Fatty acids are indispensable ingredients in a broad range of high-value products, including pharmaceuticals, cosmetics, food additives, industrial lubricants and many more. Current commercial production plants usually employ a thermal fat-splitting process that is often not economical for small- and medium-scale manufacturing. A new enzymatic fat-splitting technology developed by Novonesis Group (Lyngby, Denmark; www.novonesis.com) and thyssenkrupp Uhde GmbH (Dortmund, Germany; www.thyssenkrupp-uhde.com) requires significantly lower energy, boosts yield and can be operated efficiently at a wider range of production scales than conventional processes.
“In the fat-splitting process, triglycerides from vegetable oils are hydrolyzed into fatty acids and glycerin. Traditionally, this is done in a thermal splitter column under high temperature, high pressure and with large amounts of water, making it energy-intensive and costly. Our gentler method cuts energy use by up to 40% while boosting yield up to 2%, because fewer unwanted reactions occur. It also uses up to 40% less water, reducing not only water consumption, but the energy needed for evaporation,” explains Christian Schmock, head of Novonesis’ Oils & Fats business unit.
Source: Novonesis
Relying on Novonesis’ Lipura Split enzyme to efficiently target the triglycerides’ ester bonds and liberate fatty acids, the new technology replaces large thermal columns with simple stirred reactors. Removing equipment complexity means that the process can be economical at smaller scales, which not only decreases upfront investment costs, but also can decrease time to market for new formulations. “Traditional thermal fat-splitting requires a major investment — you’re looking at a minimum of 300-ton/d capacity just to generate a decent return on investment. At the same time, producers face limited adaptability because delivery times can exceed 18 months. By then, market conditions may have shifted,” notes Schmock, pointing out that scaling from just 50 tons/d capacity is possible, and capital-expenditure costs can be reduced by as much as 60%.
The companies have spent the last two years scaling up the enzymatic splitting process, running pilot trials and demonstrating scaleup from 2-to 20-ton reactors. “Now, with thyssenkrupp Uhde, we are investing in and operating a continuous pilot plant in Thailand with a capacity of 2 L/h — demonstrating the technology at an industrially relevant scale and allowing producers to validate performance under real-world conditions,” says Schmock.