Design of anti-saponification Ca-based catalyst with porous-shell structure from crustacean waste for biodiesel production

The rapid development of the biodiesel industry is of significant importance for achieving carbon emission reduction in the transportation sector. However, the presence of trace amounts of water in the feedstock during biodiesel synthesis may lead to severe saponification reactions, thereby reducing the yield of fatty acid methyl esters. In this study, based on our exploration of the characteristic of porous carbon to absorb moisture from the environment, we synthesized a CaO catalyst with porous carbon coating via discarded shrimp shell biomass. Because the carbonization temperature of organic matter in shrimp shells is lower than the decomposition temperature of CaCO3, the CO2 generated during pyrolysis can erode the pyrolytic carbon and form porous structure. The mesoporous carbon shell facilitates the diffusion of oil and methanol molecules while adsorbing moisture in the alcohol phase. This structure effectively minimizes the interaction between CaO and water, thereby suppressing saponification reactions and ensuring the smooth progression of the desired transesterification reaction. Through a series of physicochemical characterizations, the structure and water absorption performance of the catalyst were confirmed. The as-prepared CaO@PC-900 catalyst demonstrated the ability to maintain a biodiesel yield of over 85% in a reaction system with a water content of 3%, significantly surpassing the performance of commercial CaO and previously reported Ca-based solid bases. This work provides a new approach to the design of anti-saponification transesterification catalysts, while also offering a novel pathway for the synthesis of porous carbon from discarded crustacean biomass.