The Alcohol-to-Jet Conversion Pathway for Drop-In Biofuels: Techno-Economic Evaluation

Spatially Varying Costs of GHG Abatement with Alternative Cellulosic Feedstocks for Sustainable Aviation Fuels

Cellulosic biomass-based sustainable aviation fuels (SAFs) can be produced from various feedstocks. The breakeven price and carbon intensity of these feedstock-to-SAF pathways are likely to differ across feedstocks and across spatial locations due to differences in feedstock attributes, productivity, opportunity costs of land for feedstock production, soil carbon effects, and feedstock composition. We integrate feedstock to fuel supply chain economics and life-cycle carbon accounting using the same system boundary to quantify and compare the spatially varying greenhouse gas (GHG) intensities and costs of GHG abatement with SAFs derived from four feedstocks (switchgrass, miscanthus, energy sorghum, and corn stover) at 4 km resolution across the U.S. rainfed region. We show that the optimal feedstock for each location differs depending on whether the incentive is to lower breakeven price, carbon intensity, or cost of carbon abatement with biomass or to have high biomass production per unit land. The cost of abating GHG emissions with SAF ranges from $181 Mg-1 CO2e to more than $444 Mg-1 CO2e and is lowest with miscanthus in the Midwest, switchgrass in the south, and energy sorghum in a relatively small region in the Great Plains. While corn stover-based SAF has the lowest breakeven price per gallon, it has the highest cost of abatement due to its relatively high GHG intensity. Our findings imply that different types of policies, such as volumetric targets, tax credits, and low carbon fuel standards, will differ in the mix of feedstocks they incentivize and locations where they are produced in the U.S. rainfed region.

Trends and emerging research directions of sustainable aviation: A bibliometric analysis

This study aims to conduct a bibliometric analysis to determine trends and emerging research directions of sustainable aviation between 2001 and 2023. 726 studies indexed in the Web of Science were examined through VOSviewer software. Science mapping and performance analyses were implemented to demonstrate a systematic quantitative review and the characteristics of the research area. Moreover, by using co-occurrence of keywords, citation, bibliographic coupling, co-authorship, and co-citation analyses, the trends of the research area were revealed in detail. Findings indicated that the publications on sustainable aviation literature were mainly conducted between 2020 and 2023. Research areas of the publications were mainly on "engineering" and "energy fuels". In terms of number of the publications, "International Journal of Sustainable Aviation Fuel" was the most productive source and Heyne was the most productive author. Co-occurrence analysis demonstrated that "sustainable aviation fuel" was the most frequently used keyword. Furthermore, sustainable aviation research has shifted in focus toward more challenging and technology-oriented research over time. Citation analysis indicated that the most cited author was Heyne, the most cited study was Ma et al.'s study on "Aviation biofuel from renewable resources: routes, opportunities and challenges" and the most cited sources was "Energy". Among countries, the U.S.A was the most cited country and Chinese Academy of Sciences was the most cited organization. Bibliographic analysis showed that Heyne was the author with the highest connection strength. Co-authorship analysis demonstrated that Washington State University was the most collaborative organization. Finally, co-citation analysis of cited references indicated that fundamental subjects and related references were mainly sustainable aviation fuel, production of sustainable aviation fuel and its use in aviation studies. It is anticipated that results of this study would contribute to sustainable aviation research and ensure guidance and new perspectives for future research topics and directions on sustainable aviation.

Bimetallic Metal Sites in Metal-Organic Frameworks Facilitate the Production of 1-Butene from Electrosynthesized Ethylene

