TECHNICAL PROGRAMME | Energy Fuels and Molecules – Future Pathways
Alternative Fuels - E fuels, Biofuels and SAF
Forum 15 | Digital Poster Plaza 3
29
April
11:30
13:30
UTC+3
Alternative fuels such as e-fuels, biofuels and SAF are attracting attention as a sustainable energy source for the future. Efforts to improve the production efficiency of these alternative fuels and reduce their carbon intensity will be an important part of realising a lower carbon energy system. This forum will introduce economically rational production technologies that apply innovative and existing technologies, the contribution of low-carbon fuels to achieving net zero, and the status of preparations for fuel standards and certification for practical use. It will also discuss cooperation with local communities and stakeholders, and the building of mutually beneficial relationships.
The rapid rise of global CO2 emissions has intensified the search for innovative solutions that simultaneously mitigate climate change and ensure sustainable energy production. Among the proposed strategies, photocatalytic CO2 reduction has emerged as a promising approach, as it utilizes solar energy to convert a greenhouse gas into valuable fuels and chemicals. In particular, the selective transformation of CO2 into short-chain hydrocarbons (C1–C3) is of great interest due to their direct applicability as clean fuels and petrochemical feedstocks.
The current study aims to develop and evaluate advanced photocatalytic systems capable of reducing CO2 into short-chain hydrocarbons under mild reaction conditions. By tailoring catalyst design and reaction parameters, the study seeks to enhance conversion efficiency, control product selectivity, and provide mechanistic insights into the photocatalytic pathways involved.
A series of porous ceria-incorporated TiO2 nanoparticles were synthesized to enhance CO2 adsorption, charge separation, and light-harvesting properties. The porous structure was engineered to provide a high surface area and accessible active sites, while ceria incorporation introduced oxygen vacancies and redox-active sites that promote CO2 activation and intermediate stabilization. The materials were characterized using XRD, BET, TEM, and UV–Vis DRS to confirm structural, textural, and optical properties. Photocatalytic performance was evaluated in a batch type reactor under simulated solar irradiation, with CO2 and water vapor as reactants. Product distribution was monitored using gas chromatography, focusing on short-chain hydrocarbons (C1–C3) as the primary reduction products.
The porous ceria-incorporated TiO2 photocatalyst exhibited measurable photocatalytic activity for CO2 reduction under simulated solar light. The incorporation of ceria enhanced light absorption in the visible region and promoted efficient charge separation, resulting in the formation of short-chain hydrocarbons. Gas chromatographic analysis confirmed the production of methane, ethane, ethylene, propene, and propane in the range of a few ppm, indicating selective C1–C3 hydrocarbon formation. These findings demonstrate the synergistic effect of ceria incorporation and porous structuring in driving CO2 reduction beyond CO and CH4, extending towards multi-carbon products.
This study highlights the potential of porous ceria-incorporated TiO2 as a promising photocatalyst for solar-driven CO2 reduction into short-chain hydrocarbons. Although current yields are in the ppm range, the selective generation of C1–C3 hydrocarbons under mild conditions demonstrates a critical step toward sustainable fuel production. The results provide valuable insights into catalyst design strategies that can bridge the gap between greenhouse gas mitigation and renewable fuel generation. Advancing such photocatalytic systems contributes to the long-term vision of a circular carbon economy, offering new opportunities for the petroleum and energy sectors to transition toward cleaner and more sustainable practices.
The current study aims to develop and evaluate advanced photocatalytic systems capable of reducing CO2 into short-chain hydrocarbons under mild reaction conditions. By tailoring catalyst design and reaction parameters, the study seeks to enhance conversion efficiency, control product selectivity, and provide mechanistic insights into the photocatalytic pathways involved.
A series of porous ceria-incorporated TiO2 nanoparticles were synthesized to enhance CO2 adsorption, charge separation, and light-harvesting properties. The porous structure was engineered to provide a high surface area and accessible active sites, while ceria incorporation introduced oxygen vacancies and redox-active sites that promote CO2 activation and intermediate stabilization. The materials were characterized using XRD, BET, TEM, and UV–Vis DRS to confirm structural, textural, and optical properties. Photocatalytic performance was evaluated in a batch type reactor under simulated solar irradiation, with CO2 and water vapor as reactants. Product distribution was monitored using gas chromatography, focusing on short-chain hydrocarbons (C1–C3) as the primary reduction products.
The porous ceria-incorporated TiO2 photocatalyst exhibited measurable photocatalytic activity for CO2 reduction under simulated solar light. The incorporation of ceria enhanced light absorption in the visible region and promoted efficient charge separation, resulting in the formation of short-chain hydrocarbons. Gas chromatographic analysis confirmed the production of methane, ethane, ethylene, propene, and propane in the range of a few ppm, indicating selective C1–C3 hydrocarbon formation. These findings demonstrate the synergistic effect of ceria incorporation and porous structuring in driving CO2 reduction beyond CO and CH4, extending towards multi-carbon products.
