Sustainable and competitive process for enzymatic production of specialty esters based on the Jet Reactor technology

The production of specialty esters using enzymes is well known and has great environmental benefits compared to traditional thermochemical processes. Enzymatic esterification is an inherently safer process with a significantly lower energy demand and allows for the reduction of waste and corresponding yield losses, while also capable of making completely new ester products. Still, despite great advantages in terms of product quality and resource-efficiency, there are fundamental challenges with enzymatic esterification, mainly cost-in-use related.

Herein, we present a novel process to address these major challenges. The Jet Reactor technology enables both gentle reaction conditions for the enzymes as well as efficient water removal at high circulation rates, through which we can extend the catalyst lifetime, shorten the reaction time from >36 hrs to 12 hrs for Glycerol Tricaprylate/Tricaprate (MCT) production (see acid value and hydroxyl value trend in the chart), and ultimately provide a competitive cost-in-use of the enzyme.

After proof of concept, pilot trials on a 25-liter Jet Loop Reactor have been performed for demonstration of the technology and sample production of Isopropyl Palmitate, Isopropyl Caprylate/Caprate, Glycerol Tripalmitate and MCT. Enzyme lifetime studies have been performed in lab-scale to produce MCT, where the enzyme maintained its performance for more than 1000 hrs at 85 degC. Translating this to the Jet Reactor process, gives an enzyme cost-in-use that is < 5 % of the product value.

The novel process significantly impacts the feasibility of using enzymes in the production of a wide range of esters by enabling a switchover from the thermochemical process to a cost competitive, low-temperature process and can thus enable a broad commercial adaptation of enzymatic esterification. The technology is ready for commercial implementation.