Optimization and CFD-RSM analysis of single orifice reactor for enhanced biodiesel production

Depleting fossil fuels necessitate innovative solutions for sustainable biodiesel production from sunflower oil, addressing global energy and environmental challenges. Computational Fluid Dynamics (CFD) with the k-ε model and Response Surface Methodology (RSM) optimized frequency (5–15 Hz), baffle diameter ratio (d₀/D: 0.4–0.8mm), and baffle spacing (3–7mm) in a single-orifice oscillatory flow reactor (OFR). Optimal conditions (frequency=12.12 Hz, d₀/D=0.4mm, spacing=10mm) achieved an 83% biodiesel conversion, maximum turbulent kinetic energy (TKE) of 7.56 m²/s², maximum vorticity of 112.23 1/s, and energy dissipation of 359.82 m²/s³, validated by a TKE-yield correlation (R²=0.972). Simplified reactor design reduces energy dissipation by 20% compared to multi-orifice reactors (88% yield, higher costs) and smooth periodic constriction reactors (74.5% yield). Findings offer a scalable, eco-friendly solution for industrial biodiesel production, minimizing fossil fuel dependency and enhancing process efficiency.