Ultrasonic-Assisted Synthesis of Ni/ZSM-5 Catalyst for Efficient Bio-Jet Fuel Production via Atmospheric Hydrotreatment of Processed Palm Oil

This study investigates the synthesis and catalytic performance of a Ni/ZSM-5 catalyst prepared using ultrasonic-assisted impregnation for the hydrotreatment of processed palm oil (white butter) into bio-jet fuel. The objective was to develop a highly active and stable catalyst for sustainable aviation fuel production. The catalyst was characterized using XRD, FT-IR, SAA, NH₃-TPD, XPS, and SEM-EDX analyses, confirming the successful dispersion of NiO and metallic Ni species on the ZSM-5 support. The ultrasonic-assisted catalyst exhibited excellent physicochemical properties, including a crystal size of 19.50 nm, 73.55% crystallinity, a specific surface area of 148.1 m²/g, and a total acidity of 2.331 mmol/g. In a double-bed reactor configuration, the catalyst achieved outstanding performance, yielding 51.71% bio-jet fuel with a product selectivity of 86.21%. The obtained bio-jet fuel demonstrated an ultra-low freezing point of − 59.41°C, meeting aviation fuel standards. Moreover, the catalyst maintained its activity after three consecutive reuse cycles, indicating good stability. These results reveal that ultrasonic-assisted synthesis provides a simple, energy-efficient, and scalable method to enhance metal dispersion and surface acidity, offering valuable insights into the design of bifunctional Ni-based catalysts for green and renewable aviation fuel production.