This study highlights the potential of porous ceria-incorporated TiO2 as a promising photocatalyst for solar-driven CO2 reduction into short-chain hydrocarbons. Although current yields are in the ppm range, the selective generation of C1–C3 hydrocarbons under mild conditions demonstrates a critical step toward sustainable fuel production. The results provide valuable insights into catalyst design strategies that can bridge the gap between greenhouse gas mitigation and renewable fuel generation. Advancing such photocatalytic systems contributes to the long-term vision of a circular carbon economy, offering new opportunities for the petroleum and energy sectors to transition toward cleaner and more sustainable practices.
Background:
Diversifying energy basket by integration with nearby Petrochemical and Fertilizer plant.
In the evolving energy landscape, diversification is crucial for sustainability. Downstream refineries can bolster their energy portfolio by integrating petroleum products and chemicals. Numaligarh Refinery Limited (NRL) is strategically positioned to capitalize on this opportunity, given its proximity to a Petrochemical plant and a Fertilizer plant approximately 200 km away.
Synergistic Collaboration for Value Creation:
NRL proposes to utilize Methanol from Assam Petrochemicals Limited (APL) and Ammonia from the Assam Fertilizer Plant to produce marketable-grade Dimethylamine (DMA) at 20KTPA . This collaboration addresses APL's current offtake capacity constraints, as NRL's utilization of 90 TPD Methanol will facilitate their plant expansion done recently at 500 TPD. The reaction involves 90 TPD methanol and 27 TPD ammonia processed over a silica-alumina catalyst to produce methylamine, which can be further converted into a family of methylamines, including mono-, di-, and trimethylamine.
Market Significance of Methylamines:
These methylamines are essential ingredients for various chemicals used in:
Solvents: Dimethylformamide and dimethylacetamide.
Pharmaceuticals: Active pharmaceutical ingredients (APIs).
Agrochemicals: Herbicides and pesticides.
Flocculants: Water treatment chemicals.
Surfactants: Detergents and cleaning agents.
Rubber Chemicals: Vulcanization accelerators.
Catalysts: Industrial processes.
Strategic Benefits
Product Diversification: Enhances NRL's product profile with a wider range of chemicals.
Energy Security: Contributes to stabilized energy security for the country by increasing self-reliance.
Sustainability Alignment: Supports the SDGs' 2030 targets by adopting sustainable energy practices.
Conclusion
This initiative not only fosters economic growth through value-added products but also aligns with global sustainability goals. By leveraging local resources and synergies, NRL can play a pivotal role in enhancing India's energy security while promoting a diversified and sustainable energy basket.
The paper shall talk about the opportunity to produce Mono methyl, di-methyl, trimethyl amine and its process and value creation through product diversification to meet demand and increase energy security for the country.
Diversifying energy basket by integration with nearby Petrochemical and Fertilizer plant.
In the evolving energy landscape, diversification is crucial for sustainability. Downstream refineries can bolster their energy portfolio by integrating petroleum products and chemicals. Numaligarh Refinery Limited (NRL) is strategically positioned to capitalize on this opportunity, given its proximity to a Petrochemical plant and a Fertilizer plant approximately 200 km away.
Synergistic Collaboration for Value Creation:
NRL proposes to utilize Methanol from Assam Petrochemicals Limited (APL) and Ammonia from the Assam Fertilizer Plant to produce marketable-grade Dimethylamine (DMA) at 20KTPA . This collaboration addresses APL's current offtake capacity constraints, as NRL's utilization of 90 TPD Methanol will facilitate their plant expansion done recently at 500 TPD. The reaction involves 90 TPD methanol and 27 TPD ammonia processed over a silica-alumina catalyst to produce methylamine, which can be further converted into a family of methylamines, including mono-, di-, and trimethylamine.
Market Significance of Methylamines:
These methylamines are essential ingredients for various chemicals used in:
Solvents: Dimethylformamide and dimethylacetamide.
Pharmaceuticals: Active pharmaceutical ingredients (APIs).
Agrochemicals: Herbicides and pesticides.
Flocculants: Water treatment chemicals.
Surfactants: Detergents and cleaning agents.
Rubber Chemicals: Vulcanization accelerators.
Catalysts: Industrial processes.
Strategic Benefits
Product Diversification: Enhances NRL's product profile with a wider range of chemicals.
Energy Security: Contributes to stabilized energy security for the country by increasing self-reliance.
Sustainability Alignment: Supports the SDGs' 2030 targets by adopting sustainable energy practices.
Conclusion
This initiative not only fosters economic growth through value-added products but also aligns with global sustainability goals. By leveraging local resources and synergies, NRL can play a pivotal role in enhancing India's energy security while promoting a diversified and sustainable energy basket.
The paper shall talk about the opportunity to produce Mono methyl, di-methyl, trimethyl amine and its process and value creation through product diversification to meet demand and increase energy security for the country.
