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Sustainable Alternative Jet Fuel Conversion Processes Review

This review explores established, in-process, and approved ASTM pathways for the conversion of sustainable alternative jet fuel. The focus is on optimizing the use of a middle distillate kerosene stream for aviation fuel, with the goal of achieving net GHG reduction. Various conversion mechanisms are discussed, including gasification, hydroprocessing, and biochem conversion. The potential of using waste materials as feedstock is also explored. The review concludes with an assessment of the current pathway status and future possibilities.

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Sustainable Alternative Jet Fuel Conversion Processes Review

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  1. SAJF Conversion Process Review Activities of established, in process or approved ASTM pathways Steve Csonka, Executive Director, CAAFI 03Dec’15

  2. Jet Fuel / KeroseneAviation Enterprise optimized around the fuel A middle distillate kerosene stream is used for aviation fuel • Comprised of mixtures of aliphatic and aromatic hydrocarbons with carbon numbers predominantly in the range of C8-C16, which is typically a mixture of: • 25% / 11% normal / branched paraffins • 30% / 12% / 1% mono- / di- / tri-cycloparraffins • 16 / 5% mono- / di-nuclear aromatics (25% max aromatics – air quality concern) There is no standard “formula” for Jet Fuel • Composition that delivers the physical properties and performance-based requirements / characteristics of ASTM D1655 specification • A Gaussian distribution of hydrocarbons, represented as C12H23

  3. SAJFSustainable Alternative Jet Fuel, a.k.a. biofuel, biojet Alternative: Creating synthetic jet fuel by starting with a different set of hydrocarbons than petroleum … a synthetic comprised of molecules essentially identical to petroleum-based jet (in whole or in part) – enables drop-in approach – no changes to infrastructure or equipment Sustainable: Doing so while taking Social, Economic, and Environmental progress into account – moving in the right direction Jet Fuel: Delivering the properties of ASTM D1655 Net GHG reduction: Benefit comes from not pulling more carbon molecules out of the ground, but rather, taking them from the biosphere and/or re-using / recycling them

  4. SAJF conversion processes…or, “dispelling the fear of revisiting Chemistry 101” Start with hydrocarbon / organic building-blocks Deconstruct & remove extraneous molecules Process to workable intermediates Reformulate to appropriate C8-C16 molecules Utilize standard refinery “finishing” processes D7566 - SAJF Blending Components D1655 – Petroleum and D7566 Fuel Blends

  5. SAJF conversion mechanismsChallenge … doing it at the price of petroleum refining Fossil HC F.O.G. Plant & Animal Cellulose & Hemi- & Lignin Sugars & Starch Wastes & Syngas CH4 CO2 Gasify PyrolizeTorefySaccharify Deconstruct Digest $$ ? Separate Ferment Dehydrate Catalyze Process FT CH CC APR HL Oligomerize Distill HydrotreatHydroprocess Hydro-Isomerize FT-SPK, HEFA-SPK, HFS-SIP, FT-SPK/A, ATJ-SPK, …

  6. SAJF approved production pathwaysLimited to paraffins to-date – other molecules pending • Gasification & FT (FT-SPK) 50% max blend • Hydroprocessing F.O.G. (HEFA-SPK) 50% max blend • Biochem sugars (HFS-SIP) 10% max blend • FT-SPK/A (awaiting ASTM admin. completion)tbd Approved AltAir Fuels – First dedicated US production facility for HEFA fuels in Paramount, CA (LAX), 30+ Mgpy from FOG. Currently in completion and commissioning.

  7. Pipeline of pathwaysFocus on delivering lower CapEx and OpEx solutions • ATJ-SPK (bio/thermochem butanol) • SK/SAK (CCS - APR) • CH (lipids) • HEFA+ (wider-cut HEFA with RD) • HDCJ (pyro cellulose) • ATJ-SKA • Co-processing (multiple approaches) • Catalytic conversion of alcohols • Biochem isobutene • Hydrothermal Liquefaction • Biochem conversion of wastes • STG+, REACH. … Expecting final ATJ balloting in 1Q’16 Possible for subsequent approvals every~6-12 months thereafter Path of discovery to fully synthetic fuels In- Process Task Forces Pipeline

  8. Status of Alternative Jet Fuels Virent SK HEFA Expansion ATJ SPK (Ethanol) ATJ SKA KiOR HDCJ Virent SAK ARA CHJ ATJ SPK (Isobutanol)

  9. Recent focus on “waste” evaluationsAnd similar concepts with remediation co-benefits • Overcomes challenges associated with “classical” feedstocks – primarily price • Avoids some challenging issues with “biofuels” • Solves other landfill / conversion related issues • Enables technical proving for later conversion to biomasses • Matches interests of other constituencies Examples: • MSW • Sewage sludge • Animal waste • Animal processing • Industrial wastes • Forestry residuals

  10. Bio-Oil (F.O.G.) applicabilityMultiple conversion pathways (fats, oils & greases) • Honeywell / UOP EniEcofining • NesteNEXBTL: • SAJF Intentions (first facilities) • AltAir Fuels 30 M gpy • Emerald Biofuels 88 M gpy • SG Preston 110 M gpy SAJF Pathway • Gasification & FT • Hydroprocessing FOG • Biochem sugars • Thermochem alcohols (ATJx2) • Hydrothermoils (CH) • Thermochem various (APR / HL) • Renewable Diesel • Thermochem cellulose (HDCJ) • Refinery Co-processing Approved • ARA - unique value proposition • Potential as 100% drop-in In- Process Intent to unlock existing RD production - Already approaching 1 B+ gpy capacity Front-end: Blend with crude Mid: FCC, HC, Coker ? Back-end: Hydroprocessing 

  11. Looking diligently at F.O.G.TEA suggests feasibility is in the feedstock economics Targeting most sustainable solutions: Low, or Zero, impact LUC/ILUC & F-v-F solutions; Environmental Services a plus. • Multiple conversion processes • Lowered H2 cost & availability • Multiple feedstock developers • Multiple producers • Multiple low LUC/ILUC agri-based feedstocks, plus: • White Grease • Chicken Fat • Tallow • UCO • Yellow Grease • Brown Grease • Easier supply chain scale-up leveraging biodiesel and RD production capacity Camelina, Carinata, Canola: Rotational DGO Pennycress Rapeseed Tobacco Seed Oil Algal Oils Winter Oilseeds, Inedible Peanuts Lesquerella Algal Oils Carinata, Pongamia Algal /Aquatic Oils Halophyte Oils Jatropha, Pongamia, Macauba

  12. Steve Csonka Executive Director, CAAFI +1-513-800-7980 Csonka.CAAFI.ED@gmail.com Steve.Csonka@caafi.org www.caafi.org

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