Development and economic evaluation of an eco-friendly biocatalytic synthesis of emollient esters.

During the past decades the understanding and prospects of enzyme-catalysed reactions have been massively widened and there are a number of implemented large-scale enzymatic processes mainly based in the use of commercial biocatalysts. As it might happen that the same process can be successfully carried out by different commercial lipases, the election of the biocatalyst must rely on productivity and economic considerations. This work presents productiveness and direct operation cost evaluation as a key tool for the selection between two commercial lipase catalysts, the versatile but expensive Novozym® 435 and a much more economical option, Lipozyme® TL IM, in the synthesis of spermaceti, a mixture of emollient esters with cosmetic applications. Proving that Novozym® 435 leads to minimum savings of 10% with respect to the cheapest immobilized derivative, biocatalyst cost does not appear to be the major contribution to the economics of the processes under study, due to their great capacity to be recovered and reused. At laboratory scale, the biggest economic investment is caused by substrates, which can be massively reduced at industrial scale by using bulk reagents. In such case, energy cost may be the major contribution to the process economy. This work proposes an optimized process ready to be scaled-up in order to accurately determine the energetic requirements of the possible industrial enzymatic synthesis.

Solvent-free enzymatic production of high quality cetyl esters.

A solvent-free biocatalytic process for the synthesis of high quality cetyl laurate, myristate, palmitate and stearate has been optimized. This enzymatic procedure follows the fundamental principles of the Green Chemistry and lead to sustainable products, which can be labeled as natural and conform to the principal requirements for its use in high value-added goods. The four esters selected are the main components of spermaceti, a mixture of waxes very appreciated in cosmetic and pharmacy because of its physical properties and emolliency, which was formerly extracted from the head of the sperm whales. In this paper, the influence of the amount of biocatalyst, the commercially available Novozym(®) 435, and the temperature were studied in an open-air batch reactor before carrying out the synthesis in a high performance vacuum reactor with dry nitrogen input to shift the equilibrium towards product formation. Under optimal conditions, conversion was higher than 98.5 %. The characterization of the enzymatic cetyl esters puts in evidence that these are ultra-pure compounds, which have similar properties to the ones obtained through the conventional industrial processes with the extra benefit of being environmentally friendly.

Sustainable synthesis of branched-chain diesters.

Esters from branched alcohols and dicarboxylic linear acids are widely used as lube bases due to their good performance at low temperatures. This work proposes a new process to synthesize bis(2-ethylbutyl) adipate and bis(2-ethylbutyl) sebacate by using the lipase-based catalyst Novozym® 435 in a solvent-free system. Different reaction strategies have been tested in order to minimize 2-ethyl-1-butanol losses due to its evaporation and optimum operation conditions have been determined: 2.5 % of biocatalyst, 50 °C and a molar excess of alcohol of 15 % for the adipic diester and of 25 % for the sebacic one. It has also been proven that the immobilized enzyme can be reused in seven successive reaction cycles, achieving high yields without an appreciable reduction of activity. This biocatalytic pathway is a promising basis for the development of a more sustainable large scale process for obtaining biodegradable lubricants, as it is pointed out by productivity, economic and green metrics calculations.

Biocatalytic solutions to cyclomethicones problem in cosmetics.

Silicones are polymers that have properties of great interest for cosmetic and personal care industry, especially D4 (octamethylcyclotetrasiloxane) and D5 (decamethylcyclopentasiloxane), generically named cyclomethicones. However, different studies show the hypothesis that the use of these products is harmful and, therefore, several countries have adopted legislative actions to limit their use in personal care and cosmetic products. Faced with this new situation, different cosmetic companies began to look for different alternatives to cyclomethicones, mainly: organomodified silicones or esters. The former are based on the addition of functional groups to the main chain of silicon and oxygen. The latter represent a totally different line, since their functional group is the ester, but they have properties similar to silicones. Esters, especially branched-chain ones are currently the more promising alternative to replace cyclomethicones in cosmetic formulations. Nowadays, most of them are obtained by chemical reactions that require high temperatures and non-selective /contaminant catalysts that lead to low-quality final products. As an alternative, biocatalytic synthesis occurs always at mild operation conditions supplying ultra-pure, odor, and colorless products with less wastes and side reactions. Therefore, biocatalysis is a valid and environmentally sustainable option for the synthesis of silicone-substitute esters used in cosmetic formulations.