Publication date: 15th December 2025
Direct Conversion of Dimethyl Ether to Sustainable Aviation Fuel over Engineered Bifunctional Zeolite Catalysts
Zeineb A. Thiehmed1,2, Abdulkarem I. Amhamed1, Tareq A. Al-Ansari1,2*
1Qatar Environment and Energy Research Institute (QEERI), Hamad Bin Khalifa University, Qatar Foundation, Education City, Doha, Qatar
2College of Science and Engineering, Hamad Bin Khalifa University, Qatar Foundation, Doha, Qatar
Sustainable aviation fuel (SAF) deployment requires catalytic routes capable of producing jet-range hydrocarbons with reduced process complexity and lower carbon intensity. Dimethyl ether (DME), which can be synthesized from captured CO₂ and green hydrogen, is a promising platform molecule for developing simplified upgrading pathways. In this work, we present a novel catalytic process concept that enables direct conversion of DME to SAF range hydrocarbons, eliminating multiple intermediate upgrading steps commonly required in conventional routes. Achieving this selectivity is fundamentally a materials design challenge, as DME upgrading involves competing pathways such as oligomerization and chain growth versus undesired cracking and aromatic formation.
To address this, a series of bifunctional zeolite-based catalysts were developed by tailoring acidity and incorporating metal functionality to balance hydrogenation activity with acid-catalyzed C–C coupling. Catalyst screening was conducted using a micro-activity testing system under elevated temperature and moderate pressure, with product analysis focused on hydrocarbon distribution and selectivity control. The optimized catalyst achieved over 70% DME conversion and produced a hydrocarbon slate concentrated in the C8–C16 range, dominated by paraffinic and cycloparaffinic products, while suppressing excess aromatics compared to baseline formulations.
The structure performance relationships were rationalized through comprehensive physicochemical characterization to correlate catalyst properties with selectivity trends. X-ray diffraction (XRD) confirmed preservation of zeolite crystallinity after modification, while transmission electron microscopy (TEM) provided insights into metal dispersion and metal support interactions. NH₃ temperature-programmed desorption (NH₃-TPD) quantified acidity changes associated with support tuning, and H₂ temperature-programmed reduction (H₂-TPR) indicated modified reducibility consistent with enhanced metal functionality. Thermogravimetric analysis (TGA) supported the observed catalyst stability through coke-resistance assessment.
Overall, the results demonstrate that rational engineering of pore architecture, acidity strength, and metal support interfaces can steer DME upgrading toward jet-range hydrocarbons, supporting the feasibility of a novel and simplified pathway for sustainable aviation fuel production.
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