RSM ‐optimized dual‐catalyst system: green and efficient synthesis of bio‐based PETO from renewable plant‐derived feedstocks

Abstract BACKGROUND Bio‐based oleic acid pentaerythritol ester (PETO) is a crucial green feedstock for high‐end high‐temperature lubricants. Existing synthesis processes are hindered by low catalytic efficiency, high energy consumption, and suboptimal yields. OBJECTIVE This study aims to develop an efficient, low‐energy green synthesis process for PETO. METHOD A ‘dibutyltin oxide (DBTO) + tetrabutylammonium bromide (TBAB)’ dual‐catalyst system was used, and the transesterification process was optimized by ‘single‐factor prescreening—Box‐Behnken response surface optimization’. RESULTS The optimization model showed high reliability (R 2 > 0.99). Under optimized conditions (DBTO 1.56%, TBAB 0.7%, 269.86 °C, molar ratio 4.71:1, 4 h), PETO yield reached 96.89%, far exceeding conventional processes. TBAB synergistically enhances DBTO's catalytic efficiency by reducing interfacial resistance, and no water‐carrying agent is needed. SIGNIFICANCE The integrated DBTO+TBAB dual‐catalyst and RSM system provides a green, scalable PETO synthesis solution, facilitating industrial application and conforming to sustainable manufacturing principles. © 2026 Society of Chemical Industry (SCI).