Non-thermal plasma catalysis driven sustainable pyrolysis oil upgrading to jet fuel under near-ambient conditions

The global aviation industry is under increasing pressure to mitigate its environmental impact and achieve net-zero objectives. Reducing CO2 emissions alone is insufficient, as it overlooks crucial parts of the overall climate impacts. Addressing climate-neutral aviation fuel production from sustainable feedstock and effective technology is crucial. Here, we present a breakthrough in sustainable upgrading of pyrolysis oil with CH4 to jet fuel using non-thermal plasma triphase catalysis, characterized by an opposite gas–liquid flow and a fluidized catalyst under near-ambient conditions of atmospheric pressure and around 100 °C, resulting in an impressive liquid oil yield of almost 87%. This work delves into the strategic distribution of iridium (Ir) as minute nanoclusters on GaN, which serves to ensure robust catalytic stability and instigate synergistic interactions between plasma and catalysis. This unique configuration establishes an active surface conducive to the transformation of pyrolysis oil into essential jet fuel constituents, encompassing gasoline hydrocarbons (C5–C11), aromatics, and cycloalkanes. Both empirical experiments and computational analysis converge to confirm that methane activation can effectively occur within the plasma zone while surface reactions of cleavage of C–H, C–O, and C–N bonds with adsorbed H and CHx active species occurring on the Ir(100) surface play a crucial role in enhancing selectivity, resulting in upgraded oil meeting jet fuel commercial specifications. This novel approach holds substantial promise in the pursuit of sustainable and eco-friendly jet fuel production.