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Sustainable aviation fuel from ethanol: Techno-economic analysis and life cycle analysis

Author

Listed:
  • Uddin, Md Mosleh
  • Lee, Uisung
  • Xu, Hui
  • Li, Yuan
  • Kwon, Hoyoung
  • Zhang, Yimin
  • Smolinski, Sharon
  • Cai, Hao
  • Tao, Ling

Abstract

Sustainable aviation fuel (SAF) is crucial for improving energy security, enhancing domestic production, and reducing carbon emissions in the aviation sector. Among various SAF production technologies, the ethanol-to-jet (ETJ) pathway is a promising option due to its economic viability and technological maturity. This study integrates a techno-economic analysis (TEA) and a life cycle analysis (LCA) to evaluate emissions reduction strategies for SAF production via the ETJ pathway, considering use of ethanol derived from both corn grain and corn stover. Conventional corn grain-derived ETJ fuel reduces greenhouse gas (GHG) emissions by 22 % compared to fossil jet fuel, with potential reductions of 26 %–96 % when incorporating renewable energy sources, with a 6 %–32 % increase in the minimum fuel selling price (MFSP). Corn stover-derived ETJ achieves a 77 % GHG reduction but with higher MFSPs compared to corn grain ETJ. Carbon capture and storage (CCS without considering the cost for piping and sequestration, only compression) reduces the emissions of corn grain-derived ETJ by up to 32 gCO2e/MJ and enables negative emissions for corn stover-derived ETJ, with MFSP increases ranging from 1 % to 22 %. While carbon capture and utilization (CCU) increase ethanol yield by 47 %, it raises MFSPs by 54 % due to high electricity demand. Sustainable farming practices provide only limited carbon intensity (CI) reductions individually but do offer cumulative benefits when combined. These findings highlight the trade-offs between cost and environmental impact, providing insights to optimize SAF production strategies and support aviation sector goals for emissions reduction.

Suggested Citation

  • Uddin, Md Mosleh & Lee, Uisung & Xu, Hui & Li, Yuan & Kwon, Hoyoung & Zhang, Yimin & Smolinski, Sharon & Cai, Hao & Tao, Ling, 2025. "Sustainable aviation fuel from ethanol: Techno-economic analysis and life cycle analysis," Applied Energy, Elsevier, vol. 398(C).
    • Handle: RePEc:eee:appene:v:398:y:2025:i:c:s0306261925011031
    DOI: 10.1016/j.apenergy.2025.126373
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    References listed on IDEAS

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    1. Huang, Zhe & Grim, Gary & Schaidle, Joshua & Tao, Ling, 2020. "Using waste CO2 to increase ethanol production from corn ethanol biorefineries: Techno-economic analysis," Applied Energy, Elsevier, vol. 280(C).
    2. Fang, Zhenquan & Zhang, Xinghua & Zhuang, Xiuzheng & Ma, Longlong, 2024. "Recent advances in synthesis strategies for biomass-derived high-energy-density jet fuels," Renewable and Sustainable Energy Reviews, Elsevier, vol. 202(C).
    3. Bell, Aron & Mannion, Liam Anthony & Kelly, Mark & Ghaani, Mohammad Reza & Dooley, Stephen, 2025. "Life cycle CO2e intensity of commercial aviation with specific sustainable aviation fuels," Applied Energy, Elsevier, vol. 382(C).
    4. Chinmay V. Kurambhatti & Deepak Kumar & Kent D. Rausch & Mike E. Tumbleson & Vijay Singh, 2018. "Ethanol Production from Corn Fiber Separated after Liquefaction in the Dry Grind Process," Energies, MDPI, vol. 11(11), pages 1-12, October.
    5. Robert Perlack, Robert & Eaton, Lawrence & Thurhollow, Anthony & Langholtz, Matt & De La Torre Ugarte, Daniel, 2011. "US billion-ton update: biomass supply for a bioenergy and bioproducts industry," MPRA Paper 89324, University Library of Munich, Germany, revised 2011.
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    1. Md Nasir Uddin & Feng Wang, 2025. "Sustainable Aviation Fuels: A Review of Current Techno Economic Viability and Life Cycle Impacts," Energies, MDPI, vol. 18(20), pages 1-46, October.
    2. Zheng, Shiyuan & Jiang, Changmin & Li, Ang, 2025. "Aviation e-fuel mandates: balancing average and minimum requirements for emission reduction," Transportation Research Part A: Policy and Practice, Elsevier, vol. 202(C).

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