Process intensification of biodiesel production using pilot-scale continuous multiple baffle reactor with feed distribution

Abstract

This study aims to enhance biodiesel production through a pilot-scale continuous multiple baffle reactor. This reactor incorporates a baffle array with suitable dimension ratio into the conventional CSTR to create a series of complex flows that increase turbulence and mixing intensity, leading to an increased overall reaction rate. Additionally, this reactor also employed a method of distributing MeOH-KOCH3 solution into 5 streams to enhance mass transfer, reduce catalyst entrapment and ensure the reaction progression throughout the reactor. The investigated variables were the number of baffles, agitation speed, oil to methanol molar ratio, catalyst concentration, and residence time. Ester content of 97.70 wt. % was obtained with residence time of 10 min from single-step transesterification process. This achievement represents 6 times residence time reduction and 75 % reactor cost reduction compared to conventional CSTR with similar reaction conditions and equivalent production capabilities while maintaining simple and highly scalable design of traditional counterparts.