Boosting the efficiency of sustainable aviation fuel (SAF) production

Modular decentralized power-to-liquid (PtL) technology for SAF production.
A continuous increase in global emissions trends has been observed a decade after the adoption of the Paris Agreement, particularly pronounced in the aviation sector in 2024.[1] SAF produced via PtL technology offers a promising pathway to help achieve the European Union’s 2050 carbon neutrality target. PtL converts renewable electricity, CO₂ and water into synthetic paraffinic kerosene (SPK) with a lower aromatic content, thereby contributing to lower soot emissions and decreased contrail formation. [2]

At Karlsruhe Institute of Technology (KIT) a modular and decentralized PtL process chain based on Fischer-Tropsch (FT) synthesis has been established at PtX Lab. Two different syngas production pathways are being experimentally investigated: the conventional reverse water–gas shift (RWGS) process and a novel solid oxide co-electrolysis (Co-SOEC) unit, which enables the direct electrochemical conversion of steam and CO₂ into syngas in a single process step. Overall process efficiency and carbon utilisation has been enhanced through the recirculation of FT off-gas to the Co-SOEC unit. ... mehrStable syngas production and reliable operation of the integrated process chain have been demonstrated. In addition, the FT-crude produced in the PtX Lab has been subjected to a further upgrading step, to meet the specific requirements for sustainable aviation fuel (SAF) according to ASTM D7566.

The contribution presented combines experimental results with supporting modelling of the integrated PtL process chain. The focus is placed on the experimentally determined performance of the coupled Co-SOEC and FT synthesis modules, with key indicators of overall process efficiency presented. These results highlight the potential of this approach to boost the efficient production of synthetic fuels.