Honeywell supplies ethanol-to-jet technology for Petrobras SAF project

Refining, sustainable fuels, and aviation sectors are accelerating efforts to scale sustainable aviation fuel (SAF) production using alternative feedstocks. In this context, Honeywell has been selected by Petrobras to provide its ethanol-to-jet (ETJ) process technology for a proposed SAF project at the REPLAN refinery in São Paulo, Brazil.

Once approved, the facility is expected to produce up to 10,000 barrels per day of SAF, marking the first large-scale ETJ-based production project in Latin America. The initiative reflects a shift toward leveraging regionally available renewable resources to support aviation decarbonization.

Converting ethanol into aviation fuel
The ETJ process developed by Honeywell UOP converts ethanol into jet fuel through a series of catalytic steps, transforming a widely available bio-based feedstock into drop-in aviation fuel. Ethanol, particularly abundant in Brazil due to its established sugarcane industry, offers a scalable and relatively cost-stable input compared to other renewable feedstocks.

From an engineering perspective, the use of ethanol simplifies supply chain considerations and enables faster deployment of SAF production capacity. The process is designed to integrate with existing refinery infrastructure, supporting incremental adoption without requiring entirely new facilities.

Supporting large-scale SAF production
With global SAF demand projected to increase significantly, refining technologies that enable scalable and replicable production pathways are gaining importance. The proposed REPLAN project demonstrates how ethanol-based processes can contribute to meeting these requirements.

By utilizing Brazil’s established biofuel production ecosystem, the facility is expected to support both domestic and international aviation markets. The resulting SAF can help reduce lifecycle greenhouse gas emissions compared to conventional jet fuel, depending on feedstock sourcing and process efficiency.

Expanding renewable fuel integration in refineries
The project builds on ongoing collaboration between Petrobras and Honeywell in refining and process technologies. In addition to ETJ, Petrobras has previously adopted renewable fuel technologies for producing SAF and renewable diesel using lipid-based feedstocks such as vegetable oils and animal fats.

Compared to hydroprocessed esters and fatty acids (HEFA) pathways, ETJ provides an alternative route that relies on alcohol-based feedstocks. This diversification can improve supply resilience by reducing dependence on a single type of raw material and enabling broader feedstock flexibility.

Strategic role of ethanol in energy transition
Brazil’s ethanol industry plays a central role in the feasibility of the project, offering large-scale production capacity and established logistics. The integration of ethanol into aviation fuel production highlights its potential beyond ground transportation fuels.

As refineries adapt to evolving energy demands, technologies such as ETJ support the transition toward lower-carbon fuel portfolios while maintaining compatibility with existing distribution and aircraft systems.

Edited by Natania Lyngdoh, Induportals Editor — Adapted by AI.

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