As an alternative to fossil fuels, biodiesel can be a source of clean and environmentally friendly energy source. However, its commercial application is limited by expensive feedstock and the slow nature of the pretreatment step-acid catalysis. The conventional approach to carry out this reaction uses stirred tank reactors. Recently, the lab-scale experiments using microbubble mediated mass transfer technology have demonstrated its potential use at commercial scale. However, all the studies conducted so far have been at a lab scale~100 mL of feedstock. To analyze the feasibility of microbubble technology, a larger pilot scale study is required. In this context, a kinetic study of microbubble technology at an intermediate scale is conducted (3 L of oil). Owing to the target for industrial application of the process, a commercial feedstock (Spirulina), microalgae oil (MO) and a commercial catalyst para-toluene sulfonic acid (PTSA) are used. Experiments to characterize the kinetics space (response surface, RSM) required for up-scaling are designed to develop a robust model. The model is compared with that developed by the gated recurrent unit (GRU) method. The maximum biodiesel conversion of 99.45 ± 1.3% is achieved by using these conditions: the molar ratio of MO to MeOH of 1:23.73 ratio, time of 60 min, and a catalyst loading of 3.3 wt% MO with an MO volume of 3 L. Furthermore, predicted models of RSM and GRU show proper fits to the experimental result. It was found that GRU produced a more accurate and robust model with correlation coefficient R2 = 0.9999 and root-mean-squared error (RSME) = 0.0515 in comparison with RSM model with R2 = 0.9844 and RMSE = 3.0832, respectively. Although RSM and GRU are fully empirical representations, they can be used for reactor up-scaling horizontally with microbubbles if the liquid layer height is held constant while the microbubble injection replicates along the floor of the reactor vessel-maintaining the tessellation pattern of the smaller vessel. This scaling approach maintains the local mixing profile, which is the major uncontrolled variable in conventional stirred tank reactor up-scaling.
Keywords: RSM; biodiesel; esterification; kinetics; microbubble technology.