Energy and techno-economic analysis of aviation fuel production via biomass gasification, olefins synthesis and oligomerization

Bio-based aviation fuel is crucial for reducing carbon emissions in aviation. To address the limitations of poor selectivity inherent in traditional Fischer-Tropsch (F-T) synthesis technologies, this study introduces a novel approach: producing olefins via F-T synthesis after gasification, then generating aviation fuel through olefin oligomerization. A simulation model was developed to evaluate the energy efficiency of different feedstocks through process optimization and parameter analysis. The economic viability was assessed via discounted cash flow method and sensitivity analysis. Results indicate that the gasification process significantly influences the overall energy efficiency and yield, as the operational parameters affect the quality and ratio of CO and H2 in the produced syngas. The optimal gasification conditions are 850 °C and a steam-to-biomass ratio of 0.5, yielding energy efficiencies for the corn stover-to-aviation fuel (CS-AF) and poplar-to-aviation fuel (P-AF) scenarios are 44.5 % and 39.96 %, respectively. Different biomass types exhibit variations in composition, leading to differences in the yield and energy efficiency of the final product. The minimum fuel selling prices (MFSP) for CS-AF and P-AF are $1713.58/t and $1307.77/t, respectively, with the lower cost of poplar feedstock in the P-AF route being a key factor contributing to its superior economic viability. Further research reveals that MFSP is most sensitive to aviation fuel yield, highlighting the importance of optimizing technology to improve yield. Additionally, the gasification plant should exceed 1200 t/d capacity to mitigate scale effects. This study provides an innovative technical model for bio-aviation fuel production and serves as a valuable reference for its commercial application.