The present study explores the integrated approach for the sustainable production of biodiesel from Chlorella vulgaris microalgae. The microalgae were cultivated in 10 m(2) open raceway pond at semi-continuous mode with optimum volumetric and areal production of 28.105 kg/L/y and 71.51 t/h/y, respectively. Alum was used as flocculent for harvesting the microalgae and optimized at different pH. Lipid was extracted using chloroform: methanol (2: 1) and having 12.39% of FFA. Effect of various reaction conditions such as effect of catalyst, methanol: lipid ratio, reaction temperature and time on biodiesel yields were studied under microwave irradiation; and 84.01% of biodiesel yield was obtained under optimized reaction conditions. A comparison was also made between the biodiesel productions under conventional heating and microwave irradiation. The synthesized biodiesel was characterized by H-1 NMR, C-13 NMR, FTIR and GC; however, fuel properties of biodiesel were also studied using specified test methods as per ASTM and EN standards. (C) 2016 Elsevier Ltd. All rights reserved.