We limit Part 91 to 16 hours of duty or less. 16-24 hours if crew (both) get 6 hours of rest (hotel) at some point during the duty period or a crew swap occurs.
Max flight time was about 11 hours with a hair under 14 of duty...3 legs. I was ready to climb out of the aluminum coffin known as a CJ by the time I was done, but felt just fine.
14-16hr duty days weren't uncommon for us a few years back, but they were generally proceeded and followed by at least two days off.
Planned longer than that, we mitigate with dayrooms.
I think my longest day was close to 17hr, due to weather & mechanical delays...felt fine but definitely not something I'd want to do very often. Again, we had a number of days off following this day.
Personally, I'd rather do a 16 hour day with the day off afterward than consecutive short overnights...
0500 show 0600 go fly 4.5 hrs send FO to hotel to rest . Jump in suv drive 1.5 hrs for a 3.5 hr meeting drive back to airport 1.5 hrs catch a 1hr cat nap pick up FO grab some dinner load up pax fly 3.5 home and back for mid night.
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