Converting CO2 to synthetic hydrocarbon fuels is of increasing interest. In light of progress in electrified CO2 to ethylene, we explored routes to dimerize to 1-butene, an olefin that can serve as a building block to ethylene longer-chain alkanes. With goal of selective and active dimerization, we investigate a series of metal-organic frameworks having bimetallic catalytic sites. We find that the tunable pore structure enables optimization of selectivity and that periodic pore channels enhance activity. In a tandem system for the conversion of CO2 to 1-C4H8, wherein the outlet cathodic gas from a CO2-to-C2H4 electrolyzer is fed directly (via a dehumidification stage) into the C2H4 dimerizer, we study the highest-performing MOF found herein: M' = Ru and M″ = Ni in the bimetallic two-dimensional M'2(OAc)4M″(CN)4 MOF. We report a 1-C4H8 production rate of 1.3 mol gcat-1 h-1 and a C2H4 conversion of 97%. From these experimental data, we project an estimated cradle-to-gate carbon intensity of -2.1 kg-CO2e/kg-1-C4H8 when CO2 is supplied from direct air capture and when the required energy is supplied by electricity having the carbon intensity of wind.

Electrical-biological hybrid system for carbon efficient isobutanol production

We have developed an electrical-biological hybrid system wherein an engineered microorganism consumes electrocatalytically produced formate from CO2 to supplement the bioproduction of isobutanol, a valuable fuel chemical. Biological CO2 sequestration is notoriously slow compared to electrochemical CO2 reduction, while electrochemical methods struggle to generate carbon-carbon bonds which readily form in biological systems. A hybrid system provides a promising method for combining the benefits of both biology and electrochemistry. Previously, Escherichia coli was engineered to assimilate formate and CO2 in central metabolism using the reductive glycine pathway. In this work, we have shown that chemical production in E. coli can benefit from single carbon substrates when equipped with the RGP. By installing the RGP and the isobutanol biosynthetic pathway into E. coli and by further genetic modifications, we have generated a strain of E. coli that can consume formate and produce isobutanol at a yield of >100% of theoretical maximum from glucose. Our results demonstrate that carbon produced from electrocatalytically reduced CO2 can bolster chemical production in E. coli. This study shows that E. coli can be engineered towards carbon efficient methods of chemical production.

Impacts of the Inflation Reduction Act on the Economics of Clean Hydrogen and Synthetic Liquid Fuels

The Inflation Reduction Act (IRA) in the United States provides unprecedented incentives for deploying low-carbon hydrogen and liquid fuels, among other low-greenhouse gas (GHG) emissions technologies. To better understand the prospective competitiveness of low-carbon or negative-carbon hydrogen and liquid fuels under the IRA in the early 2030s, we examined the impacts of the IRA provisions on the costs of producing hydrogen and synthetic liquid fuel made from natural gas, electricity, short-cycle biomass (agricultural residues), and corn-derived ethanol. We determined that, with IRA credits (45V or 45Q) but excluding the incentives provided by other national or state policies, hydrogen produced by electrolysis using carbon-free electricity (green H2) and by natural gas reforming with carbon capture and storage (CCS) (blue H2) is cost-competitive with the carbon-intensive benchmark gray H2, which is produced by steam methane reforming. Biomass-derived H2 with or without CCS is not cost-competitive under the current IRA provisions. However, if the IRA allowed biomass gasification with CCS to claim a 45V credit for carbon-neutral H2 and a 45Q credit for negative biogenic CO2 emissions, this pathway would be less costly than gray H2. The IRA credit for clean fuels (45Z), currently stipulated to end in 2027, would need to be extended or similar policy support would need to be provided by other national or state policies in order for clean synthetic liquid fuel to be cost-competitive with petroleum-derived liquid fuels. The levelized IRA subsidies per unit of CO2 mitigated for all of the hydrogen and synthetic liquid fuel production pathways, except for electricity-derived synthetic liquid fuel, range from $65-$384/t of CO2. These values are within or below the range of the U.S. federal government's estimates of the social cost of carbon (SCC) in the 2030-2040 time frame.

