Catalytic conversion of paper sludge carbohydrates to jet fuel range hydrocarbons: Process optimization and techno-economic analysis

This study presents a catalytic pathway involving seven pretreatment and conversion steps to upgrade carbohydrates in paper sludge into a hydrocarbon blend compatible with conventional aviation fuel. Fuel-critical properties analysis by two independent laboratories confirmed that 44.3 % of the resulting hydrocarbon product meets Jet A standards. Nine biorefinery configurations were examined to identify strategies for reducing the minimum fuel selling price (MFSP) of the final hydrocarbon product. Techno-economic analysis revealed that replacing 1,4-dioxane with acetone and increasing sugar concentration during the dehydration step, along with using biobased methyl ethyl ketone in aldol-condensation, are key factors in reducing the MFSP from $8.6 per gasoline gallon equivalent (GGE) in the base case to $4.5/GGE in the optimized scenario. A sensitivity assessment was conducted for each configuration analyzed to identify additional process optimization opportunities to enhance the economic viability of the biorefinery process relative to conventional jet fuel.