Sustainable Aviation Fuel (SAF) is appearing as a critical solution to decrease greenhouse gas emissions from the aviation sector, which is heavily reliant on fossil-based fuels, by providing (through the adoption of) low-carbon, renewable fuels compatible with current engines. This paper describes the situation of SAF developments in total, in terms of their production methods, emerging technologies, and challenges. The paper first presents the principal pathways of SAF, including bio-based and power-to-liquid (PtL) technologies. Bio-based SAF, derived from biomass such as oilseed crops, agricultural residues, and waste oil, has played a basic role in the development of sustainable fuel. Although it stands out due to its technological readiness and low carbon emissions, particularly apparent in the Hydroprocessed Esters and Fatty Acids (HEFA) pathway, its widespread use has limited its application due to sustainability concerns associated with biomass resources, land use change environmental issues and competition with the food industries. The PtL technologies differ as they convert renewable electric energy to liquid hydrocarbons using water electrolysis and carbon capture as pathways to offer a new way of producing low-carbon fuels with potentially better benefits for environmental impacts. Yet, the high capital cost and technological complexities currently restrict PtL’s commercial feasibility. Achieving large-scale production and ensuring a continuous renewable energy supply also pose ongoing challenges. A main focus of the paper is the methanol-to-jet (MTJ) pathway, where methanol is reacted as an intermediate and converted to jet fuel through the methanol-to-olefins (MTO) pathway and subsequent olefin oligomerization and hydroprocessing. The MTJ pathway has the added bonus of feedstock flexibility, including renewable methanol that can be produced from biomass in addition to green electricity. Furthermore, the MTJ pathway can produce sustainable aviation fuel that meets international fuel specifications and reduces CO2 emissions. The paper further explores the integration of SAF production with renewable energy systems and outlines how this integrated approach can form the basis of a more sustainable and financially viable industry. This is based on life cycle assessments (LCA) and techno-economic assessments (TEA) to quantify environmental impacts and main cost factors. In summary, SAF plays an essential role in achieving a sustainable and low-carbon aviation future. The MTJ pathway, among others, is highlighted as a practical, scalable, and cost-effective approach that can significantly support worldwide climate goals. Continued research, industrial collaboration, and strong policy supports are needed to address the associated challenges with feedstock sustainability, process efficiency, and regulatory alignment.
Pars Special Economic Energy Zone (PSEEZ) as a megascale gas industries region located in Asaluyeh County, southwestern Iran, faces serious challenges in sustainable waste management. For many years, the waste generated in this zone, including urban, rural, and municipal waste from petrochemical and gas refining industries, has been primarily collected and disposed of in a rudimentary manner at an open dumping site near the city of Kangan. The present feasibility study was conducted with the aim of identifying and evaluating optimal options for establishing a modern waste management complex in PSEEZ to acheive resource and energy recovery, as well as reduce the environmental, health and social impacts of waste disposal.
Municipal waste in the special zone is mainly generated from three primary sources: urban and rural areas (approximately 33 tpd), PSEEZ organization (approximately 5 tpd), and the industrial sector (approximately 40 tpd). In addition, nearly 15 tonnes per day of green waste is also generated in the PSEEZ. Physical analysis of the generated waste indicated a significant composition of compostable organic matter (39%), combustible materials (41%), and recyclables (20%), demonstrating a high potential for resource recovery.
Considering population growth rates and per capita waste generation, the municipla waste generation in a 10-year horizon is predicted to be around 105 tonnes per day, and green waste around 25 tonnes per day. For the processing and disposal of this waste, six combined options involving material recovery facilities, composting, production of solid recovered fuel (SRF), and incineration in combination with landfilling were technically, economically, and environmentally evaluated. Comparison results showed that options 1 (dry recycling and landfilling) and 2 (dry recycling, composting, and landfilling) had the lowest costs but were excluded due to the need for land area exceeding 6 hectares (which is a limitation of the designated complex site). Among the remaining options, those based on SRF production (3 and 4) were superior to incineration-based options (5 and 6) in terms of water and energy consumption, complexity, and final cost, although the incineration-based options were more effective in landfill diversion. Given the significant cost difference (incineration options were 4 times more expensive) and operational complexity, SRF-based options were prioritized. Finally, option four, which includes a material recovery facility, biodrying of compostable and green waste, production of SRF from combustible and dried waste, and landfilling of remaining waste, was selected as the optimal option. This option had the highest diversion rate among SRF-based options, required less land, offered higher energy efficiency, and posed lower risk in the final product market compared to option 3. Successful implementation of this option requires resolving challenges such as securing long-term cooperation from the Kangan cement factory and ensuring the desired quality of the produced SRF.
Co-author/s:
Sakhavat Asadi, The CEO of the Pars Special Economic Energy Zone, National Iranian Oil Company.
Mahdi Jalili Ghazizade, Associate Professor, Department of Environmental Technologies, Environmental Sciences Research Institute (ESRI), Shahid Beheshti University.
Municipal waste in the special zone is mainly generated from three primary sources: urban and rural areas (approximately 33 tpd), PSEEZ organization (approximately 5 tpd), and the industrial sector (approximately 40 tpd). In addition, nearly 15 tonnes per day of green waste is also generated in the PSEEZ. Physical analysis of the generated waste indicated a significant composition of compostable organic matter (39%), combustible materials (41%), and recyclables (20%), demonstrating a high potential for resource recovery.
