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• Taguchi design in optimization of performance and emissions characteristics of n -butanol/diesel/biogas. • Experimentation was done using Taguchi L9 orthogonal array design. • Biogas to examine its performance and emission parameters to enhance the diminution in the CO and HC emissions. • Maximize and minimize performance of venomous exhaust emissions from the tailpipe of the engine. Combustion experts are in search of some alternative fuel from last few decades owing to diminishing petroleum products and unexpected variations in habitat, which are result of venomous emissions from the CI engines. The present investigation intended to assess the performance and emission parameters of a diesel engine by fueling it with pilot fuel (blends of diesel and n -butanol) and primary fuel (Biogas). Results revealed that BTE, HC and CO increases whilst NOx and smoke emissions were reduced by using the pilot and primary fuel together in relation with natural diesel. Experimentation was done using Taguchi L9 orthogonal array design. The engine load, flow rate of biogas and butanol in fuel blend percentage were selected as input parameters whereas brake thermal efficiency (BTE) and emission characteristics i.e., HC, CO, NOx and smoke were chosen as response variables. ANOVA was carried out for the responses by utilizing MINITAB software. The higher value of raw data and S/N ratio for BTE was noted with high engine load, low flow rate of biogas and butanol blend percent. For the emission characteristics i.e., HC, CO and smoke, lower raw data and high S/N ratio values were attained in the order of rank engine load > butanol blend percent > biogas flow rate while the similar values for NOx were attained in the rank engine load > biogas flow rate > butanol blend percent. Taguchi design was noted to be an effective tool for the optimization of various response parameters and the optimum levels of input parameters were calculated after analysis. Full engine load for BTE and HC, Biogas flow rate of 15 lpm for BTE, HC and CO, and 20 % of butanol blend for HC, CO and smoke were found to be the optimum conditions for the conducted experimentation. [ABSTRACT FROM AUTHOR]