This study presents a novel approach to the synthesis of high-performance biolubricants from Indian castor seed oil (ICSO), addressing a key gap in the current literature where most prior research has focused on single-step transesterification or biodiesel applications of castor oil. The research introduces a two-step transesterification strategy that enhances the physicochemical properties of the final product. In the first step, ethanolysis of ICSO was performed to produce Castor fatty acid ethyl esters (CFAEs), with optimized parameters ethanol-to-oil molar ratio of 6:1, 2% H₂SO₄ catalyst, at 65 °C for 60 min yielding high-purity intermediates. These CFAEs were subsequently reacted with 1,1-Tris(hydroxymethyl)propane (TMP) under optimized conditions (1:6 molar ratio, 0.8% sodium methoxide, 120 °C, 90 min) to obtain a triester-based biolubricant with a maximum yield of 85.3%. This dual-step method represents a significant improvement in process efficiency and product performance over conventional approaches. Structural confirmation using FTIR, ¹H NMR, and ¹³C NMR revealed successful esterification and high product purity. The resulting castor biolubricant exhibited a Viscosity Index of 139, Pour Point of −10 °C, and Flash Point of 250 °C values that meet ISO VG 68 specifications, indicating compatibility with commercial industrial lubricant standards. Unlike traditional castor oil modifications, this process enhances thermal stability, positioning the product as a viable, sustainable alternative to mineral-based lubricants. This work contributes a scalable, renewable, and chemically robust pathway for advanced biolubricant production from non-edible feedstocks.
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