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September 04, 2024Ethanol to jet: Now taking off
Ethanol-to-jet fuel is a newly commercial and rapidly expanding technology. While most existing sustainable aviation fuel (SAF) is produced from natural oils via hydrotreated vegetable oil (HVO) routes, the supply of these oils is insufficient to replace fossil jet fuel on the scale required by net-zero plans. There is a particular shortage of low carbon intensity (CI) oils such as used cooking oil (UCO) and tallow. Among the alternatives to HVO, ethanol-to-jet fuel is the most cost-effective and advanced option.
Ethanol to Jet (ETJ) is a process of converting ethanol, typically derived from renewable sources such as corn, sugarcane or other sustainable sources including cellulosic sugar and industrial waste gases, into a suitable fuel for jet engines, offering a potentially greener alternative to traditional fossil fuels in aviation.
Find out more…Biorenewable Insights Ethanol to Jet (ETJ) (2024 Program) The major steps involved in the generic ETJ process are shown below.
Typical ETJ Technology Overview
Although not a perfect solution, the cost of production and carbon intensity are significantly influenced by feedstock selection. Fortunately, ethanol-to-jet technologies do not face the same feedstock restrictions as low CI HVO feedstocks. Sugarcane, cellulosic biomass, and even waste gases are being utilized to generate low CI ethanols. While cellulosics and waste gases are still minimal compared to conventional ethanol feedstocks, sugarcane remains a dominant global feedstock for ethanol production. Consequently, CI issues for ethanol-to-jet fuel are primarily a concern for corn ethanol, though efforts are being made to produce low CI corn ethanol through responsible project management. NexantECA investigated the various licensors for ETJ technologies.
Aviation currently generates approximately two percent of global Greenhouse Gas (GHG) emissions, with this share projected to rise to five percent by 2050 without significant action. Since electric or fuel-cell-based propulsion options are unlikely to become practical for powering large aircraft in the medium term, Sustainable Aviation Fuel (SAF) has emerged as the most important tool for decarbonizing the sector.
Governments worldwide have announced supporting policies, including tax incentives, grants, and mandates, to promote the uptake of SAF. The United States and the EU have been leading in implementing and legislating these regulations, with many other countries following suit in order to meet their decarbonization goals. The International Air Transport Association (IATA) estimates that approximately 449 billion liters (equivalent to around 350 million tons) of SAF will be required by 2050 to meet net zero targets for aviation.
SAF is a non-fossil based aviation fuel made from sustainable feedstocks including waste fats, oil, and grease, municipal solid wastes, sugar crops, amongst many others. Its chemical composition is very similar to traditional fossil jet fuel, making it a pragmatic solution to reduce emissions in the aviation sector via blending with conventional jet fuel.
Currently, there are eight approved pathways to produce SAF, differentiated by technologies and feedstocks. Among these, Ethanol to Jet (ETJ) is seen as the most advanced pathway after Hydroprocessed Esters and Fatty Acid (HEFA) – which is projected to be constrained by the availability of sustainable feedstocks. Moreover, an added advantage of selected ETJ technologies e.g. Vertimass and KBR-Swedish Biofuels allow the production of SAF with optimal aromatic properties, which facilitates the swelling of rubber sealant in existing commercial aircrafts. As such, this presents a robust growth opportunity for ETJ – considered as the next best technology for SAF production. Each region may pursue several SAF pathways concurrently, with the rate of development varying depending on regulatory support and feedstock availability. For instance, Western Europe’s policies appear more favorable towards e-fuels due to the lower carbon intensities (CIs) as sub-mandates for e-fuels have been included in the latest revision of RefuelEU Aviation, while Asia Pacific countries leverage abundant fats and oil feedstocks for HEFA-based fuels. In the Americas, particularly in the United States and Brazil, the abundance of ethanol feedstock and policy drivers promote ETJ development.
Ethanol has a wide variety of uses, including in the beverage, chemical, industrial, and food sectors. However, over recent decades, global ethanol market is increasingly used as a transport fuel or transport fuel component. The global increase in Electric Vehicle (EV) adoption is projected to create an ethanol surplus due to reduced gasoline blending requirements. This surplus, alongside the development of advanced or second-generation ethanol, can potentially be utilized for SAF production, leveraging existing infrastructure while decarbonizing aviation
Key barriers to wider ETJ adoption include carbon intensities (CIs) and high production costs relative to both fossil jet fuel and the already mature HEFA-based SAF. While the CI measurement of corn-based ethanol has faced controversies, measures like smart farming, Carbon Capture and Sequestration (CCS), and the use of renewable power can reduce the overall CIs of the final fuel product. As ETJ technology advances, costs are expected to decline through more efficient conversion processes and the development of advanced catalysts. Despite current challenges, ETJ presents a significant growth opportunity as a practical and viable SAF pathway, aiding the aviation sector in achieving net zero targets.
Find out more…
Biorenewable Insights Ethanol to Jet (ETJ) (2024 Program)
This BI report investigates the technical, economic and commercial aspects of ethanol to jet (ETJ) technology. Cost of production estimate models and carbon intensity analysis are provided across several regions.
Market Insights: Ethanol - 2024
Market Insights: Ethanol – 2024 includes discussion regarding key market trends, as well as demand analysis by region, end use and type
- Road use ethanol: Demand, capacity, supply, net trade, regulation, blend mandates, first vs second generation;
- Aviation use ethanol (Alcohol to Jet Sustainable Aviation Fuel): Demand, capacity, supply, net trade, regulation, blend mandates, first vs second generation;
- Chemical feedstock use ethanol: Demand by end-use product
Webinar - Ethanol to Jet: Next up for take-off
Though HVO has made significant progress in growing the SAF market, the market is ultimately feedstock limited. Ethanol to jet provides an expanded feedstock pool capable of supplying this large market.
This webinar will discuss ethanol to jet technology, current trends in SAF, issues in deployment, and future prospects. The content of this webinar is sourced from the report Biorenewable Insights: Ethanol to Jet and Market Insights: Ethanol.
To listen to the presentation, please contact your Account Manager for the password.
The Author...
Steve Slome, Principal
About Us - NexantECA, the Energy and Chemicals Advisory company is the leading advisor to the energy, refining, and chemical industries. Our clientele ranges from major oil and chemical companies, governments, investors, and financial institutions to regulators, development agencies, and law firms. Using a combination of business and technical expertise, with deep and broad understanding of markets, technologies and economics, NexantECA provides solutions that our clients have relied upon for over 50 years.
