Supercritical methanolysis of leather tanning waste biomass: experimental investigation, process simulation, and sustainable biodiesel production
Abstract Background This study explores a sustainable method for biofuel production from leather tanning waste (LTW) using a novel single-step, catalyst-free supercritical methanolysis (SpCM) process. Traditional biodiesel production methods often require catalysts and involve complex purification s...
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2025-05-01
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| Series: | Beni-Suef University Journal of Basic and Applied Sciences |
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| Online Access: | https://doi.org/10.1186/s43088-025-00635-9 |
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| author | Moatasem Kamel Leonardo Vitali Ahmed Abdelnour Amr A. Abdullah Abo-alhassan N. Hassan |
| author_facet | Moatasem Kamel Leonardo Vitali Ahmed Abdelnour Amr A. Abdullah Abo-alhassan N. Hassan |
| author_sort | Moatasem Kamel |
| collection | DOAJ |
| description | Abstract Background This study explores a sustainable method for biofuel production from leather tanning waste (LTW) using a novel single-step, catalyst-free supercritical methanolysis (SpCM) process. Traditional biodiesel production methods often require catalysts and involve complex purification steps, whereas this study aims to optimize process parameters to enhance biodiesel yield while reducing energy and material consumption. Methods The research employed a Box–Behnken experimental design integrated with response surface modeling (RSM) to optimize key process variables, including alcohol-to-LTW molar ratio (r mo), operating temperature, pressure, and reaction duration. The produced biodiesel was characterized according to EN 14214 standards. Kinetic studies of the transesterification reaction were conducted, and a robust reactor model was developed in Aspen Plus to estimate the kinetic parameters. Results The activation energy (E a) and pre-exponential factor (A) were determined to be 45.085 kJ/mol and 86.24 s⁻1, respectively, with a rate constant (k) of 0.0098 s⁻1 at an optimized temperature of 322.938 °C. The optimized conditions using RSM achieved a biodiesel yield of 89.35% at an r mo of 32.35:1, a temperature of 322.938 °C, a pressure of 219.073 bar, and a reaction time of 14.26 min. The simulation model under the same conditions predicted a biodiesel yield of 89.49%, demonstrating excellent agreement with experimental results, with a maximum error of 0.54%. Conclusions This study presents a comprehensive approach to biodiesel production from LTW, demonstrating an efficient and sustainable alternative to conventional methods. The optimized catalyst-free SpCM process minimizes energy input and material usage while achieving high biodiesel yields. These findings contribute to waste valorization in the leather industry and support environmental sustainability efforts. Graphical abstract |
| format | Article |
| id | doaj-art-9676aa2f031d4e6a87ef4bbb2653b98f |
| institution | OA Journals |
| issn | 2314-8543 |
| language | English |
| publishDate | 2025-05-01 |
| publisher | SpringerOpen |
| record_format | Article |
| series | Beni-Suef University Journal of Basic and Applied Sciences |
| spelling | doaj-art-9676aa2f031d4e6a87ef4bbb2653b98f2025-08-20T02:25:13ZengSpringerOpenBeni-Suef University Journal of Basic and Applied Sciences2314-85432025-05-0114112410.1186/s43088-025-00635-9Supercritical methanolysis of leather tanning waste biomass: experimental investigation, process simulation, and sustainable biodiesel productionMoatasem Kamel0Leonardo Vitali1Ahmed Abdelnour2Amr A. Abdullah3Abo-alhassan N. Hassan4Chemical Engineering Department, Faculty of Engineering, Minia UniversityPolytechnic University of BariSudan University of Science and TechnologyEl-Robbiki Leather ClusterFaculty of Engineering, Department of Production and Design Engineering, Minia UniversityAbstract Background This study explores a sustainable method for biofuel production from leather tanning waste (LTW) using a novel single-step, catalyst-free supercritical methanolysis (SpCM) process. Traditional biodiesel production methods often require catalysts and involve complex purification steps, whereas this study aims to optimize process parameters to enhance biodiesel yield while reducing energy and material consumption. Methods The research employed a Box–Behnken experimental design integrated with response surface modeling (RSM) to optimize key process variables, including alcohol-to-LTW molar ratio (r mo), operating temperature, pressure, and reaction duration. The produced biodiesel was characterized according to EN 14214 standards. Kinetic studies of the transesterification reaction were conducted, and a robust reactor model was developed in Aspen Plus to estimate the kinetic parameters. Results The activation energy (E a) and pre-exponential factor (A) were determined to be 45.085 kJ/mol and 86.24 s⁻1, respectively, with a rate constant (k) of 0.0098 s⁻1 at an optimized temperature of 322.938 °C. The optimized conditions using RSM achieved a biodiesel yield of 89.35% at an r mo of 32.35:1, a temperature of 322.938 °C, a pressure of 219.073 bar, and a reaction time of 14.26 min. The simulation model under the same conditions predicted a biodiesel yield of 89.49%, demonstrating excellent agreement with experimental results, with a maximum error of 0.54%. Conclusions This study presents a comprehensive approach to biodiesel production from LTW, demonstrating an efficient and sustainable alternative to conventional methods. The optimized catalyst-free SpCM process minimizes energy input and material usage while achieving high biodiesel yields. These findings contribute to waste valorization in the leather industry and support environmental sustainability efforts. Graphical abstracthttps://doi.org/10.1186/s43088-025-00635-9Biodiesel productionLeather tanning waste (LTW)Supercritical methanolysis (SpCM)Kinetic modelingResponse surface methodology (RSM)Waste valorization |
| spellingShingle | Moatasem Kamel Leonardo Vitali Ahmed Abdelnour Amr A. Abdullah Abo-alhassan N. Hassan Supercritical methanolysis of leather tanning waste biomass: experimental investigation, process simulation, and sustainable biodiesel production Beni-Suef University Journal of Basic and Applied Sciences Biodiesel production Leather tanning waste (LTW) Supercritical methanolysis (SpCM) Kinetic modeling Response surface methodology (RSM) Waste valorization |
| title | Supercritical methanolysis of leather tanning waste biomass: experimental investigation, process simulation, and sustainable biodiesel production |
| title_full | Supercritical methanolysis of leather tanning waste biomass: experimental investigation, process simulation, and sustainable biodiesel production |
| title_fullStr | Supercritical methanolysis of leather tanning waste biomass: experimental investigation, process simulation, and sustainable biodiesel production |
| title_full_unstemmed | Supercritical methanolysis of leather tanning waste biomass: experimental investigation, process simulation, and sustainable biodiesel production |
| title_short | Supercritical methanolysis of leather tanning waste biomass: experimental investigation, process simulation, and sustainable biodiesel production |
| title_sort | supercritical methanolysis of leather tanning waste biomass experimental investigation process simulation and sustainable biodiesel production |
| topic | Biodiesel production Leather tanning waste (LTW) Supercritical methanolysis (SpCM) Kinetic modeling Response surface methodology (RSM) Waste valorization |
| url | https://doi.org/10.1186/s43088-025-00635-9 |
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