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

• A seven-step process was developed to upgrade paper sludge into drop-in jet fuel. • Fuel tests confirm that 44.3 % of the hydrocarbon product meets Jet A standards. • Independent labs confirm the hydrocarbon product may qualify as drop-in jet fuel. • Nine biorefinery configurations were examined to lower the hydrocarbon product MFSP. • Process modifications cut the hydrocarbon product MFSP from $8.6/GGE to $4.5/GGE. 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.