Considering population growth rates and per capita waste generation, the municipla waste generation in a 10-year horizon is predicted to be around 105 tonnes per day, and green waste around 25 tonnes per day. For the processing and disposal of this waste, six combined options involving material recovery facilities, composting, production of solid recovered fuel (SRF), and incineration in combination with landfilling were technically, economically, and environmentally evaluated. Comparison results showed that options 1 (dry recycling and landfilling) and 2 (dry recycling, composting, and landfilling) had the lowest costs but were excluded due to the need for land area exceeding 6 hectares (which is a limitation of the designated complex site). Among the remaining options, those based on SRF production (3 and 4) were superior to incineration-based options (5 and 6) in terms of water and energy consumption, complexity, and final cost, although the incineration-based options were more effective in landfill diversion. Given the significant cost difference (incineration options were 4 times more expensive) and operational complexity, SRF-based options were prioritized. Finally, option four, which includes a material recovery facility, biodrying of compostable and green waste, production of SRF from combustible and dried waste, and landfilling of remaining waste, was selected as the optimal option. This option had the highest diversion rate among SRF-based options, required less land, offered higher energy efficiency, and posed lower risk in the final product market compared to option 3. Successful implementation of this option requires resolving challenges such as securing long-term cooperation from the Kangan cement factory and ensuring the desired quality of the produced SRF.
Co-author/s:
Sakhavat Asadi, The CEO of the Pars Special Economic Energy Zone, National Iranian Oil Company.
Mahdi Jalili Ghazizade, Associate Professor, Department of Environmental Technologies, Environmental Sciences Research Institute (ESRI), Shahid Beheshti University.
The mobility sector is a significant contributor to global greenhouse gas emissions, accounting for 23% of these emissions, which necessitates urgent decarbonization efforts. Green hydrogen and its derived fuels are seen as crucial solutions for reducing emissions in this sector. The International Maritime Organisation (IMO) has committed to halving greenhouse gas emissions from shipping by 2050, based on 2008 levels, to meet Paris Agreement targets. Similarly, the International Air Transport Association (IATA) aims to halve net emissions by 2050 compared to 2005 levels, which would mean a 65% reduction compared to 2019.
E-fuels, such as e-methanol and sustainable aviation fuels (SAF), are pivotal in this transition. In 2022, SAF production tripled to approximately 300 million liters, with over 130 renewable fuel projects announced by more than 85 producers across 30 countries. Despite this growth, SAF production remains a small fraction of total jet fuel consumption, highlighting the need for further scaling. E-methanol is also gaining traction, with over 200 methanol-fueled ships ordered globally. By 2035-2040, e-methanol is expected to reach price parity with traditional fuels like VLSFO, driven by regulatory penalties on fossil fuel use.
The development of e-fuels faces several challenges, including high initial investment costs due to the energy and capital-intensive nature of projects. The lack of standardized definitions for hydrogen and its derived fuels across regions could limit the global trade of e-fuels. Additionally, the absence of long-term offtake commitments creates uncertainty, delaying final investment decisions. To overcome these hurdles, a holistic approach involving incentives and support mechanisms is necessary to ensure sustained e-fuel production on scale.
Siemens Energy is actively involved in scaling e-fuels, contributing through system optimization, scaling and standardization of e-fuel plants, and highly automated mass manufacturing. The company is also engaged in several projects worldwide, such as the Haru Oni Pilot Project in Chile, which integrates wind energy for e-fuel production. Other projects include the Kassø Power-to-X initiative in Europe, which focuses on large-scale e-methanol production.
The Elyzer P-300 platform is designed for large-scale deployment, offering customized solutions with high plant efficiency and optimized design for fast installation and low maintenance costs. Siemens Energy's capacity growth plan includes ramping up electrolyser manufacturing to deliver large-scale electrolysis systems, with a target of 3 GW annual production capacity.
The market outlook for e-fuels is promising, but progress is needed. Leadership from governments and authorities is crucial for establishing regulations, quotas, and incentives. Attractive project financing conditions and binding commitments to mid/long-term offtake agreements are also essential. A globally agreed framework for certifying the source of e-fuel and risk-sharing mechanisms among green hydrogen ecosystem actors would further support the scaling of e-fuels.
E-fuels, such as e-methanol and sustainable aviation fuels (SAF), are pivotal in this transition. In 2022, SAF production tripled to approximately 300 million liters, with over 130 renewable fuel projects announced by more than 85 producers across 30 countries. Despite this growth, SAF production remains a small fraction of total jet fuel consumption, highlighting the need for further scaling. E-methanol is also gaining traction, with over 200 methanol-fueled ships ordered globally. By 2035-2040, e-methanol is expected to reach price parity with traditional fuels like VLSFO, driven by regulatory penalties on fossil fuel use.
