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<p>This study presents a sustainable approach for large-scale biodiesel production through the valorization of leather tanning waste (LTW) using supercritical methanol, simulated via Aspen Plus<sup>®</sup>. Building on experimentally derived kinetic parameters, the process integrates mass and heat exchange networks (MEN/HEN) to minimize methanol consumption by 94.25% and reduce heating/cooling energy demands by 41.8% and 43.2%, respectively. The technoeconomic analysis reveals robust financial viability, with a net present value (NPV) of $26.8&#xa0;million, a 541.88% return on investment (ROI), and a payback period of 4.35 years. Engine performance testing via MATLAB/Simulink demonstrates that the produced biodiesel achieves torque and power outputs comparable to conventional diesel (200 Nm at 2500 RPM, 70&#xa0;kW at 5000 RPM), while significantly reducing emissions (NOx: 3 × 10⁻³, CO: 12 × 10⁻⁶, HC: 5 × 10⁻⁷ mass fractions). The biodiesel meets EN14214 standards, with triglycerides content below 0.001 wt%. By converting 7,920 tons/year of LTW oil in Egypt’s Robbiki Leather City (RLC), this work establishes a scalable, economically viable pathway for waste-to-energy conversion, aligning industrial feasibility with environmental sustainability.</p>

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Valorizing leather tanning waste for biodiesel production: a holistic approach integrating supercritical methanolysis, pinch-optimized heat exchange networks, techno-economic feasibility, and matlab/simulink-driven engine emission performance in compression-ignition engines

  • 期刊论文

  • 发表日期：

    2026年5月12日

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  • Moatasem Kamel,
  • Ali M. Bastaweesy,
  • Rasha A. Hefny,
  • Eslam A. Abdallah,
  • Leonardo Vitali,
  • Amr A. Abdullah,
  • Ahmed Abdelnour,
  • Abo-alhassan N. Hassan,
  • Al-Hussein Matar,
  • Ebram F.F. Mokbel,
  • Mohamed H. Abdelati

摘要

This study presents a sustainable approach for large-scale biodiesel production through the valorization of leather tanning waste (LTW) using supercritical methanol, simulated via Aspen Plus®. Building on experimentally derived kinetic parameters, the process integrates mass and heat exchange networks (MEN/HEN) to minimize methanol consumption by 94.25% and reduce heating/cooling energy demands by 41.8% and 43.2%, respectively. The technoeconomic analysis reveals robust financial viability, with a net present value (NPV) of $26.8 million, a 541.88% return on investment (ROI), and a payback period of 4.35 years. Engine performance testing via MATLAB/Simulink demonstrates that the produced biodiesel achieves torque and power outputs comparable to conventional diesel (200 Nm at 2500 RPM, 70 kW at 5000 RPM), while significantly reducing emissions (NOx: 3 × 10⁻³, CO: 12 × 10⁻⁶, HC: 5 × 10⁻⁷ mass fractions). The biodiesel meets EN14214 standards, with triglycerides content below 0.001 wt%. By converting 7,920 tons/year of LTW oil in Egypt’s Robbiki Leather City (RLC), this work establishes a scalable, economically viable pathway for waste-to-energy conversion, aligning industrial feasibility with environmental sustainability.