Biodiesel has been chosen as a decent alternative to diesel in the context of establishing environmentally pleasant conditions and saving petroleum‐based resources for future generations. It is well‐established that biodiesel‐powered diesel engines may achieve outcomes equivalent to those of diesel engines. The current investigation was conducted to study the effect of injection pressure (190, 210, and 230 bar) and exhaust gas recirculation (EGR) (5%, 10%, and 15%) on a single‐cylinder variable compression ratio (VCR) diesel engine running using a B20 (20% MB + 80% PD) blend of microalgae biodiesel (MABD). This experiment was conducted in two stages. During the first stage of experimentation, the efficiency and emission characteristics of a diesel engine with a B20 blend of MABD at various fuel injection pressures and fresh air were investigated. During the second phase, fresh air was mixed with 5%, 10%, and 15% exhaust gases, and the experiment was conducted. It was discovered that increasing injection pressure to 230 bar provided considerable improvements. Brake thermal efficiency increased by 2.35%, brake‐specific fuel consumption decreased by 3.57% and pollutants such as carbon monoxide (CO), hydrocarbon, and smoke were reduced by more than 50% compared to conventional diesel. These reductions were similarly significant (over 22%) as compared to the B20 blend at lower injection pressure (210 bar). However, there was a slight trade‐off: nitrogen oxide (NOx) emissions increased partially (3.14%), while exhaust gas temperature (EGT) increased by 1.72% at a higher pressure. The study then investigated the influence of EGR (5%, 10%, and 15%) at various injection pressures. The optimal value seems to be 10% EGR at 230 bar injection pressure. This combination substantially reduced NOx emissions (by over 41% compared to the normal B20 blend) and EGT (by more than 8%), while having no notable effect on other performance or emission variables. Overall, the results show that employing a B20 MABD blend with high injection pressure (230 bar) and moderate EGR (10%) improves engine performance while reducing hazardous emissions.
