High-performance process for production of sustainable aviation fuel from lean-hydrogen feedstock: an integrated case study

• SAF is produced at high selectivity from biogas at small pilot scale. • Novel iron catalyst shows high stability and performance with H 2 -lean syngas. • After a streamlined upgrading process, the fuel meets ASTM standards. • Electrifying the process enhances both product yield and cost economic viability. • Biogenic CO 2 emissions are reduced significantly by integrating an electrolyzer. The aviation industry emits over 950 million tonnes of CO 2 annually and is considered one of the hardest sectors to abate. As industry moves toward net-zero emissions, Sustainable Aviation Fuel (SAF) remains the only viable solution for decarbonizing mid- and long-haul flights. Biogas has emerged as a promising feedstock for producing syngas with a ratio of hydrogen to CO below 1. Integrating biogas with renewable electricity for syngas production offers a more sustainable and cost-effective approach for production of green fuels. This study demonstrates that the process is robust and scalable, simplifying the overall system and offering the potential to replace conventional gas-to-liquid technologies. Synthetic Paraffinic Kerosene (SPK) production from biogas via lean-hydrogen syngas was shown to be highly stable, producing hydrocarbons within the transportation fuel range, which can be readily converted into jet fuel-range hydrocarbons with high selectivity while minimizing product loss. Our proprietary commercial Fe-spinel catalyst, produced by a leading catalyst manufacturer, demonstrated stable operation in a mini-pilot plant for over 2,000 h. During this period, CO conversion and C 5+ selectivity remained above 80% and 87%, respectively. The Syncrude is predominantly olefins, alcohols and paraffins within the transportation fuel range, yielding 70% selectivity to SPK after a streamlined upgrading process. The product was tested by a certified laboratory and confirmed to meet all relevant ASTM D7566 requirements. Integrating a co-electrolysis unit enhances productivity by 37% and CO 2 utilization by a factor of two, improving both economic viability and CO 2 emission reduction.