Multi-attribute optimization of sustainable aviation fuel production-process from microalgae source

• Aviation fuel prepared from microalgal species Chlorella Pyrenoidosa . • Box-Behnken design used for economical use of resources during experiments. • Neuro-fuzzy approach used for robust prognostic modeling achieving R > 0.9995. • Desirability based optimization helped in gaining a 91% yield of esters. • Properties of aviation fuel prepared were comparable to Jet A-1 kerosene. The aviation sector has been one of the most significant contributors to greenhouse gas (GHG) emissions; there is an urgent need to transition from traditional fossil-based jet fuel to sustainable aviation fuel to meet net-zero targets by 2030. The use of renewable aviation fuel may be regarded as the most effective option for reducing GHG emissions in the aviation sector while allowing for long-term growth. In this study, the microalgae oil was transformed to develop hydrocarbons with the boiling point range of jet fuel. Following the transesterification of algal oil fatty acids to algal oil methyl ester, fractional distillation was carried out. The Box-Behnken technique was used to design experiments for efficient resource utilization by minimizing the number of tests during transesterification. The quantitative relationship function between input (molar ratio of methanol to oil, catalyst concentration, and temperature) and % yield of methyl ester as an output of the process was developed using analysis of variance (ANOVA). The ANFIS (adaptive neuro-fuzzy inference system) was utilized to develop a prognostic model with good prediction effectiveness. MORSM (multi-objective response surface methodology) was also used to build a prediction model using correlations. A set of statistical indicators and Theil's U2 were used to examine the prediction efficacy and model uncertainty of ANFIS and MORSM. On both statistical indices and Theil's U2, the ANFIS-based model outperformed. To get the best results, the desirability approach was used to improve operating parameters. According to the desirability approach, the best operating parameters were catalyst concentration at 2.09%, methanol to oil ratio at 9.17%, and temperature at 60.49 °C, which resulted in the greatest yield of 91%.