The Development of a Novel Aluminosilicate Catalyst Fabricated via a 3D Printing Mold for Biodiesel Production at Room Temperature

Biodiesel production has gained attention as a sustainable alternative to fossil fuels, but challenges related to catalyst recovery and energy consumption remain. In this study, a novel lithium-impregnated aluminosilicate catalyst (LiSA) was developed using a 3D-printed mold, providing precise control over its structure to optimize performance. The structured catalyst featured a cylindrical shape with multiple circular channels, enhancing fluid dynamics and reactant interaction in a fixed-bed reactor. Catalyst characterization by SEM, TGA, XRD, and ICP-MS confirmed high thermal stability and uniform pore distribution. Jatropha curcas oil was used as feedstock, with diethyl ether (DEE) acting as a cosolvent to improve methanol solubility and enable transesterification at room temperature. The process achieved a high fatty acid methyl ester (FAME) yield, averaging 97.1% over 508 min of continuous operation, demonstrating the catalyst’s stability and sustained activity. By reducing mass transfer limitations and energy demands, this approach highlights the potential of 3D-printed catalysts to advance sustainable biodiesel production, offering a scalable and efficient pathway for green energy technologies.