Optimization, Economic Assessment, and Quality Analyses of Waste-Based Biodiesel Fuel Production: A Case Study of Waste Cooking Oil and a Seashell Synthesized Catalyst

Valorization of environmental waste into sustainable energy and value-added products offers a strategic pathway for advancing circular economic development and resource sustainability. In this study, waste cooking oil was converted into biodiesel using biogenically generated CaO, prepared thermally at 900 °C. The reaction process was modeled and optimized with a Taguchi orthogonal array L9(34), considering four factors at three levels to yield nine experimental conditions. The model reliability was statistically validated through analysis of variance (ANOVA) at 95% confidence level (p < 0.05), achieving a high determination coefficient (R2) of 0.9965. The maximum biodiesel yield of 91.08% was obtained under the optimal conditions of the methanol to oil ratio of 15:1, a catalyst loading of 4.5 wt%, a reaction time of 90 min, a temperature of 65 °C, and a constant stirring speed of 650 rpm. The fuel property analysis confirmed compliance with international biodiesel and diesel standards). Economic evaluation of the process showed that integrating waste cooking oil with reusable seashell-derived catalysts enabled the production of high-quality biodiesel at R23.20 (~USD 1.39)/L, highlighting a sustainable and cost-competitive alternative to conventional feedstock. The study contributes to advancing waste-to-energy technologies and supports the transition towards a circular and sustainable energy future.