Multi-criteria decision analysis for the evaluation and screening of sustainable aviation fuel production pathways

The aviation sector, a significant greenhouse gas emitter, must lower its emissions to alleviate the climate change impact. Decarbonization can be achieved by converting low-carbon feedstock to sustainable aviation fuel (SAF). This study reviews SAF production pathways like hydroprocessed esters and fatty acids (HEFA), gasification and Fischer-Tropsch Process (GFT), Alcohol to Jet (ATJ), direct sugar to hydrocarbon (DSHC), and fast pyrolysis (FP). Each pathway's advantages, limitations, cost-effectiveness, and environmental impact are detailed, with reaction pathways, feedstock, and catalyst requirements. A multi-criteria decision framework (MCDS) was used to rank the most promising SAF production pathways. The results show the performance ranking order as HEFA > DSHC > FP > ATJ > GFT, assuming equal weight for all criteria.

Combustion, Chemistry, and Carbon Neutrality

Combustion is a reactive oxidation process that releases energy bound in chemical compounds used as fuels─energy that is needed for power generation, transportation, heating, and industrial purposes. Because of greenhouse gas and local pollutant emissions associated with fossil fuels, combustion science and applications are challenged to abandon conventional pathways and to adapt toward the demand of future carbon neutrality. For the design of efficient, low-emission processes, understanding the details of the relevant chemical transformations is essential. Comprehensive knowledge gained from decades of fossil-fuel combustion research includes general principles for establishing and validating reaction mechanisms and process models, relying on both theory and experiments with a suite of analytic monitoring and sensing techniques. Such knowledge can be advantageously applied and extended to configure, analyze, and control new systems using different, nonfossil, potentially zero-carbon fuels. Understanding the impact of combustion and its links with chemistry needs some background. The introduction therefore combines information on exemplary cultural and technological achievements using combustion and on nature and effects of combustion emissions. Subsequently, the methodology of combustion chemistry research is described. A major part is devoted to fuels, followed by a discussion of selected combustion applications, illustrating the chemical information needed for the future.

Properties of Selected Alternative Petroleum Fractions and Sustainable Aviation Fuels

With regard to speed, comfort, and a dense network of destinations, the popularity of air transport is on the rise. For this reason, jet fuel is a commodity with rapidly growing consumption and interesting refinery margins. At the same time, however, it is becoming a focus of attention in terms of reducing negative environmental impacts. As a response to these trends, it will be necessary to coprocess alternative petroleum fractions with sustainable aviation components in oil refineries. Six alternative jet fuel samples of different origin were used to investigate their jet fuel-specific properties, that is, aromatics (from 0 to 59.7 vol%), smoke point (from 12.2 to >50 mm), freezing point (from −49 to <−80 °C) and net specific energy (41.2–43.7 MJ·kg−1), and these properties were compared to standard hydrotreated straight-run Jet A-1 kerosene. The properties of the components studied differed significantly with respect to each other and to the requirements of Jet A-1. Nevertheless, the properties could be well correlated. This provides an opportunity to study possible synergies in blending these components. It was also found that the current methods and instruments used do not always allow a precise determination of the smoke point (>50 mm) and freezing point (<80 °C).

Techno-economic analysis of an integrated biorefinery to convert poplar into jet fuel, xylitol, and formic acid

BACKGROUND

The overall goal of the present study is to investigate the economics of an integrated biorefinery converting hybrid poplar into jet fuel, xylitol, and formic acid. The process employs a combination of integrated biological, thermochemical, and electrochemical conversion pathways to convert the carbohydrates in poplar into jet fuel, xylitol, and formic acid production. The C5-sugars are converted into xylitol via hydrogenation. The C6-sugars are converted into jet fuel via fermentation into ethanol, followed by dehydration, oligomerization, and hydrogenation into jet fuel. CO₂ produced during fermentation is converted into formic acid via electrolysis, thus, avoiding emissions and improving the process's overall carbon conversion.

RESULTS

Three different biorefinery scales are considered: small, intermediate, and large, assuming feedstock supplies of 150, 250, and 760 dry ktonne of poplar/year, respectively. For the intermediate-scale biorefinery, a minimum jet fuel selling price of $3.13/gallon was obtained at a discount rate of 15%. In a favorable scenario where the xylitol price is 25% higher than its current market value, a jet fuel selling price of $0.64/gallon was obtained. Co-locating the biorefinery with a power plant reduces the jet fuel selling price from $3.13 to $1.03 per gallon.

