Chemical and mechanical extraction for egyptian safflower bio-oil with a performance and economic analysis for renewable fuel applications

Abstract

Abstract The growing demand for sustainable biofuels has increased interest in efficient methods for extracting oil from non-edible feedstocks such as safflower. This study compares chemical and mechanical extraction techniques, including Soxhlet extraction, maceration, hydraulic pressing, and screw pressing, for biodiesel feedstock production. A Box–Behnken response surface methodology was applied to optimize screw press operating conditions. The optimal parameters were identified at 172.5 °C and a screw press speed of 1400 rpm, with an energy consumption of 3.86 W-hour and a yield of approximately 19% in 29.8 s. The oils extracted using four extraction techniques were characterized using gas chromatography-mass spectrometry and Fourier-transform infrared spectroscopy, confirming their suitability for biodiesel applications. Among the evaluated methods, a screw press proved to be the most energy-efficient and time-saving method, owing to the elimination of solvent use and its lower operational costs compared to conventional chemical methods. These findings highlight the potential of mechanical extraction as a cost-effective and environmentally sustainable approach for biodiesel production. Overall, this study provides a comparative and optimized framework for safflower oil extraction, supporting the transition toward greener and scalable biofuel production technologies.