A new generation of zirconia supported metal oxide catalysts for converting low grade renewable feedstocks to biodiesel

A new class of zirconia supported mixed metal oxides (ZnO–TiO2–Nd2O3/ZrO2 and ZnO–SiO2–Yb2O3/ZrO2) has demonstrated the ability to convert low quality, high free fatty acid (FFA) bio-oils into biodiesel. Pelletized catalysts of ZrO2 supported metal oxides were prepared via a sol–gel process and tested in continuous flow packed bed reactors for up to 6 months. In a single pass, while operating at mild to moderate reaction conditions, 195 °C and 300 psi, these catalysts can perform simultaneous esterification and transesterification reactions on feedstock of 33% FFA and 67% soybean oil to achieve FAME yields higher than 90%. Catalytic activity of the ZrO2 supported metal oxide catalysts was highly dependent on the metal oxide composition. These heterogeneous catalysts will enable biodiesel manufacturers to avoid problems inherent in homogeneous processes, such as separation and washing, corrosive conditions, and excessive methanol usage.