CONCLUSION

A unique integrated biorefinery to produce jet fuel was successfully modeled. Analysis of the biorefinery scales shows that the minimum jet fuel selling price for profitability decreases with increasing biorefinery scale, and for all scales, the biorefinery presents favorable economics, leading to a minimum jet fuel selling price lower than the current price for sustainable aviation fuel (SAF). The amount of xylitol and formic produced in a large-scale facility corresponds to 43% and 25%, respectively, of the global market volume of these products. These volumes will saturate the markets, making them infeasible scenarios. In contrast, the small and intermediate-scale biorefineries have product volumes that would not saturate current markets, does not present a feedstock availability problem, and produce jet fuel at a favorable price given the current SAF policy support. It is shown that the price of co-products greatly influences the minimum selling price of jet fuel, and co-location can further reduce the price of jet fuel.

Comparative functional genomics identifies an iron-limited bottleneck in a Saccharomyces cerevisiae strain with a cytosolic-localized isobutanol pathway

Metabolic engineering strategies have been successfully implemented to improve the production of isobutanol, a next-generation biofuel, in Saccharomyces cerevisiae. Here, we explore how two of these strategies, pathway re-localization and redox cofactor-balancing, affect the performance and physiology of isobutanol producing strains. We equipped yeast with isobutanol cassettes which had either a mitochondrial or cytosolic localized isobutanol pathway and used either a redox-imbalanced (NADPH-dependent) or redox-balanced (NADH-dependent) ketol-acid reductoisomerase enzyme. We then conducted transcriptomic, proteomic and metabolomic analyses to elucidate molecular differences between the engineered strains. Pathway localization had a large effect on isobutanol production with the strain expressing the mitochondrial-localized enzymes producing 3.8-fold more isobutanol than strains expressing the cytosolic enzymes. Cofactor-balancing did not improve isobutanol titers and instead the strain with the redox-imbalanced pathway produced 1.5-fold more isobutanol than the balanced version, albeit at low overall pathway flux. Functional genomic analyses suggested that the poor performances of the cytosolic pathway strains were in part due to a shortage in cytosolic Fe-S clusters, which are required cofactors for the dihydroxyacid dehydratase enzyme. We then demonstrated that this cofactor limitation may be partially recovered by disrupting iron homeostasis with a fra2 mutation, thereby increasing cellular iron levels. The resulting isobutanol titer of the fra2 null strain harboring a cytosolic-localized isobutanol pathway outperformed the strain with the mitochondrial-localized pathway by 1.3-fold, demonstrating that both localizations can support flux to isobutanol.

Metabolic engineering of Clostridium ljungdahlii for the production of hexanol and butanol from CO2 and H2

BACKGROUND

The replacement of fossil fuels and petrochemicals with sustainable alternatives is necessary to mitigate the effects of climate change and also to counteract diminishing fossil resources. Acetogenic microorganisms such as Clostridium spp. are promising sources of fuels and basic chemical precursors because they efficiently utilize CO and CO₂ as carbon source. However the conversion into high titers of butanol and hexanol is challenging.

RESULTS

Using a metabolic engineering approach we transferred a 17.9-kb gene cluster via conjugation, containing 13 genes from C. kluyveri and C. acetobutylicum for butanol and hexanol biosynthesis, into C. ljungdahlii. Plasmid-based expression resulted in 1075 mg L^-1 butanol and 133 mg L^-1 hexanol from fructose in complex medium, and 174 mg L^-1 butanol and 15 mg L^-1 hexanol from gaseous substrate (20% CO₂ and 80% H₂) in minimal medium. Product formation was increased by the genomic integration of the heterologous gene cluster. We confirmed the expression of all 13 enzymes by targeted proteomics and identified potential rate-limiting steps. Then, we removed the first-round selection marker using CRISPR/Cas9 and integrated an additional 7.8 kb gene cluster comprising 6 genes from C. carboxidivorans. This led to a significant increase in the hexanol titer (251 mg L^-1) at the expense of butanol (158 mg L^-1), when grown on CO₂ and H₂ in serum bottles. Fermentation of this strain at 2-L scale produced 109 mg L^-1 butanol and 393 mg L^-1 hexanol.

