Scientists are turning corn waste into sustainable jet fuel

Why it matters: At 100 billion gallons and counting, global jet fuel consumption creates a huge carbon footprint. The industry’s goal is to transition to 100% renewable fuels, and research is bringing it closer to that goal. A new study has found that it is possible to reuse agricultural waste into a sustainable fuel.

Scientists at Washington State University have successfully tested a new method for producing jet fuel from agricultural waste, specifically lignin-based materials.

A research team led by Professor Bin Yang from the Department of Biological Systems Engineering has developed a continuous process for converting lignin polymers into jet fuel. This process, called “simultaneous depolymerization and hydrodeoxygenation”, breaks down lignin and removes oxygen to produce fuel.

Lignin, a key component of plant cells, comes from corn – stalks, cobs and leaves left after harvest. The new lignin-based jet fuel is cleaner and easier to use in jet engines compared to conventional fuels.

Hydrocarbons derived from lignin could replace aromatic compounds derived from fossil fuels, which are associated with the formation of contrails and a negative impact on the climate. Flavors are still used in jet fuel because they increase its energy content and help maintain seals in engine parts.

Global jet fuel consumption reached nearly 100 billion gallons in 2019, and demand is expected to grow in the coming decades. The aviation industry hopes to one day be able to produce 100% renewable jet fuel, said Josh Heyne, research team member and co-director of the WSU-PNNL Bioproducts Institute. According to Heyne, lignin-based jet fuel brings the industry closer to this goal because it complements existing technologies such as increasing the density of fuel blends.

One of the key advantages of this new fuel is its potential for drop-in use, meaning it can be used in existing engines, infrastructure and aircraft, much like current fossil fuel-based aviation fuels. The researchers’ goal is to create a commercially suitable technology for a supplemental blend ingredient that can achieve the 100% reduction goal, Heyne said.

This research represents the first successful test of a continuous manufacturing process that is more feasible for commercial applications. The team used a less processed, cheaper form of lignin called “technical lignin”, making the process more cost-effective.

The research, published in the journal Fuel Processing Technology, was supported by several organizations, including the U.S. Department of Energy’s Office of Bioenergy Technologies and Pacific Northwest National Laboratory.

The research team is currently working to refine their process for greater efficiency and lower costs, which would bring sustainable aviation fuel much closer to widespread commercial use.