(135b) Decentralized production of sustainable aviation fuels through coupling of Co-Electrolysis, Fischer Tropsch Synthesis and Product Upgrading

The aviation industry is responsible for approximately 3% of global CO₂ emissions, with an even greater climate impact when considering non-CO₂ effects like contrails and high-altitude emissions. Its reliance on high-energy-density fuels for long-haul flights makes it a challenging sector to decarbonize, highlighting the need for sustainable alternatives. Sustainable Aviation Fuel (SAF) produced through Power-to-Liquid (PtL) technologies offers a viable pathway to mitigate these emissions. By integrating Co-electrolysis, Fischer-Tropsch synthesis (FTS), and advanced product upgrading, PtL enables the decentralized production of 100% drop-in SAF, meeting ASTM D1655 standards while leveraging renewable energy resources.

Co-electrolysis simultaneously converts water and CO₂ into syngas—a customized mixture of hydrogen and carbon monoxide—using renewable electricity from sources such as wind and solar. This syngas undergoes Fischer-Tropsch synthesis in microstructured reactors, which ensure precise temperature control through evaporative cooling, optimizing hydrocarbon yields and maintaining catalyst efficiency.

The resulting Fischer-Tropsch crude is upgraded through processes such as hydrotreatment, hydrocracking, isomerization, and aromatization. These refining steps enhance key properties like energy density, freezing point, and combustion stability. Aromatics, essential for maintaining seal integrity and system reliability, are carefully balanced to minimize contrail formation and soot emissions, reducing their environmental impact.

This decentralized production approach takes advantage of areas rich in renewable energy, like sunny deserts or windy coastal regions, to produce SAF efficiently and sustainably. By combining co-electrolysis, Fischer-Tropsch synthesis, and refining, Power-to-Liquid (PtL) technologies offer a practical way to help aviation reach net-zero emissions. These fuels work with both current and future aircraft without needing engine changes, paving the way for a cleaner and more sustainable future for air travel.