CONCLUSIONS

We thus confirmed the function of the butanol/hexanol biosynthesis genes and achieved hexanol biosynthesis in the syngas-fermenting species C. ljungdahlii for the first time, reaching the levels produced naturally by C. carboxidivorans. The genomic integration strain produced hexanol without selection and is therefore suitable for continuous fermentation processes.

Biosensor for branched-chain amino acid metabolism in yeast and applications in isobutanol and isopentanol production

Branched-chain amino acid (BCAA) metabolism fulfills numerous physiological roles and can be harnessed to produce valuable chemicals. However, the lack of eukaryotic biosensors specific for BCAA-derived products has limited the ability to develop high-throughput screens for strain engineering and metabolic studies. Here, we harness the transcriptional regulator Leu3p from Saccharomyces cerevisiae to develop a genetically encoded biosensor for BCAA metabolism. In one configuration, we use the biosensor to monitor yeast production of isobutanol, an alcohol derived from valine degradation. Small modifications allow us to redeploy Leu3p in another biosensor configuration that monitors production of the leucine-derived alcohol, isopentanol. These biosensor configurations are effective at isolating high-producing strains and identifying enzymes with enhanced activity from screens for branched-chain higher alcohol (BCHA) biosynthesis in mitochondria as well as cytosol. Furthermore, this biosensor has the potential to assist in metabolic studies involving BCAA pathways, and offers a blueprint to develop biosensors for other products derived from BCAA metabolism.

There are a lack of eukaryotic biosensors specific for branched-chain amino acid (BCAA)-derived products. Here the authors report a genetically encoded biosensor for BCAA metabolism based on the Leu3p transcriptional regulator; they use this to monitor yeast production of isobutanol and isopentanol.

Potential for the Integrated Production of Biojet Fuel in Swedish Plant Infrastructures

Replacing fossil jet fuel with biojet fuel is an important step towards reducing greenhouse gas (GHG) emissions from aviation. To this end, Sweden has adopted a GHG mandate on jet fuel, complementing those on petrol and diesel. The GHG mandate on jet fuel requires a gradual reduction in the fuel’s GHG emissions to up to 27% by 2030. This paper estimates the potential production of biojet fuel in Sweden for six integrated production pathways and analyzes what they entail with regard to net biomass input and the amount of hydrogen required for upgrading to fuel quality. Integrated production of biofuel intermediates from forestry residues and by-products at combined heat and power plants as well as at the forest industry, followed by upgrading to biojet fuel and other transportation fuels at a petroleum refinery, was assumed in all the pathways. The potential output of bio-based transportation fuels was estimated to 90 PJ/y, including 22 PJ/y of biojet fuel. The results indicate that it will be possible to meet the Swedish GHG mandate for jet fuel for 2030, although it will be difficult to simultaneously achieve the GHG mandates for road transportation fuels. This highlights the importance of pursuing complementary strategies for bio-based fuels.

Biofuels for Maritime Transportation: A Spatial, Techno-Economic, and Logistic Analysis in Brazil, Europe, South Africa, and the USA

Low or zero carbon fuels are crucial for maritime transportation decarbonization goals. This paper assesses potential localities for maritime biofuels (biobunkers) production in Brazil, Europe, South Africa, and United States considering geographical, logistic, and economic aspects. This assessment combines georeferenced and techno-economic analyses to identify suitable fuel production hotspots based on not only plant performance and costs but also on logistic integration and biomass seasonality. Five technology pathways were considered: Straight vegetable Oils (SVO), Hydrotreated Vegetable Oils (HVO), Fischer–Tropsch Biomass-to-liquids (FT-BTL), Alcohol oligomerization to middle distillates (ATD), and Hydrotreated Pyrolysis Oil (HDPO). Findings reveal that biomass concentration in Brazil makes it the region with highest biobunker potential, which are mostly close to coastal areas and surpasses regional demand. Although other regions registered more limited potentials, hotspots proximity to ports would enable fossil fuel replacements in these areas. For all cases, biobunker costs (USD 21–104/GJ) are higher than conventional marine fuels prices (USD 11–17/GJ). Only 15% of the hotspots’ carbon prices that would allow its competitiveness are lower than USD 100/tCO2. Alternatives to incentivize biobunker production would be, first, to establish mandatory fuel blends and second, to join forces with other sectors that would be benefited from the co-production of advanced biofuels.

