Novel two-stage catalytic technology transforms plastic waste into aviation-grade fuel at competitive costs, offering a promising pathway for plastic recycling and sustainable aviation.
Researchers in China have developed a low-cost catalytic process that converts mixed plastic waste directly into aviation-grade jet fuel, offering a promising new approach to tackling plastic pollution while supporting the production of sustainable aviation fuel. The study demonstrates that difficult-to-recycle plastic waste can be transformed into high-value fuel with production costs comparable to conventional fossil-derived jet fuel.
The technology, developed by researchers from Nanjing Forestry University and Tsinghua University, uses a two-stage tandem reactor system combining hydro-pyrolysis and hydrogenolysis. Plastic waste is first broken down into smaller hydrocarbon molecules at high temperatures before being upgraded into jet-fuel-range cycloalkanes using a highly efficient single-atom ruthenium catalyst. The catalyst reportedly delivers hydrogenation performance more than 100 times greater than conventional catalyst systems.
According to the researchers, the process can produce aviation fuel at an estimated cost of US$1.00–1.80 per kilogram, placing it within the cost range of conventional jet fuel. The resulting fuel exhibits key performance characteristics required for aviation applications, including high energy density and suitable low-temperature properties, making it a promising candidate for sustainable aviation fuel production.
Unlike conventional mechanical recycling, which often requires extensive sorting and produces lower-value recycled plastics, the new chemical recycling approach converts waste polymers into a premium transportation fuel. The innovation could provide an effective solution for managing mixed plastic waste streams that are difficult to recycle using existing technologies while creating additional value from end-of-life plastics.
The researchers are now focused on scaling up the catalyst manufacturing process and improving overall system efficiency to support commercial deployment. If successfully industrialized, the technology could help reduce plastic waste, improve resource recovery, and contribute to the aviation industry’s transition toward lower-carbon fuels.
The breakthrough highlights the growing role of advanced catalytic recycling technologies in supporting the circular plastics economy. By converting discarded plastics into high-value aviation fuel, the process has the potential to address two major global challenges simultaneously—plastic waste management and the development of more sustainable fuel solutions for the aviation sector.