanisms.Their initial velocity of the kinetic equations was derived. It was found that after fitting and of trending the parameters of the equation the calculated values were in agreement with the experimental data,reaction mechanism and model inferred is reasonable assumptions.
     The continuous process of methyl esterification of SODD was investigated by using fill-bed reactor.The conversion of fatty acids to methyl esters was optimized by using a statistical design.Through the single factor experimental and the orthogonal experiment,each influence factor(under experimental condition which the influence order in this experiment applies) to the response was:the substrate ratio>the reaction temperature>the input speed ratio. The optimum methyl esterification response conditions were:substrate ratio:1:2,temperature: 55℃,the input speed 0.075ml/min·cm.The obtained conversion rate was 90.87%.Under the optimum condition,the half-life of the Novoyme 435 is 45 hours.
     Secondly,by using sodium methoxide in the SODD that had been methyl esterficated and separated sterols,triglyceride and methanol were reacted.The reaction conditions were the 0.5% (W/W oil-based) sodium methoxide,0.7:1(V/W) methanol,temperature 70℃,the reaction time 1h.Glycerol analysis showed trilyceride components had been better conversion.The purity of vitamin E was 10.14%,the preserving rate was 96.27%.
     The kinematic viscosity of esterification product which had been crystallized under different temperature and separated sterols was analysed,and the sterol purity and the recovery rate were analyzed,then 5℃was determined to be the temperature of crystallization of esterification.
     Application of the molecular distillation process to enrich vitamin E of SODD was studied. It was tested that was first distillation temperature,second distillation temperature,feed rate, distillation pressure,speed scraping rate and times of distillation which impact the purity and recovery rate of the vitamin E.Through response surface analysis,the effects of second distillation temperature,feed rate,scraping speed on vitamin E content were set up in the regression equation,and the optimum experimental condition was identified:first distillation temperature of 110℃,the second distillation temperature of 151~152℃,press 0.1Pa,feed speed 98~99 ml/h,scraping speed 156.0~157.0r/min.Under the best conditions,the content of vitamin E was up to 50.98%,and the recovery rate reached to 60.21%.The times of distillation was studied,the content of vitamin E was 73.31%,and the recovery rate was 50.25%by three times distillation;the content of vitamin E was 85.35%,and the recovery rate only was 45.62%by four times distillation.
     Solvent extraction method was used to refine sterols.Through sterol purity and obtaining ratio and economic analysis,hexane was chosen as a washing decolorization agent for the raw sterols;Through the single factor experiments and response surface analysis,a regression equation was set up,and a significant test was done,the optimum conditions were determined: hexane to material 16.7:1,temperature 30℃,and time 10min.The confirmation test results verified that sterol purity was up to 85.10%,the recovery rate was 77.51%under the optimum conditions.The sterol purity was 95.34%,but the obtaining ratio was only 49.47%after 3 times of hexane extractions.
     Natural vitamin E is a better antioxidant in fish oil.Using glyceride fish oil and ethyl fish oil as raw materials,through heat-resistant test we found that vitamin E can indeed prevent fish oil from automatic oxidation.Compared to adding 0.12%mass fraction of the natural vitamin E, the oil containing 30%EPA and DHA which was added 0.1%mass fraction of the natural vitamin E had better antioxidant effect.The shelf-life can be extended to 144 days.For the fish oil containing 80%EPA and DHA with the addition of 0.12%natural vitamin E,its antioxidant effect was better.
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