Strategies to improve viability of a circular carbon bioeconomy-A techno-economic review of microbial electrosynthesis and gas fermentation

A circular carbon bioeconomy has potential to halt atmospheric accumulation of greenhouse gases causing climate change and sustainably produce chemical, agricultural and fuel products. Here, we report application of a simplified technoeconomic assessment to critically review two approaches in this space - microbial electrosynthesis and gas fermentation. For microbial electrosynthesis, decoupling of surface-dependant abiotic process for electron delivery from volume-dependant biotic carbon fixation, is shown as the only economically viable strategy to scale-up due to comparatively low biofilm electron consumption rate. This is effectively an electrolyser-assisted gas fermentation system. Targeting high-value products, such as protein for human food consumption is one of the few pathways forward for electrolyser-assisted gas fermentation. Alternatively, gas fermentation of reformed biogas presents an interesting and potentially more sustainable implementation pathway to improve economic viability of chemicals. This critical review suggests linking water treatment resource recovery with gas fermentation is attractive for bioplastics and butanol in terms of competitiveness and market demand.

Recent advances in the microbial production of isopentanol (3-Methyl-1-butanol)

As the effects of climate change become increasingly severe, metabolic engineers and synthetic biologists are looking towards greener sources for transportation fuels. The design and optimization of microorganisms to produce gasoline, diesel, and jet fuel compounds from renewable feedstocks can significantly reduce dependence on fossil fuels and thereby produce fewer emissions. Over the past two decades, a tremendous amount of research has contributed to the development of microbial strains to produce advanced fuel compounds, including branched-chain higher alcohols (BCHAs) such as isopentanol (3-methyl-1-butanol; 3M1B) and isobutanol (2-methyl-1-propanol). In this review, we provide an overview of recent advances in the development of microbial strains for the production of isopentanol in both conventional and non-conventional hosts. We also highlight metabolic engineering strategies that may be employed to enhance product titers, reduce end-product toxicity, and broaden the substrate range to non-sugar carbon sources. Finally, we offer glimpses into some promising future directions in the development of isopentanol producing microbial strains.

Analytical Enzymatic Saccharification of Lignocellulosic Biomass for Conversion to Biofuels and Bio-Based Chemicals

Lignocellulosic feedstocks are an important resource for biorefining of renewables to bio-based fuels, chemicals, and materials. Relevant feedstocks include energy crops, residues from agriculture and forestry, and agro-industrial and forest-industrial residues. The feedstocks differ with respect to their recalcitrance to bioconversion through pretreatment and enzymatic saccharification, which will produce sugars that can be further converted to advanced biofuels and other products through microbial fermentation processes. In analytical enzymatic saccharification, the susceptibility of lignocellulosic samples to pretreatment and enzymatic saccharification is assessed in analytical scale using high-throughput or semi-automated techniques. This type of analysis is particularly relevant for screening of large collections of natural or transgenic varieties of plants that are dedicated to production of biofuels or other bio-based chemicals. In combination with studies of plant physiology and cell wall chemistry, analytical enzymatic saccharification can provide information about the fundamental reasons behind lignocellulose recalcitrance as well as about the potential of collections of plants or different fractions of plants for industrial biorefining. This review is focused on techniques used by researchers for screening the susceptibility of plants to pretreatment and enzymatic saccharification, and advantages and disadvantages that are associated with different approaches.