Synthetic Kerosene: The Future of Sustainable Aviation Fuel

Synthetic Kerosene

The Need for Sustainable Aviation Solutions

As the world grapples with climate change, the aviation industry faces increasing pressure to reduce its carbon footprint. While electric and hydrogen-powered flight may eventually revolutionize short-haul travel, long-haul aviation remains dependent on liquid fuels. ​Synthetic kerosene (also called sustainable aviation fuel or e-kerosene) has emerged as a promising solution to decarbonize air travel without compromising global connectivity.

This comprehensive article explores every aspect of synthetic kerosene, from production methods to market adoption, environmental benefits, and future prospects.

What Is Synthetic Kerosene?

Definition and Composition

Synthetic kerosene is a liquid hydrocarbon fuel chemically identical to conventional jet fuel but produced from non-fossil sources. It can be:

  • Power-to-Liquid (PtL): Made from green hydrogen (produced via electrolysis) and captured CO₂.
  • Bio-based: Derived from biomass (e.g., waste oils, agricultural residues).

Key Properties

  • Same energy density as fossil kerosene (critical for long-haul flights).
  • Drop-in compatible with existing aircraft engines and infrastructure.
  • Net-zero emissions potential when produced with renewable energy.

How Is Synthetic Kerosene Produced?

Power-to-Liquid (PtL) Process

  1. Green Hydrogen Production: Electrolysis powered by wind/solar splits water into H₂ and O₂.
  2. CO₂ Capture: Direct Air Capture (DAC) or industrial emissions are collected.
  3. Fischer-Tropsch Synthesis: H₂ and CO₂ are converted into hydrocarbons via catalytic reactions.
  4. Refining: The raw product is refined into jet fuel.

Bio-based Kerosene

  • Derived from ​waste biomass (e.g., used cooking oil, forestry residues).
  • Processed via ​hydroprocessing or ​gasification to create synthetic fuels.

Hybrid Approaches

Some projects combine bio-feedstocks with green hydrogen to enhance efficiency.

Environmental Benefits

Carbon Neutrality Potential

  • PtL kerosene: Emissions are recaptured during production, making it ​carbon-neutral if powered by renewables.
  • Bio-kerosene: Reduces lifecycle emissions by ​80-90% compared to fossil fuels.

Air Pollution Reduction

  • Burns cleaner than conventional jet fuel, reducing ​soot and sulfur emissions.

Scalability Challenges

  • Current production is ​energy-intensive and expensive (~2-5x fossil kerosene cost).
  • Requires massive renewable energy deployment for large-scale viability.

Market Adoption and Industry Initiatives

Regulatory Support

  • EU ReFuelEU Aviation: Mandates increasing SAF blends (including synthetic kerosene) from 2025.
  • US Inflation Reduction Act: Provides tax credits for clean fuel production.
  • International Civil Aviation Organization (ICAO): Promotes SAF under CORSIA.

Key Players and Projects

Company Project Location Capacity
Lufthansa + Synhelion Solar kerosene pilot Switzerland Small-scale
Shell + Siemens Energy PtL demo plant Germany 10,000 tons/year
Norsk e-Fuel Power-to-Liquid plant Norway 10 million liters/year (planned)

Airlines Committing to SAF

  • KLM, United, Lufthansa, Emirates have tested synthetic kerosene flights.
  • Qantas aims for 10% SAF by 2030.

Economic and Technical Challenges

High Production Costs

  • Green hydrogen remains expensive (~1-2/kg for fossil-based H₂).
  • CO₂ capture and refining add significant costs.

Infrastructure Gaps

  • Limited ​dedicated production facilities.
  • Requires ​new pipelines or shipping logistics for distribution.

Certification and Standardization

  • ASTM D7566 governs SAF blends (up to 50% synthetic currently approved).
  • Full ​100% synthetic kerosene certification is in progress.

Future Outlook and Innovations

Cost Reduction Pathways

  • Economies of scale (larger plants, cheaper renewables).
  • Technological breakthroughs in electrolyzers and CO₂ capture.

Hybrid Fuel Strategies

  • Blending synthetic kerosene with biofuels to balance costs and sustainability.

Long-Term Vision

  • 2030: 1-2% of global jet fuel from synthetic sources.
  • 2050: Potential for ​30-50% of aviation fuel to be synthetic.

A Key Pillar for Decarbonizing Aviation

Synthetic kerosene is ​not a silver bullet but a ​critical component of the aviation industry’s net-zero strategy. While challenges remain in cost and scalability, rapid advancements in renewable energy and policy support are accelerating its adoption.

For long-haul flights—where battery-electric and hydrogen propulsion are impractical—synthetic kerosene offers the ​only viable path to sustainable air travel.

 

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