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<p>The depletion of fossil fuels underscores the urgency of renewable, low-impact alternatives for sustainable energy. This study presents an integrated Aspen Plus simulation and RSM-based optimization framework for biodiesel production from tomato-seed oil (TSO), a waste-derived feedstock, using butanol transesterification in a plug-flow reactor (PFR). Detailed reaction kinetics are embedded in Aspen Plus, and multivariable optimization with MATLAB-based RSM identifies optimal conditions—reactor length 3.0&#xa0;m, diameter 1.1&#xa0;m, and a 6:1 butanol-to-oil molar ratio—yielding 99.94 wt% biodiesel. A cradle-to-gate life-cycle assessment (LCA; ISO 14044) quantifies environmental trade-offs, showing that compact PFR designs minimize energy use and achieve footprints as low as 0.6–1.0&#xa0;kg CO₂-eq kg⁻¹ and 4–12&#xa0;L kg⁻¹ biodiesel. Hotspot analysis indicates that butanol recovery and downstream purification dominate impacts, while glycerol valorization and alkali recovery (KOH→K₃PO₄) offset emissions and enhance circularity. Overall, the Aspen Plus–RSM–LCA framework shows that high conversion alone is insufficient for sustainability; optimal biodiesel production couples yield optimization with separation efficiency and by-product utilization to meet circular-economy goals.</p>

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Integrated Simulation, Optimization, and Life Cycle Assessment of Biodiesel Production from Tomato Seed Oil in Plug Flow Reactors

  • 期刊论文

  • 发表日期：

    2025年12月27日

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  • Abhijith S. Nair,
  • Salmanul Faris K. K.,
  • Ramya Sankar M. S.,
  • Vincentius Surya Kurnia Adi

摘要

The depletion of fossil fuels underscores the urgency of renewable, low-impact alternatives for sustainable energy. This study presents an integrated Aspen Plus simulation and RSM-based optimization framework for biodiesel production from tomato-seed oil (TSO), a waste-derived feedstock, using butanol transesterification in a plug-flow reactor (PFR). Detailed reaction kinetics are embedded in Aspen Plus, and multivariable optimization with MATLAB-based RSM identifies optimal conditions—reactor length 3.0 m, diameter 1.1 m, and a 6:1 butanol-to-oil molar ratio—yielding 99.94 wt% biodiesel. A cradle-to-gate life-cycle assessment (LCA; ISO 14044) quantifies environmental trade-offs, showing that compact PFR designs minimize energy use and achieve footprints as low as 0.6–1.0 kg CO₂-eq kg⁻¹ and 4–12 L kg⁻¹ biodiesel. Hotspot analysis indicates that butanol recovery and downstream purification dominate impacts, while glycerol valorization and alkali recovery (KOH→K₃PO₄) offset emissions and enhance circularity. Overall, the Aspen Plus–RSM–LCA framework shows that high conversion alone is insufficient for sustainability; optimal biodiesel production couples yield optimization with separation efficiency and by-product utilization to meet circular-economy goals.