Sustainable power-to-liquids aviation fuels: Modelling and comparison of two Fischer-Tropsch upgrading process concepts
Fredrik Nyholm, Sami Toppinen, Henrik Saxén
Abstract
The aviation industry’s decarbonization journey highlights Sustainable Aviation Fuels as a critical solution, with Power-to-Liquids (PtL) technologies emerging as a frontrunner. PtL decouples fuel production from limited biomass by synthesizing kerosene from renewable CO 2 and H 2 , aligning with climate goals and regulatory mandates like the EU Renewable Energy Directive III. This study evaluates two Fischer-Tropsch-based PtL process configurations, analyzing their technical and economic viability through key performance indicators, such as energy efficiency, product slate, and material utilization. Concept 1 focuses on simplicity, while Concept 2 integrates wax upgrading for enhanced kerosene yield and resource efficiency. Both concepts demonstrate high hydrocarbon yields (99 %) and meet ASTM D7566-22 specifications for FT-SPK blendstock. Concept 2 achieves marginally higher kerosene selectivity (86.3 %) and energy efficiency (57.8 %) but requires more complex operations and likely higher CAPEX (estimated to 376 M€ 2019 vs 339 M€). Conversely, Concept 1 offers competitive performance with a simpler design, making it favorable for early industrial adoption. Scaling to 100 kt/a capacity is feasible, positioning a plant based on these technologies to meet up to 32 % of the EU’s 2030 synthetic kerosene demand. However, further scaling is constrained by significant electricity requirements. The study underscores the importance of process optimization, advanced reactor kinetics, and heat integration to enhance PtL viability. These findings provide actionable insights into PtL’s role in advancing sustainable aviation and meeting global decarbonization targets.