Advancing Ethanol-to-Jet cost Effectiveness via direct conversion to n-Butene-Rich olefins and Co-Product Valorization

Journal Article · Mon Mar 09 00:00:00 UTC 2026 · Bioresource Technology

DOI: https://doi.org/10.1016/j.biortech.2026.134390 · OSTI ID:3028154

Xu, Yiling ^[1]; Jiang, Yuan  ^[1]; Snowden-Swan, Lesley J. ^[1]; Xu, Shuang  ^[1]; Phillips, Steven D.  ^[1]; Dagle, Vanessa ^[1]; Dagle, Robert A.  ^[1]

---

1. Pacific Northwest National Laboratory (PNNL), Richland, WA (United States)

Ethanol is a promising feedstock for sustainable aviation fuel production; however, conventional routes face significant energy and cost challenges, particularly due to the ethanol dehydration step to ethylene. Here, this study leverages breakthrough experimental data to perform comprehensive techno-economic and life-cycle assessments of an innovative ethanol-to-jet process. The process employs a single-step catalytic conversion, enabled by multifunctional Cu-ZrO₂/SBA-16 catalyst, to directly upgrade ethanol into a mixed olefin stream rich in n-butene. The single-step conversion eliminates the costly ethanol dehydration step in the conventional process. High selectivity toward n-butene offers key advantages: it simplifies downstream oligomerization into jet-range hydrocarbons and enables the co-production of renewable n-butene alongside sustainable aviation fuel. The analysis estimates a minimum fuel selling price as low as $$\$$$$2.50 per gallon, whether using corn ethanol or cellulosic ethanol from corn stover. Life cycle CO₂ equivalent emissions are projected to be as low as 10.6 g CO₂eq/MJ sustainable aviation fuel, representing over 70% reduction compared to conventional petroleum-based jet fuel. This one-step ethanol upgrading approach not only facilitates SAF and n-butene co-production but also provides operational flexibility. The ability to tailor product outputs allows the ethanol-to-jet process to adapt to varying feedstocks, incentive programs, and market dynamics, ultimately enhancing the economic viability of sustainable aviation fuel production.

• Research Organization: Pacific Northwest National Laboratory (PNNL), Richland, WA (United States)
• Sponsoring Organization: USDOE Office of Critical Minerals and Energy Innovation (CMEI)
• Grant/Contract Number: AC05-76RL01830
• OSTI ID: 3028154
• Report Number(s): PNNL-SA-216235
• Journal Information: Bioresource Technology, Journal Name: Bioresource Technology Vol. 449; ISSN 0960-8524
• Publisher: ElsevierCopyright Statement
• Country of Publication: United States
• Language: English