Presented during workshop on oleochemicals by MPOC -Cairo By: Eng: Ahmad Mustafa R&D and Quality Manager, Oleo Misr

1. Current Situation and Future Prospects of Oleochemical Industry
Ahmad Mustafa
R&D and Quality Manager, Oleo Misr
ahmedm@oleomisr.com
www.oleomisr.com

2. Focus Points
Current Situation of Oleochemicals
Specialty Oleochemicals (Production)
Specialty Oleochemicals (Definition)
Enzymatic Processes
Oleo Misr R&D
Conclusion

3. • Most of oleochemicals plants now are producing
basic oleochemicals.
• Few years ago, plants some plants started shifting
their production to specialty oleochemicals.
• Producing specialties need information and know
how which is not fully commercialized now.
Basic Specialty
Oleochemicals

4. • Main processes
 Fat Splitting
 Fractionation
 Transestrification
 Hydrogenation
 Saponification
• High-Value Processes
 Esterification
 Amidation
 Quaternization
 Sulfonation
 Ethoxylation
 Epoxidation
 Alcoholyses of epoxidized
fats
Basic Oleochemicals
Fatty acid, Crude glycerin
Methylesters
Fractionated acids & methylesters
Fatty alcohols
Soap noodles
Specialty Oleochemicals
MCT, IPM, IPP, monoglycerides
amides, amido amines
Quats, amine oxides
Sulfates
Ethoxylates
Plasticizers, stabilizers,
Polyols

5. Specialty esters are considered as a high value
oleochemicals that are produced in low quantities but
are highly priced with high profit margins.
5
With bioinnovation…

6. Basic Specialties
Specialty Oleochemicals

7. Profitability Profile
Profitability
ConsumptionLow
Low
High
High
Pharmaceuticals
Cosmetics and personal care
Biolubricant & Grease
Soap & Detergent
Source: ZAINAB IDRIS, exploring the potential of downstream sector in the palm oil
industry in Sabah. SEMINAR ON INVESTMENT OPPORTUNITIES IN HIGH GROWTH
SECTORS IN SABAH 2012

10. • Non-Toxic/ non corrosive, Thus eliminating environmental
risks.
• Eliminate side reactions.
• Plant using enzymatic technology has less investment.
• Less Energy Consumption.
• Less Processes Steps.
• Produces clean and pure product.
• Selective Reaction.

11. Glycerin
Monolaurate
Feed
additive
Emulsifier
Isopropyl
Palmitate
Bio-
solvent
Emollient
2-Ethylhexyl
Oleate
Placticizer
Bio-
lubricant

12. Glycerin Laurate has wide range of applications
FOOD COSMETICS Dietary
Supplements
Feed
Additive

13. 13

14. Experimental design
ue
1.05796
1.79715
2.53634
3.27554
4.01473
48
51
54
57
60
40
50
60
70
80
90
100
Conversion(%)
A: Temp. (C)B: Enzyme load (%)
lue
1.05796
1.79715
2.53634
3.27554
4.01473
48
51
54
57
60
40
50
60
70
80
90
100
Conversion(%)
A: Temp. (C)C: Molar ratio
Design-Expert® Software
Factor Coding: Actual
Conversion (%)
Design points below predicted value
93.23
43.2
X1 = B: Enzyme load
X2 = C: Molar ratio
Actual Factor
A: Temp. = 54
1.05796
1.79715
2.53634
3.27554
4.01473
1.05796
1.79715
2.53634
3.27554
4.01473
40
50
60
70
80
90
100
Conversion(%)
B: Enzyme load (%)C: Molar ratio
14Interactive Effects of Different Variables on Glycerin Laurate Formation

15. 1 0 . 0 0 1 5 . 0 0 2 0 . 0 0 2 5 . 0 0 3 0 . 0 0 3 5 . 0 0 4 0 . 0 0 4 5 . 0 0
1 0 0 0 0 0 0
2 0 0 0 0 0 0
3 0 0 0 0 0 0
4 0 0 0 0 0 0
5 0 0 0 0 0 0
6 0 0 0 0 0 0
7 0 0 0 0 0 0
8 0 0 0 0 0 0
9 0 0 0 0 0 0
T im e -- >
A b u n d a n c e
T I C : 0 2 0 1 0 0 2 . D d a t a . m s
1 1 . 6 0 7
1 5 . 9 7 6
1 6 . 8 5 8
1 7 . 1 5 6
2 3 . 6 7 3
2 3 . 8 8 5
3 4 . 9 4 3
15
GC Chromatogram for Glyceryl Laurate
Triester
Monoester
Diester
Lauric

