Heterogeneous Acid Catalytic Filaments for Three-Dimensional Printing: Their Preparation, Characterization, and Reduction of Free Fatty Acids in Crude Palm Oil

This study focuses on the fabrication and application of heterogeneous acid catalytic filaments for free fatty acid (FFA) reduction in crude palm oil (CPO) via esterification. Amberlyst-15 catalyst was blended with acrylonitrile butadiene styrene (ABS) using a single-screw filament extruder to produce Amberlyst-15/ABS catalytic filaments. A 5 wt.% concentration of fine Amberlyst-15 particles was considered optimal for blending with ABS, making them a suitable acid catalyst for FFA reduction. The mechanical properties, thermal behavior, and morphology of the Amberlyst-15/ABS catalytic filaments were assessed. The esterification process was optimized by varying three independent variables: the methanol-to-oil molar ratio, catalytic filament loading, and reaction time. The results revealed that under the recommended conditions—26.7:1 methanol-to-oil molar ratio, 78.5 wt.% catalytic filament loading, and a reaction time of 20.2 h at 500 rpm and 60 °C—the FFA content in CPO was reduced from 10.05 to 0.83 wt.%. Additionally, the reusability of the catalytic filaments was evaluated under the recommended conditions of the esterification process. The results demonstrated that the filaments remained effective for at least two cycles, achieving FFA levels below 2 wt.%, thereby confirming their stability and catalytic efficiency. The methodology employed in this study for the preparation and characterization of Amberlyst-15/ABS catalytic filaments offers a promising approach for fabricating acid catalytic materials via 3D printing, especially for heterogeneous catalysis in esterification reactions.