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Fuel 87 (2008) 2590–2597

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Winterization of biodiesel by micro process engineering

S. Kerschbaum, G. Rinke *, K. Schubert
Karlsruhe Research Center, Institute for Micro Process Engineering, Postfach 3640, 76021 Karlsruhe, Germany

Received 26 July 2007; received in revised form 18 January 2008; accepted 23 January 2008
Available online 21 February 2008

Abstract

A new method for winterization of biodiesel based on waste cooking oil is demonstrated, using micro heat exchangers with channel
diameters of 200 lm. Biodiesel is pumped from a vessel through a micro heat exchanger in such a way, that pure seed crystals of satu-
rated fatty acid methyl esters are produced at the outlet of the micro channels and injected back into the biodiesel vessel. Thus micro
process engineering allows the reduction of the sum of saturated fatty acid methyl esters within biodiesel based on waste cooking oil
from 21.3% to 9.6%. This corresponds to a reduction in CFPP value of 11 K, which means that this biodiesel can be used at temperatures
down to 264 K.
Ó 2008 Elsevier Ltd. All rights reserved.

Keywords: Biodiesel; Winterization; Micro heat exchanger

1. Introduction
Rapeseed oil can be used as fuel for combustion engines,
but its viscosity is much higher than usual diesel fuel and
requires modifications of the engines. To avoid such mod-
ifications of the engines rapeseed oil is converted into bio-
diesel by transesterification. Biodiesel fuels have a lot of
environmental advantages [1–3], e.g. they are biodegrad-
able, non-toxic and show low emission during combustion.
However, there are some disadvantages. The costs of pro-
ducing biodiesel are larger than of normal diesel fuel and
biodiesel is often only competitive because it is tax-
favoured. These costs can be reduced if waste cooking oil
is used as raw material instead of rapeseed oil [4–6].
A technical aspect is that parts of automotive engines may
be chemically attacked by biodiesel components. Biodiesel
has a limited storage stability, which depends on chemical
composition of biodiesel [7]. Furthermore, in winter crystal-
lization of high melting saturated fatty acid methyl esters
may lead to plugging of filters and tubes. A fuel suited for
*
Corresponding author. Tel.: +49 7247 823556; fax: +49 7247 823186.
E-mail address: guenter.rinke@imvt.fzk.de (G. Rinke).
low ambient temperatures must have a low cold filter plug-
ging point (CFPP). There is a correlation between saturated
fatty acid methyl esters, the higher the concentration of sat-
urated compounds the higher CFPP value [8].
One possibility to overcome this disadvantage arising at
low temperatures is the so-called winterization. This tech-
nique can be applied to pure oils [9] or biodiesel [10,11].
In case of biodiesel the concentration of saturated fatty
acid methyl esters has to be reduced. One possibility is to
ozonize vegetable oil [11], which cannot prevent the forma-
tion of crystals, but will lead to smaller crystals. The sim-
plest method is to cool down biodiesel with subsequent
removal of crystals by filtration [10]. In this paper, biodie-
sel based on waste cooking oil was used and the treatment
resulted in a reduction of the CFPP value of 4 K. However,
the method did not work reliable and sometimes failed. To
enhance the yield, it may be advantageous to use a solvent,
e.g. hexane [12]. After this treatment hexane has to be
removed. This is associated with additional process engi-
neering and costs. Another possibility to produce biodiesel
with low cloud points is the chemical reaction of soy oil
using solid acid catalysts at high temperatures [13], where
the cloud point (first crystals arise) of biodiesel based on
soy oil, was reduced for 6 K. Unfortunately the viscosity

