A master programme thesis from Aalborg University
Process Modelling and Optimization of Methanol-to-Jet for eSAF
Author(s)
Term
4. term
Education
Publication year
2025
Submitted on
2025-05-27
Pages
64 pages
Abstract
To reach long-term greenhouse gas (GHG) neutrality in aviation, replacing fossil-based jet fuels with Sustainable Aviation Fuels (SAF) from renewable sources is crucial. This study investigates the process modeling and optimization of the Methanol-to- Jet (MtJ) pathway for e-SAF production using Aspen Plus V12.1, integrating methanol synthesis from CO2 and H2, methanol-to-olefins (MTO) conversion, oligomerization, and hydrogenation. A novel dynamic modeling approach was implemented for oligomerization, linking a custom MATLAB model to Aspen Plus via Excel to predict product distribution using the Anderson–Schulz– Flory (ASF) mechanism parameterized by reactor conditions. Process optimization through response surface methodology targeted maximization of kerosene yield and minimization of cost. The optimized process achieved a kerosene yield of 0.40 Cmole/Cmole, a sustainable aviation fuel production rate of 9395 tonnes/year, and a Levelized Cost of SAF (LCOSAF) of 6980 €/tonne. Overall, the results demonstrate the technical feasibility and optimization potential of the MtJ process, but further reductions in feedstock cost and improved heat integration are needed for economic viability at scale.
Keywords
eSAF ; SAF ; Methanol ; Methanol-to-Jet ; Aviation Fuel ; Optimization ; Aspen ; Process Simulation ; Techno-economic ; LCOSAF
Documents
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