This first-of-a-kind research emphasizes the influence of exhaust gas recirculation (EGR) on engine characteristics, and exergy, sustainability, and exergoeconomic aspects of compression ignition engine, powered by plastic grocery bag-extracted plastic oil-diesel-water emulsion blend dosed with bio-nano-additive extracted from areca nut husk (D10EPO-15 ppm). Three EGR rates (5%, 10%, and 15%) were incorporated at varying engine loads. At 100% load, the EGR incorporation reduced the peak heat release rate and peak pressure up to 6.5 and 5.6%, respectively, in comparison to the base fuel without EGR. Up to 5.2 and 9.1% reduction in exhaust gas temperature and nitrogen oxide emission (NOx) was noticed with the EGR incorporation. However, carbon monoxide (CO), hydrocarbon (HC), and smoke emissions increased with the EGR incorporation. Nevertheless, considering the overall characteristics, 5% EGR was the most suitable one to have a lower NOx (3.4%) with a minimum penalty on CO (4.3%), HC (5.4%), and smoke (3.6%) emissions as well as fuel consumption (3%), at full load. Amongst the three EGR rates, 5% EGR incorporation also has the highest exergy efficiency (20.9%) and sustainability index (1.26). Exergoeconomic analysis also revealed the favorability of 5% EGR, and at full load, 5% EGR showed the lowest specific exergy cost inflow rate (0.8957 $/hr), the lowest specific exergy cost rate for shaft work (75.27 $/GJ), the lowest relative cost difference (3.99), and the highest exergoeconomic factor (9.95%).