0016-2361/$ - see front matter Ó 2008 Elsevier Ltd. All rights reserved.
doi:10.1016/j.fuel.2008.01.023
 S. Kerschbaum et al. / Fuel 87 (2008) 2590–2597
Fig. 1. Gas chromatogram of biodiesel based on waste cooking oil, see Table 1 for more details.
increased. A simple method is the blending of biodiesel
with mineral diesel to get a lower CFPP value [14].
Recently, attempts were made to use additives, e.g. Visco-
plex 10-305TM [15]. In this case biodiesel based on a mix-
ture of 80% rapeseed oil and 16% pork lard methyl ester
showed a reduction of CFPP value of 7 K. Although the
crystals produced with these additives are small enough
to fulfil the CFPP standard, they are not always small
enough to pass modern fuel filters. For this and other rea-
sons Viscoplex 10-305 is no more available commercially.1
Aim of this work is the winterization of biodiesel based
on waste cooking oil, which is less expensive than biodiesel
based on rapeseed oil. Until now, no method and no addi-
tives are known to solve this problem in an economic way.
Our new method does not use additives or blends and
employs a pure physical method. The method is based on
winterization with micro system technology using micro
heat exchangers [16] developed by the Karlsruhe Research
Center.
2. Experimental procedures
2.1. Samples
All experiments were done with samples based on waste
cooking oil methyl ester (WME). They were taken directly
after production from a biodiesel plant2 and consumed
within one month.
1
RohMax Additives GmbH, Kirschenallee, 64293 Darmstadt,
Germany.
2 3
Biowerk Sohland GmbH, Saxony, Germany.
2591
2.2. Analytics
For analyzing the chemical composition of biodiesel
during the winterization process we used a gas chromato-
graph (Agilent 6850 Series II, Injector Agilent 7683) with
a DB-Wax column (length: 30 m) and a FID at 573 K.
Helium was used as carrier gas with a throughput of
64 ml min1. Furthermore H2 with 30 ml min1 and air
with 400 ml min1 were employed. The temperature pro-
gram started at 403 K. This temperature was hold for
1 min and then heated up with a rate of 5 K min1 to a
temperature of 513 K. This temperature was hold for
10 min for the rest of the chromatogram. The calibration
of this column was done with three standard samples Rot-
ichrom ME11, ME19 and FO73 containing all fatty acid
methyl esters, we needed. The temperature program was
optimized to get well separated peaks. The integrated peaks
of all measured compounds were linear as a function of
concentration. The reproducibility and accuracy of these
measurements amount ±0.1%. Fig. 1 shows a typical chro-
matogram of our biodiesel sample. The relevant com-
pounds are shown in Table 1 together with the retention
times.
2.3. Preliminary investigations
The simplest idea for winterization is to cool down bio-
diesel slowly in order to precipitate high melting saturated
fatty acid methyl esters. This was done first with a double-
Carl-Roth GmbH, Karlsruhe, Germany.
2592 S. Kerschbaum et al. / Fuel 87 (2008) 2590–2597

Table 1
Retention times of gas chromatographic peaks for each compound
Compound Retention time (min)
Myristic acid methyl ester 8.44
Palmitic acid methyl ester 11.78
Stearic acid methyl ester 15.14
Oleic acid methyl ester 15.50
Linoleic acid methyl ester 16.22
a-Linolenic acid methyl ester 17.19
Arachidic acid methyl ester 18.26
11-Eicosenic acid methyl ester 18.56
Behenic acid methyl ester 21.28
Eruric acid methyl ester 21.60

walled glass vessel, filled with biodiesel in its middle part. A

cooled ethylene–glycol mixture was flowing through the
double-walled space. In spite of the fact that crystals were
produced, no change in chemical composition was
observed. Another experiment was done with a vessel, sur-
rounded by a cooling coil and thermal insulation. At the
inner wall of this vessel crystals were generated and
removed by a rotating scraper. In this experiment no
change in chemical composition of the liquid phase was
observed, neither. The compositions were measured by
the described gas chromatographic method. Because the
concentrations of the liquid phase did not change, the crys-
tals have to be clusters of saturated fatty acid methyl esters
containing liquid unsaturated fatty acid methyl esters
inside. As fractionized crystallization methods failed, we
looked for possibilities to produce pure crystals of satu-
rated fatty acid methyl esters. Micro process engineering
was found to solve the problem. This method is described
in detail in the following.
For a proper design of micro heat exchangers for cool-
ing of biodiesel the cold flow behaviour of biodiesel must
be known. The most important property is viscosity, as
the pressure drop in heat exchangers depends on viscosity.
So far most measurements have been done at room temper-
ature or above [17,18]. Little information is available for
temperatures below room temperature. Therefore, we mea-
sured the viscosity of biodiesel based on waste cooking oil
at temperatures down to 258 K [19].
Fig. 2. Schematic view of the experimental setup.
2.4. Experimental setup
Fig. 2 gives a schematic view of the experimental setup.
A thermally insulated 5 l beaker was filled with a biodiesel
sample, which may be stirred with a magnetically coupled
stirrer. The biodiesel is delivered by a gear pump (pump
2) to a cross flow micro heat exchanger [16], which is shown
in Fig. 3. The micro heat exchanger consists of 75 foils per
passage, each foil having 100 rectangular channels 40 mm
long with 200 lm width and 100 lm depth. Having passed
the micro heat exchanger the biodiesel returns back to the
beaker. To be sure that no crystals of saturated fatty acid
methyl esters enter the micro heat exchanger, the tube
between the beaker containing biodiesel with crystals and
the micro heat exchanger was surrounded with a heating
tube. Within this heating tube hot water of 323 K was cir-
cled, coming from thermostat 3. For cooling the biodiesel
within the micro heat exchanger thermostat 1 (Haake Phö-
nix C25P), filled with a 1:1 mixture by volume of water and
ethylene glycol, was used. This cooling liquid is pumped
(pump 1) through the second passage of the micro heat
exchanger and then back to thermostat 1. Thermostat 2
is filled with the same refrigerant and is cooling the beaker

