Production of sustainable aviation fuels (SAFs) can significantly
reduce the aviation industry’s carbon footprint. Current pathways
that produce SAFs in significant volumes from ethanol and fatty acids
can be costly, have a relatively high carbon intensity (CI), and impose
sustainability challenges. There is a need for a diversified approach
to reduce costs and utilize more sustainable feedstocks effectively.
Here, we map out catalytic synthesis routes to convert furanics derived
from the (hemi)cellulosic biomass to alkanes and cycloalkanes using
automated network generation with RING and semiempirical thermochemistry
calculations. We find >100 energy-dense C8–C16 alkane and cycloalkane SAF candidates over 300 synthesis
routes; the top three are 2-methyl heptane, ethyl cyclohexane, and
propyl cyclohexane, although these are relatively short. The shortest,
least endothermic process chemistry involves C–C coupling,
oxygen removal, and hydrogen addition, with dehydracyclization of
the heterocyclic oxygens in the furan ring being the most endothermic
step. The global warming potential due to hydrogen use and byproduct
CO2 is typically 0.7–1 kg CO2/kg SAF
product; the least CO2 emitting routes entail making larger
molecules with fewer ketonization, hydrogenation, and hydrodeoxygenation
steps. The large number of SAF candidates highlights the rich potential
of furanics as a source of SAF molecules. However, the structural
dissimilarity between reactants and target products precludes pathways
with fewer than six synthetic steps, thus necessitating intensified
processes, integrating multiple reaction steps in multifunctional
catalytic reactors.