An innovative microreactor approach for sustainable biodiesel production: process design, continuous purification and comparative LCA

Abstract

This study presents a fully integrated continuous-flow approach for the production and purification of fatty acid methyl esters (FAME), addressing key inefficiencies in conventional batch processes. Unlike traditional methods that require prolonged reaction times, excessive methanol use, and large volumes of water for purification, our microreactor-based system optimizes transesterification efficiency while significantly reducing waste generation. This study aims to seamlessly integrate microreactors with downstream purification steps—including extraction and biphasic liquid–liquid separation—to achieve continuous production. The optimized system achieved a FAME yield of 91.14 ± 13.85%, with an acid value as low as 0.268 mg KOH per g, well below the standard limit. The phase separation purities ranged from 73.15% to 95.11%. Life cycle assessment at an industrial scale demonstrated a 35% reduction in water consumption and a lower carbon footprint compared to batch production. This scalable and automated continuous approach advances sustainable biodiesel manufacturing by enhancing efficiency, reducing environmental impact, and promoting decentralized energy production.