EPOXIDATION OF CASTOR OIL WITH CR-DUPED NANO ALUMINA CATALYST : PROCESS OPTIMIZATION USING CENTRAL COMPOSITE RESPONSE SURFACE METHODOLOGY

The growing demand for sustainable and eco-friendly chemical processes has prompted the development of advanced catalytic systems for modifying bio-based feedstocks. This study investigates the epoxidation of castor oil using a chromium- doped nano-alumina (Cr/Al₂O₃) catalyst and optimizes the process using Response Surface Methodology (RSM), specifically a Box-Behnken design. Castor oil, rich in ricinoleic acid, serves as a suitable substrate for epoxidation due to its inherent unsaturation. The catalyst was synthesized and characterized, then employed in reactions under varying conditions of catalyst concentration (1–4% w/w), temperature (60–100°C), and time (60–240 minutes). The extent of epoxidation was quantified using oxirane value measurements. Statistical analysis via ANOVA revealed that catalyst concentration and time were the most significant factors influencing oxirane yield, while temperature had a less pronounced effect. The highest oxirane value (1.98%) was achieved at 100°C, 4% catalyst concentration, and 150 minutes. Perturbation and 3D surface plots further supported the dominance of catalyst concentration and time. The optimized reaction conditions enabled efficient conversion with minimal by-product formation, aligning with green chemistry principles. The study demonstrates the effectiveness of Cr-doped nano-alumina as a heterogeneous catalyst in achieving selective and efficient epoxidation. It also highlights the importance of process optimization in reducing resource consumption and enhancing product yield. The results underscore the potential for industrial application and future scale-up of this environmentally friendly epoxidation approach.