Synthesis of alcohols for sustainable aviation fuels under unconventional cold plasma and thermo-catalysis technology

Climate change and its potentially dramatic consequences at a global level force us to seek more efficient and sustainable solutions and technologies. In 2022, around 25% of the world’s CO₂ emissions came from the transportation sector, where aviation contributed around 14% of the total transport emissions. Moreover, global demand for jet fuels is projected to double between now and 2050. To this, the use of sustainable aviation fuels (SAFs) is essential to reduce the environmental impact and dependence on fossil fuels and foreign petrol-sources.

To date, several SAF production processes have been developed and have demonstrated commercial success, although with limited capacity. However, further research is needed for the sustainable, clean, affordable, and safe production of C_{12+ alcohols}.

In this presentation, we will present the concept of Hy⁺₄SAF approach, funded by Agencia Estatal de Investigación (Generación de Conocimiento 2024), which will develop a disruptive technology of a cascade reactor for producing synthetic relevant chemicals and SAFs via CO₂ hydrogenation at mild conditions. In particular, it will involve the selective synthesis of chemicals (C_{8+ alcohols}) and SAF precursors (C_{12+ alcohols}) from renewable fuels (CO₂ and H₂) via an ethanol-mediated route under mild conditions. To this end, designed catalysts will be tested in near-real-world environments: 1) functionalized catalysts for plasma ethanol synthesis on digitally structured supports will be tested with near-real-world RFNBO feedstocks, impure CO₂, and H₂ with varying H₂O content; 2) cooperative multi-element MOF catalysts for C_{8+ alcohol} synthesis on digitally structured supports from plasma-synthesized ethanol will be tested, also evaluating the catalytic effects of byproducts such as methanol, ethanal, ethylene, CH₄, or CO from CO₂ hydrogenation. Hy4OL will benefit from a pioneering design in catalytic and process engineering to enhance aspects related to fluid separation, reaction engineering, and materials engineering. This efficient and systematic integration of process intensification concepts will optimize the novel cascade reactor using a safe, compact, and energy-efficient dual-reaction technology. Verification of the progress achieved in capillary condensation-enhanced thermocatalytic chain-growth reactions under realistic conditions will pave the way for future application in commercial reactor.