Empty fruit bunches (EFB) are waste products in the palm oil industry. Upon pressing of EFB, a liquor is produced which contains low grade fats, oils, and greases (FOG). These are the least valuable products of palm oil production, and are often discarded as waste. It is shown here that the EFB pressed liquor can be thermally transformed at or below 350 °C to produce a series of hydrocarbons in the range of kerosene and diesel fuel. This is distinctly different from other studies of biofuels from palm oil, which were based entirely on biodiesel (fatty acid methyl ester (FAME)) and biogas production. Furthermore, this transformation takes place without addition of an external catalyst, as was shown by comparison to reactions with the potential Lewis acid catalysts, ferric sulfate, and molecular sieves. The product distribution is similar to that obtained from brown grease, another waste FOG stream obtained from the sewage treatment industry, although the products from palm oil waste are less sensitive to reaction conditions.

Brown grease is a generic term for the oily solids and semi-solids that accumulate in the sewer system and in sewage treatment plants. It has previously been shown that brown grease undergoes pyrolysis to form a homologous series of alkanes and 1-alkenes between 7 and 17 carbon atoms, with smaller amounts of higher hydrocarbons and ketones up to about 30 carbon atoms. The initial study was performed in batch mode on a scale of up to 50 grams of starting material. However, continuous processes are usually more efficient for large scale production of fuels and commodity chemicals. This work describes the research and development of a continuous process. The first step was to determine the required reactor temperature. Brown grease consists largely of saturated and unsaturated fatty acids, and they react at different rates, and produce different products and intermediates. Intermediates include ketones, alcohols, and aldehydes, and Fe(III) ion catalyzes at least some of the reactions. By monitoring the pyrolysis of brown grease, its individual components, and intermediates, it was determined that a reactor temperature of at least 340 °C is required. A small scale (1 L) continuous stirred tank reactor was built and its performance is described.

The conversion of brown grease using pyrolysis reactions represents a very promising option for the production of renewable fuels and chemicals. Brown grease forms a mixture of alkanes, alkenes, and ketones at a temperature above 300°C at atmospheric pressure. This work is a computational study of the detailed reaction mechanisms of brown grease pyrolysis using DFT methodology. Prior experimental investigations confirmed product formation consistent with a set of radical reactions with CO₂ elimination, as well as ketone by product formation, CO forming reactions, and formation of alcohols and aldehydes as minor byproducts. In this work, computational quantum chemistry was used to explore these reactions in greater detail. Particularly, a nonradical pathway formed ketone byproducts via the ketene, which we refer to as Pathways A1 and A2. Radical formation by thermal decomposition of unsaturated fatty acids initiates a set of reactions which eliminate CO₂, regenerating alkyl radicals leading to hydrocarbon products (Pathway B). A third pathway (Pathway C) is an alternative set of radical reactions, resulting in decarbonylation and formation of minor byproducts. The results of the calculations are in good agreement with recent experimental studies.

A combined computational and ¹³C NMR study was used to investigate the formation of mixed aggregates of 1‐methoxyallenyllithium and lithium chloride in tetrahydrofuran (THF) solution. The observed and calculated chemical shifts, as well as the calculated free energies of mixed aggregate formation (MP2/6‐31+G(d)), are consistent with the formation of a mixed dimer as the major species in solution. Free energies of mixed dimer, trimer, and tetramer formation were calculated by using the B3LYP and MP2 methods and the 6‐31+G(d) basis set. The two methods generated different predictions of which mixed aggregates will be formed, with B3LYP/6‐31+G(d) favoring mixed trimers and tetramers in THF solution, and MP2/6‐31+G(d) favoring mixed dimers. Formation of the sterically unhindered mixed dimers is also consistent with the enhanced reactivity of these compounds in the presence of lithium chloride. The spectra are also consistent with some residual 1‐methoxyallenyllithium tetramer, as well as small amounts of higher mixed aggregates. Although neither computational method is perfect, for this particular system, the calculated free energies derived using the MP2 method are in better agreement with experimental data than those derived using the B3LYP method.