Fig. 3. Cross flow micro heat exchanger with inner structures.

 S. Kerschbaum et al. / Fuel 87 (2008) 2590–2597
filled with biodiesel by a PVC tube wrapped around this
beaker. The surrounding is enclosed with a thermal insula-
tion. In order to observe crystals, we used an inspection cell
with two glass plates mounted at the outlet of the micro
heat exchanger. The experimental setup allows controlling
the throughput of biodiesel and of the cooling liquid by
variation of the pump speed.
At the inlets of the micro heat exchanger platinum tem-
perature sensors and pressure sensors were used. The tem-
peratures at the outlets of the micro heat exchanger and
within the beaker were monitored, too. All data were mea-
sured with a data acquisition system (Yokogawa DX220-1-
2). The temperatures of the cooling liquids can be con-
trolled and programmed with a precision of ±0.2 K.
3. Results
Two experiments were done to investigate two different
methods.
3.1. Method 1
Biodiesel in the beaker was cooled down just above the
cloud point indicated by the formation of crystals and scat-
tering of light in the inspection cell. This value was deter-
mined before this experiment by measuring the
temperature when the first crystals arise. Then the biodiesel
was pumped through the micro heat exchanger at a
throughput of 100 ml min1. The throughput of the
water–ethylene mixture flowing through the other passage
of the micro heat exchanger amounted to 1000 ml min1.
Fig. 4. Temperature and sum of concentrations of saturated fatty acid methyl esters as function of time, crystallization method 1.
2593
This large ratio was chosen to get a uniform temperature
profile at the biodiesel outlet of the cross flow micro heat
exchanger. When the temperature of the water–ethylene
mixture flowing through the micro heat exchanger was low-
ered, small crystals were observed visually in the inspection
cell, which were injected into the beaker. After that the
temperature in the beaker was kept constant. The biodiesel
within the beaker was stirred continuously in order to dis-
tribute all crystals homogeneously. Then the temperature
of the biodiesel in the beaker was lowered by changing
the temperature of thermostat 2 with a rate dependent on
the experiment. The composition of the liquid phase of bio-
diesel was measured with the GC. Fig. 4 shows the temper-
ature of biodiesel in the beaker and the sum of
concentrations of saturated fatty acid methyl esters in the
beaker as function of time. The concentration drops and
after 16 days the concentration is reduced to about half
of its initial value. Table 2 shows the concentrations of
the most important compounds of biodiesel at the begin-
ning and the end of the experiment.
3.2. Method 2
The second experiment was similar to the first one.
Again, the production and injection of crystals were started
after the cloud point had been reached. The difference to
method 1 was that after 1 day the injection of crystals
and stirring within the beaker were stopped. Therefore,
sedimentation of saturated fatty acid methyl esters could
begin. Fig. 5 shows the temperature of biodiesel in the bea-
ker and the sum of concentrations of saturated fatty acid
2594 S. Kerschbaum et al. / Fuel 87 (2008) 2590–2597

