Effects of mixing technologies on continuous methyl ester production: Comparison of using plug flow, static mixer, and ultrasound clamp

Four types of continuous reactors, namely plug flow reactor (PF), static mixer reactor (SM), ultrasound clamp on tubular reactor (US), and static mixer combined with ultrasound (SM/US) were compared for their purities of methyl ester in biodiesel production from refined palm oil (RPO). The reactor conditions were: KOH 4, 6, 8, 10, and 12 g L−1, methanol content 20 vol.%, and under 20 L h−1 RPO flow rate at 60 °C temperature. The highest purity of methyl esters: 81.99 wt.% for PF, 95.70 wt.% for SM, 98.98 wt.% for US, and 97.67 wt.% for SM/US, were achieved with 900 mm, 900 mm, 700 mm, and 900 mm reactor lengths respectively, and 12 g L−1 of KOH was used in all cases. The 16 × 400 W ultrasound clamp was operated at 20 kHz frequency, and among short length reactors the US case was more effective than PF, SM, or SM/US. Moreover, ester purity from the US reactor was slightly decreased by the lowest 4 g L−1 KOH. The US reactor was clearly superior over the other types of continuous reactor, and had the potential to reduce KOH consumption by sonochemical effects on the base-catalyzed transesterification reaction.