The development of e-fuels faces several challenges, including high initial investment costs due to the energy and capital-intensive nature of projects. The lack of standardized definitions for hydrogen and its derived fuels across regions could limit the global trade of e-fuels. Additionally, the absence of long-term offtake commitments creates uncertainty, delaying final investment decisions. To overcome these hurdles, a holistic approach involving incentives and support mechanisms is necessary to ensure sustained e-fuel production on scale.
Siemens Energy is actively involved in scaling e-fuels, contributing through system optimization, scaling and standardization of e-fuel plants, and highly automated mass manufacturing. The company is also engaged in several projects worldwide, such as the Haru Oni Pilot Project in Chile, which integrates wind energy for e-fuel production. Other projects include the Kassø Power-to-X initiative in Europe, which focuses on large-scale e-methanol production.
The Elyzer P-300 platform is designed for large-scale deployment, offering customized solutions with high plant efficiency and optimized design for fast installation and low maintenance costs. Siemens Energy's capacity growth plan includes ramping up electrolyser manufacturing to deliver large-scale electrolysis systems, with a target of 3 GW annual production capacity.
The market outlook for e-fuels is promising, but progress is needed. Leadership from governments and authorities is crucial for establishing regulations, quotas, and incentives. Attractive project financing conditions and binding commitments to mid/long-term offtake agreements are also essential. A globally agreed framework for certifying the source of e-fuel and risk-sharing mechanisms among green hydrogen ecosystem actors would further support the scaling of e-fuels.
This paper is concerned with a comprehensive analysis of selected non-edible feedstocks in a co-process for the production of advanced biofuels. The research was aimed to study the co-process of standard refinery gasoil with the addition of vegetable oils (camelina, carinata, karanja, post-fermentation corn oil, spent coffee ground oil) and UCO. Their effect on NiMoP/Al2O3 catalyst activity and product properties was evaluated. Hydrotreating co-processing experiments were performed in a trickle bed bench-scale stainless steel tubular reactor (ø78x500 mm, total volume 250 mL) with an effective catalyst bed volume of 150 mL. The co-process was operated at hydrogen pressure 5 MPa, LHSV=1h-1, hydrogen to feedstock ratio 350 NL/L.h and with addition of 2.5 and 10 % by volume of different bio-oils.
Much attention has been paid to pretreatment of the feedstocks as they have significant catalyst deactivation potential. There was necessary to remove unwanted phospholipids and reduce the content of metal cations present in the oil prior to the. Degumming was done with citric acid at 50 °C. The washed degummed oil was dried and refined on silica gel column.
In the measured range of pressure and temperature parameters in the co-process, complete deoxygenation of free fatty acids and glycerides to alkanes (acid number and simdist) occurred. The cracking rate was minimal. The yield of C5+ was above 97.5 %.
From the distribution of n-alkanes in the product, it is evident that the proportion of C15-C19 n-alkanes increased which resulted in a marked increase in the cetane index from 54.1 to 59.6-62.2. The low-temperature properties met the normalized values for the summer season when 2, 5 and 10 % by volume of bio-oils were injected. The aromatic content was significantly reduced (7.9 % wt.), especially di-and polyaromatics. At the operating conditions tested, co-processing of the bio-oils used did not have a significant effect on the efficiency of hydrodesulphurization or hydrodenitrogenation of the catalyst and the low-temperature properties of the diesel.
Acknowledgment:
This work was supported by the Research and Development Agency under contracts APVV-18-0348 and APVV-16-0097.
Co-author/s:
Jozef Mikulec, Project Manager, VÚRUP.
András Peller, Scientific and Technical Worker,Slovak technical university, Faculty of Chemical and Food Technology.
Dr. Ladislav Danč, Head of Laboratory Development Department, VÚRUP.
Much attention has been paid to pretreatment of the feedstocks as they have significant catalyst deactivation potential. There was necessary to remove unwanted phospholipids and reduce the content of metal cations present in the oil prior to the. Degumming was done with citric acid at 50 °C. The washed degummed oil was dried and refined on silica gel column.
In the measured range of pressure and temperature parameters in the co-process, complete deoxygenation of free fatty acids and glycerides to alkanes (acid number and simdist) occurred. The cracking rate was minimal. The yield of C5+ was above 97.5 %.
From the distribution of n-alkanes in the product, it is evident that the proportion of C15-C19 n-alkanes increased which resulted in a marked increase in the cetane index from 54.1 to 59.6-62.2. The low-temperature properties met the normalized values for the summer season when 2, 5 and 10 % by volume of bio-oils were injected. The aromatic content was significantly reduced (7.9 % wt.), especially di-and polyaromatics. At the operating conditions tested, co-processing of the bio-oils used did not have a significant effect on the efficiency of hydrodesulphurization or hydrodenitrogenation of the catalyst and the low-temperature properties of the diesel.
Acknowledgment:
This work was supported by the Research and Development Agency under contracts APVV-18-0348 and APVV-16-0097.
Co-author/s:
Jozef Mikulec, Project Manager, VÚRUP.
András Peller, Scientific and Technical Worker,Slovak technical university, Faculty of Chemical and Food Technology.
