Microwave-Assisted Transesterification of Enriched Crude Glycerol to Glycerol Carbonate: Optimization, Simulation, and Techno-Economic Evaluation

This research presents a novel approach to create glycerol carbonate (GC) from refined crude glycerol through microwave-assisted transesterification. It integrates experimental enhancement with techno-economic and ecological assessments. The refining procedure raised the glycerol content from 40.56 wt % to 98.83 wt %, ensuring a high-quality input. Response surface methodology (RSM) was used to aid optimization of the reaction conditions. The best conditions were a 6.5 wt % catalyst concentration, 2.74:1 dimethyl carbonate:glycerol molar ratio, a reaction temperature of 78.36 °C, and a reaction duration of 36.5 min, which gave a 73.65% yield of GC. Experimental data matched the model estimates under these settings, validating the RSM dependability. The activation energy was calculated as 54.57 kJ/mol. A techno-economic assessment, performed using the Aspen Plus V11 software, revealed that the process is a viable investment possibility, with a net present value of $31.23 million, an internal rate of return of 27.96%, and a payback duration of 4.11 years. A sensitivity assessment revealed that the GC selling price considerably affected the profit and that the CO₂ releases tied to GC creation totaled 2.11 kg CO₂ per kg of GC. Catalyst reuse tests over three cycles exhibited a sound steadiness, with only a 10% efficiency reduction. These outcomes display a scalable, lasting path to GC output, accentuating industrial practicality besides economic strength.