ABSTRACT The use of Azolla pinnata oil for the production of biodiesel, coupled with the use of industrial waste dolomite as a catalyst, represents a novel approach with significant potential. This innovative process offers several key advantages, such as utilizing a non-edible feedstock, reducing waste generation, and providing an alternative to fossil fuels. This research aims to investigate the viability of creating biodiesel using Azolla pinnata oil and evaluate its technical and economic appropriateness for large-scale manufacturing. A pilot plant reactor with a 10 L biodiesel capacity carries out the transesterification reaction, using dolomite from industrial waste as a heterogeneous catalyst. The reaction was conducted for 4 h at a temperature of 70°C, and biodiesel yielded approximately 99.14%. Aspen Plus is employed to simulate and design a biodiesel plant, with the reaction kinetics derived from the pilot plant reaction and inputted into Aspen Plus. Plant optimization and economic analysis are performed using the Aspen Economic Analyzer. The biodiesel blends (Azolla 20, Azolla 40, and Azolla 60) were tested in a CI engine and compared with diesel results. Based on the engine test results, the Azolla 20 blend provides less HC (12.9%), CO (13.07%), and smoke (10%) emissions; therefore, it can serve as a better alternative to neat diesel. The primary units of the proposed plant have been designed, and the process’s economic viability was determined. It was discovered that the total capital investment needed is approximately 5.054 million USD, which will be repaid within 1.97 years of operation. This research encompasses pilot plant experiments, process simulation, engine testing, and economic analysis, demonstrating the novelty, technical feasibility, and potential socio-economic impact of this biodiesel production process.
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