Dr. Ladislav Danč, Head of Laboratory Development Department, VÚRUP.
In the global trend toward carbon neutrality, circular carbon strategies where CO₂ is captured, converted, and reused, are gaining unprecedented momentum. Over US $28 billion has been collectively invested in circular‑carbon technologies to date, with US $6.6 billion entering the sector in 2024, reflecting escalating interest in CO₂ valorization. Concurrently, circular‑carbon systems are recognized as vital for achieving mid‑century climate targets and transitioning from linear fossil pathways to regenerative, decarbonized fuel cycles.
Against this backdrop, direct CO₂ Fischer-Tropsch synthesis emerges as a compelling route to e‑fuels-drop‑in replacements like synthetic diesel and kerosene-when supplied with renewable hydrogen. However, a persistent challenge in direct CO₂ FT using iron (Fe) catalysts is water (H₂O). H₂O accumulation induces Fe catalyst oxidation and deactivation, while also competing with CO₂ for adsorption sites, leading to suppressed conversion and lower hydrocarbon yields.
To address these bottlenecks, we introduce a membrane reactor design employing a high-temperature resistant ZSM-5 type zeolite membrane. This hydrophilic membrane selectively permeates H₂O, effectively reducing its partial pressure within the reaction zone. By maintaining a water-less environment, the membrane mitigates catalyst oxidation and restores active sites for CO₂ conversion, thus enhancing overall catalytic activity.
Our experimental evaluation reveals that the water‑selective membrane significantly boosts CO₂ conversion and hydrocarbon productivity across a broad temperature range. Remarkably, at 260oC-where conventional fixed‑bed reactors fail to initiate direct CO₂ FT-our membrane reactor sustains steady hydrocarbon synthesis. This low‑temperature performance underscores the membrane’s strong capacity to shift equilibrium by effective H₂O removal, enabling milder operational conditions and reduced thermal energy demand.
In the broader context, membrane reactors present a niche advantage. While scale‑up may be constrained by fabrication complexities and membrane area requirements, their modularity makes them well‑suited for small‑scale, local production of e‑fuels, ideal for integrating with distributed CO₂ and H₂ sources in industrial, agricultural, or residential settings.
This study thus demonstrates that integrating ZSM‑5 membranes into direct CO₂ FT aligns with the emerging paradigm of circular carbon economies, supporting local e‑fuel generation, enabling efficient CO₂ utilization, and contributing to decarbonization pathways. Our membrane offers a promising addition to the toolset: it enhances catalyst life, improves conversion under milder conditions, and supports resilient, decentralized fuel production.
Against this backdrop, direct CO₂ Fischer-Tropsch synthesis emerges as a compelling route to e‑fuels-drop‑in replacements like synthetic diesel and kerosene-when supplied with renewable hydrogen. However, a persistent challenge in direct CO₂ FT using iron (Fe) catalysts is water (H₂O). H₂O accumulation induces Fe catalyst oxidation and deactivation, while also competing with CO₂ for adsorption sites, leading to suppressed conversion and lower hydrocarbon yields.
To address these bottlenecks, we introduce a membrane reactor design employing a high-temperature resistant ZSM-5 type zeolite membrane. This hydrophilic membrane selectively permeates H₂O, effectively reducing its partial pressure within the reaction zone. By maintaining a water-less environment, the membrane mitigates catalyst oxidation and restores active sites for CO₂ conversion, thus enhancing overall catalytic activity.
Our experimental evaluation reveals that the water‑selective membrane significantly boosts CO₂ conversion and hydrocarbon productivity across a broad temperature range. Remarkably, at 260oC-where conventional fixed‑bed reactors fail to initiate direct CO₂ FT-our membrane reactor sustains steady hydrocarbon synthesis. This low‑temperature performance underscores the membrane’s strong capacity to shift equilibrium by effective H₂O removal, enabling milder operational conditions and reduced thermal energy demand.
In the broader context, membrane reactors present a niche advantage. While scale‑up may be constrained by fabrication complexities and membrane area requirements, their modularity makes them well‑suited for small‑scale, local production of e‑fuels, ideal for integrating with distributed CO₂ and H₂ sources in industrial, agricultural, or residential settings.
This study thus demonstrates that integrating ZSM‑5 membranes into direct CO₂ FT aligns with the emerging paradigm of circular carbon economies, supporting local e‑fuel generation, enabling efficient CO₂ utilization, and contributing to decarbonization pathways. Our membrane offers a promising addition to the toolset: it enhances catalyst life, improves conversion under milder conditions, and supports resilient, decentralized fuel production.
