Researchers Explore New Corn to Methanol Fuel Pathway

Minnesota Corn Funds Innovative Biofuel Efficiency Research

A new project funded by Minnesota Corn is aiming to revolutionize the way corn is used for renewable fuel. Professor Paul Dauenhauer, a chemical engineering researcher at the University of Minnesota, is leading a study to explore how corn can be transformed into methanol through a more efficient, inorganic catalytic process. 

Modern ethanol production already achieves remarkable efficiency, producing nearly three gallons of fuel from each bushel of corn.  

However, about one-third of the glucose molecules are lost during fermentation as CO2, limiting the fuel yield. Dauenhauer’s work challenges this limitation by proposing a chemical process that uses 100 percent of corn glucose polymers to produce methanol instead. 

“Methanol has a universality to it,” Dauenhauer said. “Using existing technology you can make methanol into jet fuel. You can also make clean burning diesel fuel, and you can make polyethylene polymers—plastics.” 

His research, funded by the Minnesota corn checkoff, is testing various metal catalysts to identify which can achieve the highest yield and economic efficiency. The process could yield 50 percent more fuel while still preserving corn byproducts like fiber, oil, and protein for animal feed. 

Corn-based methanol could significantly reduce carbon emissions by creating Sustainable Aviation Fuel (SAF), potentially supplying the entire U.S. jet fuel market. Methanol-based diesel also offers environmental advantages, as Dauenhauer explained, “The benefit of using dimethyl ether in a diesel engine versus conventional diesel is it burns really cleanly.” 

The research will continue through 2028, including an economic feasibility study for converting existing ethanol plants to methanol production. 

Meanwhile, Minnesota Corn also supports related projects exploring high-ethanol diesel engines and carbon-capturing ethanol-to-jet fuel models, reinforcing ethanol’s evolving role in renewable energy.