EUBCE 2026 - Adriano ENSINAS - Optimization of a Methanol-to-Olefins SAF Supply Chain via Bagasse and CO2 Valorization in Integrated Sugarcane Bioethanol Distilleries

Optimization of a Methanol-to-Olefins SAF Supply Chain via Bagasse and CO2 Valorization in Integrated Sugarcane Bioethanol Distilleries

Short Introductive summary

This study proposes a multi-period Mixed Integer Linear Programming (MILP) model to optimize the production of electro-sustainable aviation fuel (e-SAF) in integrated sugarcane biorefineries, addressing the growing demand for low-carbon jet fuels. The framework considers methanol synthesis from three renewable carbon sources: (i) CO2 from sugarcane fermentation, (ii) CO2 from vinasse anaerobic digestion, and (iii) syngas from bagasse gasification. Methanol is subsequently converted to SAF via the methanol-to-jet (MTJ) route, using renewable hydrogen from electrolysis. The MILP simultaneously optimizes sugarcane supply, SAF demand, and investment in process units and storage systems across multiple periods. Results show that 8.2 Mt of SAF can be produced from 712.7 Mt of sugarcane, yielding 2,566,001 TJ of energy distributed among bioethanol, green diesel, SAF, green gasoline, and biomethane, with an overall efficiency of 53.6%. e-SAF production leverages CO2 and bagasse valorization, avoiding additional land use. The minimum selling price was USD 4.12 L?¹, with PEM electrolysis representing 51.3% and methanol synthesis 27.5% of total investment.

A. Ensinas, Federal University of Lavras, BRAZIL
J.E. Infante-Cuan, Federal University of ABC, Santo André, BRAZIL
V.F. Garcia, Federal University of ABC, Santo André, BRAZIL
R. Palacios-Bereche, Federal University of ABC, Santo André, BRAZIL