The acid-catalyzed pre-treatment esterification process is required for low-cost feedstock with high free fatty acids (FFAs) to avoid the saponification that occurs during alkali-catalyzed transesterification for the production of fatty acid alkyl esters (FAAE). Reverse hydrolysis in acid-catalyzed esterification causes a decrease in fatty acid methyl ester (FAME) yield. Therefore, the esterification process must be intensified. This study aims to develop and optimize a low-temperature intensification process to enhance biodiesel yield and reduce energy consumption. Three intensification systems were studied: co-solvent technique, co-solvent coupled with adsorption of water using molecular sieves, and entrainer-based continuous removal of water. The process variables of esterification reaction in co-solvents without the adsorption system were optimized by using central composite design (CCD). The study showed that the co-solvent without the adsorption system was effective in intensifying the FFA conversion (X_FFA) at low temperatures, compared to the other two systems, due to the dilution effect at high co-solvent/entrainer amount required for sufficient vapors in the adsorption system. Optimized process variables have achieved 95% X_FFA within 75 min at 55 °C, 20 mL/100 g of oil DEE, 9 MR, 3 wt % H₂SO₄, and 320-350 RPM in a co-solvent without the adsorption system.

In the race for industrialization and urbanization, the concentration of greenhouse gases like CO₂ and CH₄ is growing rapidly and ultimately resulting in global warming. An Ni-based catalyst over MgO support (Ni/MgO) offers a catalytic method for the conversion of these gases into hydrogen and carbon monoxide through the dry reforming of methane (DRM) reaction. In the current research work, 1–4 wt% strontium is investigated as a cheap promoter over a 5Ni/MgO catalyst to modify the reducibility and basicity for the goal of excelling the H₂ yield and H₂/CO ratio through the DRM reaction. The fine catalytic activities’ correlations with characterization results (like X-ray diffraction, surface area porosity, photoelectron–Raman–infrared spectroscopy, and temperature-programmed reduction/desorption (TPR/TPD)) are established. The 5Ni/MgO catalyst with a 3 wt.% Sr loading attained the highest concentration of stable active sites and the maximum population of very strong basic sites. 5Ni3Sr/MgO surpassed 53% H₂ yield (H₂/CO ~0.8) at 700 °C and 85% H₂ yield (H₂/CO ratio ~0.9) at 800 °C. These outcomes demonstrate the catalyst’s effectiveness and affordability. Higher Sr loading (>3 wt%) resulted in a weaker metal–support contact, the production of free NiO, and a lower level of catalytic activity for the DRM reaction. The practical and cheap 5Ni3Sr/MgO catalyst is scalable in industries to achieve hydrogen energy goals while mitigating greenhouse gas concentrations.

COx-free H₂, along with uniform carbon nanotubes, can be achieved together in high yield by CH₄ decomposition. It only needs a proper catalyst and reaction condition. Herein, Fe-based catalyst dispersed over titania-incorporated-alumina (Fe/Ti-Al), with the promotional addition of lanthanides, like CeO₂ and La₂O₃, over it, is investigated for a methane decomposition reaction at 800 °C with GHSV 6 L/(g·h) in a fixed-bed reactor. The catalysts are characterized by temperature-programmed reduction (TPR), powder X-ray diffraction (XRD), Raman spectroscopy, and transmission electron microscopy (TEM). The promoted catalysts are facilitated with higher surface area and enhanced dispersion and concentration of active sites, resulting in higher H₂ and carbon yields than unpromoted catalysts. Ceria-promoted 20Fe/Ti-Al catalyst had the highest concentration of active sites and always attained the highest activity in the initial hours. The 20Fe-2.5Ce/Ti-Al catalyst attains >90% CH₄ conversion, >80% H₂-yield, and 92% carbon yield up to 480 min time on stream. The carbon nanotube over this catalyst is highly uniform, consistent, and has the highest degree of crystallinity. The supremacy of ceria-promoted catalyst attained >90% CH₄ conversion even after the second cycle of regeneration studies (against 87% in lanthanum-promoted catalyst), up to 240 min time on stream. This study plots the path of achieving catalytic and carbon excellence over Fe-based catalysts through CH₄ decomposition.

The development of cost-effective non-noble metal catalysts for the partial oxidation of methane (POM) remains a key strategy for producing hydrogen-rich syngas while mitigating greenhouse gas emissions. In this study, cobalt-supported alumina (Co/Al₂O₃) catalysts were prepared using 5 wt.% of Co and calcined at 600, 700, and 800 °C. Subsequently, Co/Al₂O₃ catalysts were promoted with 10 wt.% Mg, Si, Ti, and Zr at the optimized calcination temperature. The catalysts were systematically characterized by FT-IR, XRD, N₂ physisorption, H₂-TPR, and XPS analyses. Catalytic activity tests for POM of CH₄ were conducted at 600 °C (CH₄/O₂ = 2 and GHSV = 14,400 mL g⁻¹ h⁻¹). Catalysts calcined at 700 °C (5Co/Al_700) exhibited the highest activity among unpromoted samples, with CH₄ conversion of 43.9% and H₂ yield of 41.8%. The superior performance was attributed to its high surface area and the abundance of reducible Co³⁺ species, generating a greater number of Co⁰ active sites. XPS results confirmed the structural stability of γ-Al₂O₃ and preserved Co–Al interactions across calcination temperatures, while promoters mainly modulated Co dispersion and redox accessibility. Among the promoted catalysts, the activity order followed: 5Co/10ZrAl > 5Co/10MgAl> unpromoted-5Co/Al_700 > 5Co/10SiAl > 5Co/10TiAl. Si and Ti promoted catalysts acquired less concentration of active sites and less activity as well. The concentration of reducible species as well as initial activity towards POM are comparable over Zr and Mg-promoted catalysts. However, earlier one has a higher edge of reducibility and sustained constant activity over time in a stream study. The Zr-promoted catalyst exhibited superior reducibility and remarkable stability, achieving 47.3% CH₄ conversion and 44.4% H₂ yield sustained over 300 min time-on-stream. TEM analysis of spent 5Co/10ZrAl indicated that Zr promotion suppressed graphitic carbon formation.