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DOE OSTI · 3385017

Cost-effective valorization of 2,3-butanediol to high-value chemicals and jet fuel

Cordon, Michael J. [Oak Ridge National Laboratory (ORNL), Oak Ridge, TN (United States)] (ORCID:0000000256758027)·Olcay, Hakan [National Laboratory of the Rockies (NLR), Golden, CO (United States)]·Neate, Peter G. N. [Los Alamos National Laboratory (LANL), Los Alamos, NM (United States)]·Kidder, Michelle K. [Oak Ridge National Laboratory (ORNL), Oak Ridge, TN (United States)] (ORCID:000000030851835X)·Lawal, Ajibola [Oak Ridge National Laboratory (ORNL), Oak Ridge, TN (United States)] (ORCID:0000000187266570)·Li, Meijun [Oak Ridge National Laboratory (ORNL), Oak Ridge, TN (United States)] (ORCID:0000000221648629)·Purdy, Stephen C. [Oak Ridge National Laboratory (ORNL), Oak Ridge, TN (United States)] (ORCID:0000000298701029)·Wang, Chenxi [Los Alamos National Laboratory (LANL), Los Alamos, NM (United States)]·Klein, Bruno C. [National Laboratory of the Rockies (NLR), Golden, CO (United States)]·Tan, Eric C. D. [National Laboratory of the Rockies (NLR), Golden, CO (United States)]·Yang, Xiaokun [Los Alamos National Laboratory (LANL), Los Alamos, NM (United States)]·Davis, Ryan E. [National Laboratory of the Rockies (NLR), Golden, CO (United States)]·Sutton, Andrew D. [Oak Ridge National Laboratory (ORNL), Oak Ridge, TN (United States)]
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Abstract

Here, this work outlines an optimized process for converting 2,3-butanediol (BDO) into sustainable aviation fuel (SAF) and C4 chemicals. BDO is reactively separated from fermentation broth by forming dioxolanes, which are converted to isobutyraldehyde, methyl ethyl ketone (MEK), and 1,3-butadiene. These intermediates are reduced and dehydrated over Cu/ZSM-5 to form alkenes, which can be oligomerized and hydrotreated to jet-range alkanes. Previous BDO-dioxolane-alkene processes are limited by the requirement for a continuous aldehyde source for dioxolane formation. Brønsted acidic zeolites catalyze dioxolane deacetalization to form isobutyraldehyde and MEK in a >2:1 molar ratio, providing an internal, recyclable aldehyde source. Dioxolane formation optimization was performed to achieve >95% dioxolane yields over Amberlyst-15 and minimize isobutyraldehyde recycle. The overall BDO-dioxolane-fuel process yields an alkane mixture that enables at least a 50% v/v blend with Jet-A. Techno-economic analyses and life cycle assessments for this BDO-dioxolane-fuel process yield scenarios with <$2.50 per gallon gas equivalent and >58% reduction in CO2 emissions.

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2,3-butanediolLCATEAalkenesisobutyraldehydelife cycle assessmentmethyl ethyl ketonereactive extractionsustainable aviation fueltechno-economic analysis

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Cordon, Michael J. [Oak Ridge National Laboratory (ORNL), Oak Ridge, TN (United States)] (ORCID:0000000256758027), Olcay, Hakan [National Laboratory of the Rockies (NLR), Golden, CO (United States)], Neate, Peter G. N. [Los Alamos National Laboratory (LANL), Los Alamos, NM (United States)], Kidder, Michelle K. [Oak Ridge National Laboratory (ORNL), Oak Ridge, TN (United States)] (ORCID:000000030851835X), Lawal, Ajibola [Oak Ridge National Laboratory (ORNL), Oak Ridge, TN (United States)] (ORCID:0000000187266570), Li, Meijun [Oak Ridge National Laboratory (ORNL), Oak Ridge, TN (United States)] (ORCID:0000000221648629), Purdy, Stephen C. [Oak Ridge National Laboratory (ORNL), Oak Ridge, TN (United States)] (ORCID:0000000298701029), Wang, Chenxi [Los Alamos National Laboratory (LANL), Los Alamos, NM (United States)], Klein, Bruno C. [National Laboratory of the Rockies (NLR), Golden, CO (United States)], Tan, Eric C. D. [National Laboratory of the Rockies (NLR), Golden, CO (United States)], Yang, Xiaokun [Los Alamos National Laboratory (LANL), Los Alamos, NM (United States)], Davis, Ryan E. [National Laboratory of the Rockies (NLR), Golden, CO (United States)], Sutton, Andrew D. [Oak Ridge National Laboratory (ORNL), Oak Ridge, TN (United States)]. 2026-11-18. Cost-effective valorization of 2,3-butanediol to high-value chemicals and jet fuel. https://doi.org/10.1016/j.joule.2026.102536

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