In efforts to reduce the impact of anthropogenic CO2 emissions, green hydrogen and captured CO2 have recently become key components in producing a range of synthetic chemicals, including e-kerosene, a sustainable aviation fuel. E-kerosene can be blended with conventional jet fuel to decrease its carbon footprint. Although e-kerosene can reduce CO2 emissions in a closed cycle, the current methods for e-kerosene production are prohibitively expensive, mainly due to the high cost of water electrolysis. This study has developed a techno-economic model to analyze the effects of different processes used to produce E-kerosene. The findings indicate that several parameters affect the cost of E-kerosene, including the type of electrolyzer and the pathways used to convert CO2 and hydrogen into kerosene-range molecules, such as Fischer-Tropsch or methanol-to-jet. The results also show that the operating cost of electrolyzers has a notable contribution to the cost of E-kerosene, highlighting that the cost of renewable electricity is a crucial factor in determining E-kerosene’s price. Process intensification techniques, such as the co-electrolysis of CO2 and H2O in solid oxide electrolyzers to produce syngas directly, can eliminate the need for the reverse water-gas shift reaction. This could reduce the cost of e-kerosene. However, achieving this cost reduction depends on lowering the capital and operational costs associated with co-electrolysis in solid oxide cells, as well as increasing their lifespan. Similarly, developing efficient catalysts for the Fischer-Tropsch reaction using a CO2 and H2 mixture could reduce the cost of e-kerosene by eliminating the need for reverse water-gas shift reaction. With predictions of lower prices for renewable electricity and advancements in solid oxide electrolyzer technology, the cost of e-kerosene may become competitive with conventional kerosene under optimized conditions by 2050.
Emissions abatement is a critical pillar of global energy transition, with increasing pressure on industry to reduce its carbon footprint. A major source of greenhouse gas emissions (GHGs) is associated gases, primarily composed of light hydrocarbons such as methane which is over 80 times more potent than CO₂ over a 20-year period. These gases are often vented or flared, contributing to significant environmental impacts without any economic value. A more sustainable and economically viable alternative is to monetize these gases by converting them into low-carbon liquid fuels. This approach reduces GHG emissions while creating economic value, aligning profitability with environmetal compliance.
Herein, we present a modular and integrable solution that monetizes associated gases by converting them into low-carbon liquid fuels such as methanol, gasoline, diesel, or jet fuel. The gas is first conditioned and then catalytically reformed into syngas, which is subsequently processed via proven and commercially mature technologies to produce drop-in fuels. We describe the key aspects of the solution:
This solution offers a scalable and practical way to cut emissions and utilize associated gases. It also accommodates variable off-gas compositions, making it suitable for both upstream and downstream integration. The produced fuels are drop-in quality and compatible with conventional products and existing infrastructure.
Overall, this technology platform is a techno-economically viable and attractive solution to reduce industrial emissions while creating additional revenue streams by converting associated gases into certified low-carbon fuels. Its modular and adaptable desing allow alignment with local regulations, diverse feedstocks, and meet end-user requirements. This enables rapid deployment of the solution across various industrial settings, including brownfield sites with minimal retrofitting.
Herein, we present a modular and integrable solution that monetizes associated gases by converting them into low-carbon liquid fuels such as methanol, gasoline, diesel, or jet fuel. The gas is first conditioned and then catalytically reformed into syngas, which is subsequently processed via proven and commercially mature technologies to produce drop-in fuels. We describe the key aspects of the solution:
- Chemistry and process engineering desing of the solution.
- Modularization and process integration, especially for brownfield projects.
- Carbon intensity (CI) of end products, assessed by life cycle methodologies.
This solution offers a scalable and practical way to cut emissions and utilize associated gases. It also accommodates variable off-gas compositions, making it suitable for both upstream and downstream integration. The produced fuels are drop-in quality and compatible with conventional products and existing infrastructure.
Overall, this technology platform is a techno-economically viable and attractive solution to reduce industrial emissions while creating additional revenue streams by converting associated gases into certified low-carbon fuels. Its modular and adaptable desing allow alignment with local regulations, diverse feedstocks, and meet end-user requirements. This enables rapid deployment of the solution across various industrial settings, including brownfield sites with minimal retrofitting.
The increasing urgency to mitigate climate change has intensified the search for sustainable fuels, particularly in the aviation sector, where decarbonization remains a formidable challenge. Sustainable aviation fuels (SAFs), particularly e-fuels, present a promising avenue for reducing greenhouse gas emissions associated with air travel. However, the intrinsic variability in the chemical composition and properties of e-fuels poses substantial barriers to their widespread adoption. To overcome these hurdles, it is crucial to identify suitable additives that can augment critical fuel properties such as energy density, combustion efficiency, and thermal stability.
In response to this challenge, our research leverages the power of machine learning (ML) to predict and optimize the properties of SAFs. Utilizing the Chemical SuperLearner (ChemSL) framework, we demonstrate the effectiveness of ML models in estimating key aviation fuel properties, including density, net heat of combustion, cetane number, boiling point, and freezing point. The ChemSL framework integrates multiple molecular representations with a SuperLearner ensemble model, allowing for the construction of highly accurate and robust property prediction models.
Our results show that the ChemSL models achieve high predictive accuracy, as evidenced by low mean absolute errors and high R-squared values for all considered properties. Furthermore, the diversity of base learners included in the ChemSL models underscores the complexity of the prediction tasks and highlights the importance of employing ensemble methods to capture intricate relationships within the data.
