This study investigates the potential of fused deposition modeling (FDM) three-dimensional (3D) printing techniques for manufacturing catalytic static mixers during biodiesel synthesis. The printed catalytic mixing elements comprises acrylonitrile butadiene styrene (ABS) plastic with 15 wt% calcium oxide (CaO) as a solid catalyst. When the reactants flowed through the CaO/ABS mixing device, the blending and acceleration processes were both significantly impacted. Moreover, their characteristics, performance in biodiesel production, reusability, and economy were analyzed. The effects of methanol to oil (M:O) molar ratio, circulation time, and sonication time on methyl ester (ME) purity were also examined. The results showed that CaO crystals were distributed on the CaO/ABS mixer’s surface, which is crucial for catalytic purposes. During circulation process of ME from pretreated sludge palm oil (PSPO), catalytic static mixer (CSM) and CSM coupled with ultrasound (CSM/US) reactors were employed. The full ultrasonic power of CSM/US reactor of 16 × 400 W (total 6400 W) was operated at 20 kHz frequency. Moreover, the continuous and pulse ultrasonic modes of CSM/US reactor were compared to determine the ME purity and electricity consumption for ME production. For the CSM reactor, 12:1 M:O molar ratio and 8.5 h circulation time were recommended to realize 94.2 wt% ME purity. For the CSM/US reactor, 12:1 M:O molar ratio and 2.25 h circulation time were recommended to achieve 96.5 wt% ME purity. Under the pulsed mode operation, ME purity of 95.09 wt% was achieved, with a reduction in electricity consumption by approximately 37.6 % compared to continuous mode operation. Furthermore, the CaO/ABS catalytic static mixer was determined to be reusable for up to three cycles in both CSM and CSM/US reactors. Thus, CaO/ABS catalytic static mixers assure high purity ME production through FDM 3D printing technology with a CaO solid catalyst.

中文翻译：

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使用 CaO/ABS 催化静态混合器耦合超声波夹具从预处理的污泥棕榈油中生产甲酯的循环过程


本研究调查了熔融沉积建模 （FDM） 三维 （3D） 打印技术在生物柴油合成过程中制造催化静态混合器的潜力。印刷的催化混合元件由丙烯腈丁二烯苯乙烯 （ABS） 塑料和 15 wt% 的氧化钙 （CaO） 作为固体催化剂组成。当反应物流经 CaO/ABS 混合装置时，混合和加速过程都受到显著影响。此外，还分析了它们的特性、在生物柴油生产中的性能、可重用性和经济性。还研究了甲醇与油 （M：O） 的摩尔比、循环时间和超声处理时间对甲酯 （ME） 纯度的影响。结果表明，CaO 晶体分布在 CaO/ABS 混合器表面，这对催化目的至关重要。在预处理污泥棕榈油 （PSPO） ME 的循环过程中，采用催化静态混合器 （CSM） 和 CSM 耦合超声 （CSM/US） 反应器。CSM/US 反应器的全超声波功率为 16 × 400 W（总功率为 6400 W），在 20 kHz 频率下运行。此外，比较了 CSM/US 反应器的连续和脉冲超声模式，以确定 ME 生产的 ME 纯度和电力消耗。对于 CSM 反应器，建议 12：1 M：O 摩尔比和 8.5 h 循环时间以实现 94.2 wt% ME 纯度。对于 CSM/US 反应器，建议 12：1 M：O 摩尔比和 2.25 h 循环时间以达到 96.5 wt% ME 纯度。在脉冲模式操作下，ME 纯度达到 95.09 wt%，与连续模式操作相比，耗电量减少了约 37.6%。 此外，CaO/ABS 催化静态混合器被确定在 CSM 和 CSM/US 反应器中可重复使用长达三个循环。因此，CaO/ABS 催化静态混合器通过带有 CaO 固体催化剂的 FDM 3D 打印技术确保高纯度 ME 生产。