Table 2 Table 3
Concentrations in weight percent of different biodiesel compounds Concentrations in weight percent of different biodiesel compounds
(unsaturated and followed by saturated saturated fatty acid methyl esters) (unsaturated and followed by saturated fatty acid methyl esters) at the
at the beginning and at the end (15.8 days) of the crystallization beginning and at the end (8 days) of the crystallization procedure, method
procedure, method 1 2
Compound Starting concentration Final concentration Compound Starting concentration Final concentration
[%] [%] [%] [%]
Oleic acid ME 40.7 45.5 Oleic acid ME 40.7 46.5
Linoleic acid ME 33.2 37.5 Linoleic acid ME 33.6 38.6
a-Linolenic acid ME 3.6 4.1 a-Linolenic acid ME 3.6 4.2
11-Eicosenic acid 0.8 0.9 11-Eicosenic acid 0.8 1.0
ME ME
Eruric acid ME 0.3 0.3 Eruric acid ME 0.2 0.3
Myristic acid ME 0.4 0.5 Myristic acid ME 0.4 0.5
Palmitic acid ME 15.8 8.2 Palmitic acid ME 15.4 6.6
Stearic acid ME 4.4 2.2 Stearic acid ME 4.3 1.8
Arachidic acid ME 0.4 0.2 Arachidic acid ME 0.4 0.2
Behenic acid ME 0.5 0.3 Behenic acid ME 0.5 0.3
Lignoceric acid ME 0.3 0.2 Lignoceric acid ME 0.3 0.2
Sum of saturated 21.8 11.6 Sum of saturated 21.3 9.6
ME ME
ME = methyl ester. ME = methyl ester.

methyl esters in the beaker as function of time. The concen- 4. Discussion

tration drops, too. The rate of temperature decrease was
varied again in order to see the influence on the rate of
the concentration decrease. In this experiment the concen-
tration is reduced to about half of the initial value after 7
days. Table 3 shows the concentrations of the most impor-
tant compounds of biodiesel at the beginning and the end
of the experiment.
For the following discussion it is important to note that
the CFPP value is correlated to the sum of concentrations
of saturated fatty methyl esters according to the following
equation [10]:
CFPP= C ¼ 0:99 ð% Saturated fatty methyl estersÞ  19:0
ð1Þ