16. 0
10
20
30
40
50
60
70
80
90
100
1 2 3 4 5 6 7
Residualactivity
Number of cycles
16

17. 17
0
10
20
30
40
50
60
70
80
90
100
0 30 60 90 120 150 180
Conversion,%
Time, min
Without emulsifier
with emlsifier
Lipase reusabilityEmulsifier addition

18. Plasticizer is a substance that is added to other polymeric
substances to aid processing of the polymer and to impart
flexibility, plasticity, softness, and reduce brittleness.
Influence of plasticizer
Lower hardness
Higher elongation
Better low Temperature
On Processing
Lower Viscosity
Faster filler
incorporation
Lower power demand
On Physical properties
i.e. Green Non Phthalate Plasticizer

19. First
Plasticizer
1860 1930
Phthalates
Introduced
1980’s
DEHP Declared
Carcinogenic
2001
IARCRe-classifies
DEHP as non-
carcinogenic
1998
European
Parliament calls for
alternatives to
phthalates
Timeline (history) for Plasticizers
2005
Green Plasticizer

20. Safety Data Sheet
For DOP
Replacing Plasticizer derived from petroleum with
plasticizer based oleochemicals is Urgent

21. Oleomisr pays attention to produce a green
replacer of DEHP and DOP Utilizing Palm Oil
• Utilizing Palm FA to produce
Green Polymer Additives
combines functionality with
innovation using renewable and
cheap feedstock.
• Producing epoxized palm oil is
not only used as a placticizer,
however it can be used also as a
starting material for producing
polyurethane which has a large
potential market.
Palm Based Placticizer
(Oleo Misr R&D)

23. 23
0
20
40
60
80
100
0 30 60 90 120 150 180
Conversion,%
Time, min
As isopropyl palmitate is a non-greasy emollient that is has good
spreading characteristics, it finds a numerous applications in
cosmetics industry such as: bath oils, creams, lotions, make-up,
hair care products, deodorants, and pressed powders. Also it has
other versatile applications in different areas such as a solvent or
co-solvent in ink and paint industries.

24. ware
e predicted value
w predicted value
d
onc. = 5.5
1
1.6
2.2
2.8
3.4
4
3
6
9
12
15
40
50
60
70
80
90
100
Conversion(%)
A: Molar ratio (mmol)B: Enzyme amount (w/w, %)
Design-Expert® Software
Factor Coding: Actual
Conversion (%)
Design points above predicted value
Design points below predicted value
90
45
X1 = A: Molar Ratio
X2 = C: Molecular sieves conc.
Actual Factor
B: Enzyme Load = 2.5
1
2
3
4
5
6
7
8
9
10
3
6
9
12
15
40
50
60
70
80
90
100
Conversion(%)
A: Molar ratio (mmol)C: Molecular sieves amount (w/w, %)
t® Software
: Actual
%)
nts above predicted value
nts below predicted value
me Load
cular sieves conc.
o = 9
1
2
3
4
5
6
7
8
9
10
1
1.6
2.2
2.8
3.4
4
40
50
60
70
80
90
100
Conversion(%)
B: Enzyme amount (w/w, %)C: Molecular sieves amount (w/w, %)
Experimental design
Interactive Effects of Different Variables on Isopropyl palmitate Formation

25. 25
Comparison between Chemical and Enzymatic Methods.
Pretreatment
Reaction
Washing
Bleaching
Filtration
Distillation
Catalyst
Acid/water
Bleaching earth
Filter aid &
Bleaching earth
Soaps
Unreacted
fatty acids
By-products,
color, etc.
>200 °C
>100 °C
50−60 °C
Spent Bleaching
earth
Chemical
FFA
Pretreatment
Reaction
Distillation
Enzyme
reuse
Enzymatic
Soaps, etc.
By-products
FiltrationSeparationGlycerin
Glycerine laurate Glycerine laurate

26. 26
1. Specificity.
2. Low Energy
Consumption.
3. Green & Sustainable
Products.
4. Environmental Friendly.
Enzymes have a Great Leap to Make

27. 27
1. Enzyme cost.
• Reusability.
2. Reaction time.
• Media emulsification
But there are some Challenges along the Path to
Commercialization
Lauric acid
Glycerin

29. Environmental Footprint
29
83%
Reduction

30. 30
Environmental Footprint
88%
Reduction

31. 31
Environmental Footprint
100%
Reduction

32. 32

37. Thank You
Ahmad Mustafa
R&D and Quality Manager, Oleo Misr
ahmedm@oleomisr.com
www.oleomisr.com