A highly efficient activated porous catalyst, BPAC-500-S, derived from waste banana peels through a novel synthesis involving pyrolysis; and functionalization with 4-benzene diazonium sulphonate, has been developed. For comparison of catalytic activity, the material was also functionalized with sulphuric acid (BPAC-500-SX). The (BPAC-500-S) catalyst underwent impregnation and activation with ZnCl2, and its properties were extensively characterized using BET, SEM, XPS, XRD, FT-IR, and TGA techniques. Comparative analysis of catalysts obtained at different pyrolysis temperatures (400, 500, and 600 ºC) revealed that BPAC-500-S pyrolyzed at 500 ºC, exhibited maximum surface area (840.83 m2g-1) and sulphur density (4.7 %). Utilizing BPAC-500-S as a catalyst, an efficient process for biodiesel synthesis from Jatropha curcas oil (JCO) was developed, achieving a remarkable 98.91 % conversion, as confirmed by 1H-NMR spectroscopy. Notably, life cycle cost analysis demonstrated a low biodiesel production cost of $ 0.70/L. The BPAC-500-S catalyst exhibited exceptional reusability maintaining more than 80 % biodiesel yield over seven reaction cycles. This study presents a sustainable and cost-effective approach to biodiesel production, emphasizing the potential of waste-derived catalysts in green and economically viable processes.

Response surface optimization, kinetics, thermodynamics, and life cycle cost analysis of biodiesel production from Jatropha curcas oil using biomass-based functional activated carbon catalyst