Optimization of Continuous FAME Production in High-Performance Bumpy Surface Rotor Reactor under Theoretical Molar...

The continuous production of fatty acid methyl ester (FAME) from waste cooking oil (WCO) via transesterification was carried out under theoretical methanol to oil molar ratio using a high-performance bumpy surface rotor reactor (BSRR). Three types of rotors with different area fractions (A_F) of 6.9%, 13.8% and 27.6% were used to equip the BSRR. The selection of the highest performance rotor was compared by factorial experiments. Absolute methanol with 99.9 vol% purity was used as the reactant and potassium hydroxide with 90 wt% purity was used as the base catalyst. Response surface methodology (RSM) was applied to design the experiments and predict the optimal conditions. The three variables in RSM were 0.58-1.43 wt% potassium hydroxide concentration [KOH], 2160-3840 rpm rotor speed, and 1.38-4.74 L/min flow rate. The performance was the specific energy consumption (SEC). The highest performance rotor was A_F27.6%. In the first step, the transesterification process was performed using [KOH] 1.5 wt%, a rotor speed of 3000 rpm and a flow rate of 2.027 L/min to produce 98.6 wt% FAME and using SEC at 12.5 W h/kg. In the second step, RSM predicted the optimal condition of [KOH] 1.016 wt%, rotor speed 2910 rpm, flow rate 2.134 L/min and FAME content 97.3 wt%. The actual FAME content averaged 97.16 wt%. The biodiesel properties complied with the EN 14214 standard. This biodiesel production can reduce the cost of methanol by one-half and the cost of KOH by one-third. The energy consumption is only 0.012 kW・h/kg, so the methanol recovery process is not necessary. It has low KOH residue, so washing with water is superfluous and uses minimal energy, which can reduce a lot of costs. The high flow rate of 128 L/h can be used to scale up commercial production.