Fig. 5. Temperature and sum of concentrations of saturated fatty acid methyl esters as function of time, crystallization method 2.
 S. Kerschbaum et al. / Fuel 87 (2008) 2590–2597
Fig. 6. Sum of concentrations of saturated fatty acid methyl esters as function of biodiesel bath temperature, crystallization methods 1 and 2.
Our biodiesel had 21% saturated fatty methyl esters
before winterization, which gives a CFPP value of 1.8 °C
(275 K) according Eq. (1), which is within the accuracy
of Eq. (1). The CFPP value was measured only one time4
before the beginning of our experiments and amounted
274 K. It was not possible to measure the CFPP value dur-
ing the winterization process, because the volume of the 5 l
biodiesel sample was too small and the measurement would
disturb the experiment. To establish a supersaturation of
saturated fatty methyl esters the bath temperature should
be lower than the CFPP value.
Fig. 4 (method 1) shows a decrease in the sum of the
concentrations of saturated fatty acid methyl esters as a
function of time. This is a result of crystallization of satu-
rated fatty acid methyl esters, which was achieved by
decreasing the bath temperature. At the beginning the con-
centration drops slowly with falling temperature within
1 day. Though the temperature was hold constant for the
following 3 days, the concentration was still falling with
the same rate (0.4% d1). This means that crystallization
has set in and continues independently of the temperature
of the bath. Even when the temperature was set to fall
again (0.7 K d1) after 4 days, the concentration drops
with the same rate. This means that the supersaturation
is still large enough for crystallization. After 6.3 days the
concentration drops with a larger slope although the rate
of temperature decrease is kept constant, because supersat-
uration increases again.
4
Biowerk Sohland GmbH, Saxony, Germany.
2595
After 8.4 days from the beginning the temperature of the
biodiesel bath was hold constant again for nearly 3 days.
During this time the concentration drops further, similar
to the first temperature plateau. However, after these 3
days the concentration values did not change any more
and equilibrium is reached. This means that the bath tem-
perature is too high to establish the same supersaturation
as at the beginning.
After 11.2 days from the beginning the temperature was
set to a rate of 1.25 K d1 and the concentration drops
further, indicating supersaturation again.
The rates of concentration decrease at the beginning and
the end of this experiment are nearly the same and amount
0.4% d1. The largest slope was reached after 6.3 days
and amounts 2.0% d1.
Fig. 5 (method 2) shows a similar behaviour. The initial
temperature rate was 1.25 K d1. The largest concentra-
tion change was reached at the beginning and amounts
4.7% d1. The rate of concentration at the end of this
experiment amounts 1.0% d1.
Generally, the sum of concentrations of saturated fatty
acid methyl esters is linearly correlated to the CFPP value
[10]. If these concentrations are low, the CFPP values are
low, too. In our experiments the CFPP values could not
be measured, because the volume needed for this analytical
technique is too large compared to our 5 l biodiesel beaker.
In Fig. 6 the sum of concentrations of saturated fatty
acid methyl esters, which is proportional to the CFPP
value, is plotted against bath temperature. Deviations from
the straight lines can be explained by deviations between
the CFPP values and the measured bath temperatures. Ide-
ally the bath temperatures should be chosen in such a way,
2596 S. Kerschbaum et al. / Fuel 87 (2008) 2590–2597
Fig. 7. Concentrations of some saturated and unsaturated fatty acid methyl esters as function of bath temperature, crystallization method 1.
that the difference between the CFPP value and the bath
temperature would be constant.
With method 2 we got the best winterization. At the
beginning the concentration of saturated fatty methyl
esters was 21.3%, corresponding to a CFPP value of
275 K using Eq. (1). At the end of the winterization process
we measured a concentration of saturated fatty methyl
esters of 9.6%, which corresponds to a CFPP value of
264 K.
Fig. 7 shows the concentrations of the most important
saturated and unsaturated fatty acid methyl esters as func-
tion of bath temperature for crystallization method 1. The
behavior is nearly the same for method 2. Palmitic acid
methyl ester has the highest concentration among the satu-
rated fatty acid methyl esters. Its concentration is reduced
to half of its initial value just like stearic acid methyl ester
concentration. Tables 2 and 3 show this behavior for all
compounds at the beginning and end of the process in more
detail. The concentrations of nearly all saturated fatty acid
methyl esters are reduced by a factor of two. This is impor-
tant to know, if the method is applied to biodiesel based on
feedstocks with different chemical compositions.
The winterization procedure described in this paper
changes the chemical composition of biodiesel (Tables 2
and 3). This may have an influence on other biodiesel prop-
erties, e.g. storage stability. In our case the chemical com-
position of the winterized biodiesel based on waste cooking
oil resembles that of biodiesel based on rapeseed oil (RME)
and will show properties similarly to RME. Properties such
as calorific value or damaging effects in engines should not
change.
5. Conclusions
Comparing our preliminary investigations in Section 2.3
with those in Section 2.4, the difference is only the use of
micro process technology for the generation of pure seed
crystals of saturated fatty acid methyl esters without unsat-
urated fatty acid methyl esters inside. This is a consequence
of the small channel diameters, which have a hydraulic
diameter of only 133 lm, and of the powerful heat
exchange of micro heat exchangers [16]: the biodiesel flows
laminary through each of the 7500 micro channels (Rey-
nolds-numbers in each micro channel are below 1 for all
relevant temperatures). The temperature profile is thus par-
abolic with minimum temperatures at the walls. Saturated
fatty acid methyl esters with their high melting temperature
will start to crystallize near the walls. Ideally this point
should lie near the outlet of the micro heat exchanger.
There is no chance for unsaturated molecules in the middle
of the micro channel to get between this layer and the wall.
The throughput of biodiesel, cooling temperature and the
construction of the micro heat exchanger have to be chosen
properly. Otherwise crystallization will begin inside the
micro heat exchanger resulting in plugging. For an optimi-
zation of this procedure it is important to decrease the bath
temperature with the same rate as the CFPP value
decreases as a result of winterization.
 S. Kerschbaum et al. / Fuel 87 (2008) 2590–2597
The most important result of this research project is that
biodiesel based on waste cooking oil can be winterized
without using additives. Pure seed crystals of saturated
fatty acid methyl esters are generated by micro process
technology stimulating quantitative crystallization in a
bath of biodiesel. The total concentration of saturated fatty
acid methyl esters within the biodiesel could be reduced
from 21.3% to 9.6% within 8 days, which may be improved
further. This corresponds to a reduction in the CFPP value
of 11 K [10], which means that this biodiesel can be used at
temperatures down to 264 K.
The reduction in concentration to half of its initial value
could have been reached within 6 days (method 1) and 2
days (method 2), if the optimum temperature ramp had
been used. Therefore, next investigations will focus on opti-
mization of the crystallization process and the micro heat
exchanger. It should be possible to scale up this winteriza-
tion procedure to an industrial process. First contacts were
made with a German Company,5 which produced our bio-
diesel based on waste cooking oil. There are possibilities to
apply the procedure as a batch process or even as continu-
ous process. The saturated fatty acid methyl esters could be
used in a combined heat and power unit. However, this
work is at an early stage and there is a lot of work to do.
The economic advantage will depend on feedstock prices,
taxes and costs of our procedure.
Acknowledgements
We thank Biowerk Sohland in Germany for supplying
us with biodiesel samples and Herbert Holpe for general
support in biodiesel technology.
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