This study focuses on advancing the production of sustainable aviation biofuels by employing a one-pot integrated catalytic approach to convert Clostridium beijerinckii strain SR-44 ABE fermentation products into higher-value compounds, specifically ketones, using Pd/Ni@BNNS bimetallic catalysts. The influence of various parameters, such as salting-out agents, temperature, catalyst loading, and reaction time, significantly improved the ABE conversion to 98% with 86% higher ketone (C5–C11) selectivity. Furthermore, the heterogeneity and recyclability of the Pd/Ni @BNNSs catalyst were investigated, confirming its suitability for industrial-scale applications. By advancing biofuel synthesis technology and overcoming the drawbacks of conventional biofuels, this study contributes to the mitigation of the environmental and energy challenges facing the aviation industry.