From tannery waste to sustainable fuel: An integrated optimized experimental-simulation approach for biodiesel synthesis with mass- heat synergy and comprehensive financial feasibility analysis

Q1 Environmental Science

Bioresource Technology Reports Pub Date : 2025-09-01 DOI:10.1016/j.biteb.2025.102291

Moatasem Kamel , Mohsen A. Hashem , Ibrahim Ashour

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Abstract

The tannery industry produces significant leather fleshing waste (LFW), posing environmental concerns. This study explores LFW for sustainable biodiesel production. Extracted oil was degummed to enhance quality, reducing viscosity by 29 % and acid value by 18 %, then transesterified using calcium oxide. Process parameters—molar ratio, catalyst loading, and temperature—were optimized via response surface methodology (RSM), achieving a 96.38 % yield under optimal conditions (9:1 molar ratio, 6 wt% CaO, 60 °C, 3 h). The quadratic model (R² = 0.999) showed high predictive accuracy. Aspen Plus simulation confirmed scalability, and heat/mass integration improved efficiency—cutting energy demand by 51.9 % and enabling methanol reuse by 66 % through recycling. The biodiesel met ASTM/EN standards, with a cetane number of 64.2 and a higher heating value of 44.1 MJ/kg. Economic analysis showed strong feasibility: $42.81 million NPV, 39 % IRR, and 3.69-year payback. This work demonstrates LFW's potential as a cost-effective and eco-friendly biodiesel source.

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从制革废料到可持续燃料：生物柴油合成的综合优化实验模拟方法，具有质量-热量协同作用和全面的财务可行性分析

制革业产生大量的皮革肉废物（LFW），引起环境问题。本研究探讨了LFW在可持续生物柴油生产中的应用。提取油后进行脱胶以提高品质，粘度降低29%，酸值降低18%，然后用氧化钙进行酯交换。通过响应面法（RSM）对工艺参数（摩尔比、催化剂负载和温度）进行优化，在最佳条件下（摩尔比9:1、CaO浓度6 wt%、60°C、3 h），收率达到96.38%。二次模型（R2 = 0.999）具有较高的预测准确率。Aspen Plus模拟证实了可扩展性，热/质量集成提高了效率，减少了51.9%的能源需求，并通过循环利用使甲醇的再利用率提高了66%。该生物柴油符合ASTM/EN标准，十六烷值为64.2，热值为44.1 MJ/kg。经济分析显示了很强的可行性：净现值4281万美元，内部收益率39%，投资回收期3.69年。这项工作证明了LFW作为一种具有成本效益和生态友好型生物柴油来源的潜力。

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