Advances in 3D-Printed Microreactors for Biodiesel Production: Performance Evaluation, Challenges, and Sustainable Design Perspectives

Résumé fourni par la source

The growing demand for renewable fuels has renewed interest in biodiesel production, prompting exploration beyond conventional reactors. This review assesses three-dimensional (3D) printed microreactors for biodiesel synthesis via transesterification, with a focus on their potential for enhanced process efficiency, sustainability, and modular deployment. Compared with conventional batch and stirred-tank reactors, 3D-printed microstructured systems often offer superior mass and heat transfer, enabling biodiesel yields up to ~99% in some studies, with critically short residence times (e.g., as low as ~5 s) and reported energy reductions of 60% to 90% under optimal conditions. Optimized configurations in recent work achieved energy requirements as low as ~0.05 to 0.12 kWh L−1, substantially lower than the typical 0.25 to 0.60 kWh L−1 for conventional setups. However, existing studies remain limited in number and scope: issues such as catalyst leaching, chemical and thermal stability of printing materials, dimensional inaccuracies, and scalability of microreactor networks remain under-investigated. Long-term durability, real-world feedstock variation (e.g., high-FFA waste oils), and comprehensive lifecycle assessments are often lacking, limiting confident extrapolation to industrial scale. Despite these challenges, the emerging evidence suggests significant promise for 3D-printed microreactors as a pathway toward modular, energy-efficient, and potentially low-carbon biodiesel production, provided that future work addresses their practical limitations and validates performance under industrially realistic conditions.

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