BREAKTHROUGH HYBRID TECHNOLOGY • PCT/CH2025/050039

PET to Sustainable Aviation Fuel

Revolutionary hybrid chemical-thermal process enabling high-PET-content plastic waste (15-50%) conversion to ASTM D7566-certified sustainable aviation fuel through staged catalytic pyrolysis

80% CO₂ Reduction

Dual-Zone Catalysis

60% H₂ Savings

The Hybrid Process

Integrating chemical pre-treatment with advanced catalytic pyrolysis to overcome PET's unique challenges

Key Innovation: Dual-Zone Catalytic Reactor (Stage 2)

Hybrid Process Stage Details

Stage	Process Step	Description
01	Selective Partial GlycolysisPATENTED INNOVATION	PET undergoes controlled glycolysis at 150-180°C to produce BHET monomers and reactive oligomers
02	Dual-Zone Catalytic PyrolysisPATENTED INNOVATION	Zone 1: Fe-ZSM-5 catalyst for deoxygenation \| Zone 2: Ni-Mo catalyst for hydrogenation
03	Vapor Separation	Hot separation removes non-condensables and heavy wax, optimizing downstream processing
04	Fractional Distillation	Kerosene-range (C₁₀-C₁₅) fraction isolated for jet fuel production
05	Hydrotreating (Reduced Severity)PATENTED INNOVATION	40-60% lower hydrogen consumption thanks to pre-deoxygenation in Stage 2
06	Hydroisomerization & Blending	Final conversion to ASTM D7566-compliant Sustainable Aviation Fuel

Patented Innovations

Four breakthrough innovations that enable economical PET-to-SAF conversion

Substoichiometric Glycolysis

Partial depolymerization (30-50% BHET) creates reactive intermediates without costly full conversion

40-60% lower ethylene glycol consumption

Fe-Modified ZSM-5 Catalyst

Optimized Fe/Al ratio (0.15-0.35) enables selective PET deoxygenation while preserving aromatics

65-75% oxygen removal as CO₂/CO

In-Situ Hydrogen Donation

Co-fed polyolefins provide hydrogen-rich species, eliminating external H₂ during pyrolysis

Eliminates high-pressure H₂ requirement

Staged Oxygen Management

Spatial separation of deoxygenation (Zone 1) and hydrogenation (Zone 2) prevents catalyst poisoning

2-3x longer catalyst life

Technical Specifications

Performance metrics demonstrating breakthrough capability for high-PET feedstocks

PET Tolerance

15-50%

wt% of feedstock

Jet Fuel Yield

45-60%

wt% from plastic

Oxygen Removal

75-85%

in pyrolysis

H₂ Consumption

40-60%

reduction vs. conventional

Freezing Point

≤-52°C

ASTM D7566 compliant

Aromatics

12-18%

vol% (optimized)

Environmental Impact

Converting difficult-to-recycle PET into sustainable aviation fuel with superior environmental benefits

Carbon Credit Partnership

ESAF TradeCo collaborates with Verra to establish dedicated methodologies for carbon credits and plastic credits generated from pyrolysis with PET-rich recycled feedstock, maximizing both environmental impact and economic returns.

Benefits Per 1 Ton SAF

CO₂ Avoided

2.1

tons CO₂e

PET Diverted

2.5

tons from landfill

Carbon Credits

$110

ISCC+ certified

Revenue Potential

$1,440

fuel + credits

Benefits Per 1,000 Tons SAF

CO₂ Avoided

2,100

tons CO₂e/year

PET Diverted

2,500

tons/year

Carbon Credits

$110,000

annual revenue

Total Revenue

$1.44M

fuel + credits

Breakthrough Advantages

First-of-its-kind technology enabling economical SAF production from PET-rich plastic waste

15-50% PET

3-10x higher tolerance

45-60% Yield

2x better than conventional

60% H₂ Savings

dramatically lower costs

ASTM D7566

fully certified SAF