To address the urgent demand for efficient catalyst systems in biodiesel production, this study proposes a one-step carbonization-sulfonation strategy to overcome the challenges of complex multi-step processes and prolonged preparation cycles of traditional carbon-based monolithic catalysts. A monolithic carbon-based solid acid reactor with high catalytic activity and excellent fluid dynamic properties was successfully constructed. The reactor not only preserves low pressure drop, prolonged flow paths, and high throughput inherent advantages of monolithic aerogels, but also constructs strong acidic active sites on the inner pore surfaces via in-situ sulfonation. Furthermore, partial graphitization is induced to enhance skeletal stability and mass transfer capabilities. The catalyst exhibited outstanding performance in the continuous esterification of oleic acid with methanol, achieving a conversion rate of 95.3 %, a turnover frequency of 20.37 min−1, low activation energy (22.26 kJ/mol), excellent reproducibility, and rapid regenerability. Extension experiments demonstrated its applicability to a range of fatty acid esterification reactions. Furthermore, through 3D multiphysics coupled simulations, the synergistic mechanism of mass transfer and reaction within the reactor was systematically revealed, with theoretical models showing excellent agreement with experimental results. This provides valuable theoretical guidance for reactor design and process optimization. This study establishes a paradigm of combining experimental validation with theoretical modeling. It offers a high-performance catalytic reactor solution for continuous biodiesel production and opens new pathways for the green and efficient preparation as well as industrial application of carbon-based monolithic catalysts.
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