Techno-economic analysis and network design for CO₂ conversion to jet fuels in the United States

The conversion of carbon dioxide (CO₂) into jet fuel holds significant potential for reducing CO₂ emissions, providing an alternative to carbon-based resources, and offering a renewable means of energy storage. The objective of this study is to conduct a techno-economic analysis and optimize the supply chain network for converting CO₂ to jet fuel in the United States, aiming to minimize total costs while assessing the environmental and economic feasibility of two CO₂ conversion pathways. This first pathway is based on Fischer-Tropsch synthesis (FTS), and the other one is based on the valorization and upgrading of light methanol (MeOH). Incorporating spatial and techno-economic data, a mixed-integer linear programming model was developed to select source plants and conversion pathways, locations of conversion refinery sites, and the amount of captured CO₂ across the United States. The optimal results indicate that the FTS pathway is adopted at all selected refineries when the hydrogen price is $1000/t and the operating cost, mainly electricity used in conversion, is reduced to 5 % of its current level. Under this scenario, the total annual profit is $8B and the net carbon emissions are −88,783,284 tons. The sensitivity analyses reveal that the prices of electricity and hydrogen significantly contribute to total production costs. The CO₂ recycle percentage of the FTS pathway influences the choice of applied pathways at refineries. Additionally, a higher conversion rate holds a substantial promise for reducing the total production cost and can make the MeOH pathway a viable choice.