This study paves the way for the rapid identification of suitable additives to enhance the performance of sustainable aviation e-fuels, thereby contributing to a more efficient and environmentally friendly transition towards sustainable aviation. Future research directions include expanding the molecular database to screen additives compatible with middle distillates and exploring the applicability of the ChemSL framework to other challenging problems in fuel design and optimization.
In response to this challenge, our research leverages the power of machine learning (ML) to predict and optimize the properties of SAFs. Utilizing the Chemical SuperLearner (ChemSL) framework, we demonstrate the effectiveness of ML models in estimating key aviation fuel properties, including density, net heat of combustion, cetane number, boiling point, and freezing point. The ChemSL framework integrates multiple molecular representations with a SuperLearner ensemble model, allowing for the construction of highly accurate and robust property prediction models.
Our results show that the ChemSL models achieve high predictive accuracy, as evidenced by low mean absolute errors and high R-squared values for all considered properties. Furthermore, the diversity of base learners included in the ChemSL models underscores the complexity of the prediction tasks and highlights the importance of employing ensemble methods to capture intricate relationships within the data.
This study paves the way for the rapid identification of suitable additives to enhance the performance of sustainable aviation e-fuels, thereby contributing to a more efficient and environmentally friendly transition towards sustainable aviation. Future research directions include expanding the molecular database to screen additives compatible with middle distillates and exploring the applicability of the ChemSL framework to other challenging problems in fuel design and optimization.
Leif-Erik Schulte
Chair
Executive Vice President
IFM - Institute for Vehicle Technology and Mobility, TÜV NORD Mobilität GmbH & Co. KG
Mohamed Hamdy
Speaker
Professor of Physical Chemistry and Catalysis
King Khalid University
The rapid rise of global CO2 emissions has intensified the search for innovative solutions that simultaneously mitigate climate change and ensure sustainable energy production. Among the proposed strategies, photocatalytic CO2 reduction has emerged as a promising approach, as it utilizes solar energy to convert a greenhouse gas into valuable fuels and chemicals. In particular, the selective transformation of CO2 into short-chain hydrocarbons (C1–C3) is of great interest due to their direct applicability as clean fuels and petrochemical feedstocks.
The current study aims to develop and evaluate advanced photocatalytic systems capable of reducing CO2 into short-chain hydrocarbons under mild reaction conditions. By tailoring catalyst design and reaction parameters, the study seeks to enhance conversion efficiency, control product selectivity, and provide mechanistic insights into the photocatalytic pathways involved.
A series of porous ceria-incorporated TiO2 nanoparticles were synthesized to enhance CO2 adsorption, charge separation, and light-harvesting properties. The porous structure was engineered to provide a high surface area and accessible active sites, while ceria incorporation introduced oxygen vacancies and redox-active sites that promote CO2 activation and intermediate stabilization. The materials were characterized using XRD, BET, TEM, and UV–Vis DRS to confirm structural, textural, and optical properties. Photocatalytic performance was evaluated in a batch type reactor under simulated solar irradiation, with CO2 and water vapor as reactants. Product distribution was monitored using gas chromatography, focusing on short-chain hydrocarbons (C1–C3) as the primary reduction products.
The porous ceria-incorporated TiO2 photocatalyst exhibited measurable photocatalytic activity for CO2 reduction under simulated solar light. The incorporation of ceria enhanced light absorption in the visible region and promoted efficient charge separation, resulting in the formation of short-chain hydrocarbons. Gas chromatographic analysis confirmed the production of methane, ethane, ethylene, propene, and propane in the range of a few ppm, indicating selective C1–C3 hydrocarbon formation. These findings demonstrate the synergistic effect of ceria incorporation and porous structuring in driving CO2 reduction beyond CO and CH4, extending towards multi-carbon products.
This study highlights the potential of porous ceria-incorporated TiO2 as a promising photocatalyst for solar-driven CO2 reduction into short-chain hydrocarbons. Although current yields are in the ppm range, the selective generation of C1–C3 hydrocarbons under mild conditions demonstrates a critical step toward sustainable fuel production. The results provide valuable insights into catalyst design strategies that can bridge the gap between greenhouse gas mitigation and renewable fuel generation. Advancing such photocatalytic systems contributes to the long-term vision of a circular carbon economy, offering new opportunities for the petroleum and energy sectors to transition toward cleaner and more sustainable practices.
The current study aims to develop and evaluate advanced photocatalytic systems capable of reducing CO2 into short-chain hydrocarbons under mild reaction conditions. By tailoring catalyst design and reaction parameters, the study seeks to enhance conversion efficiency, control product selectivity, and provide mechanistic insights into the photocatalytic pathways involved.
A series of porous ceria-incorporated TiO2 nanoparticles were synthesized to enhance CO2 adsorption, charge separation, and light-harvesting properties. The porous structure was engineered to provide a high surface area and accessible active sites, while ceria incorporation introduced oxygen vacancies and redox-active sites that promote CO2 activation and intermediate stabilization. The materials were characterized using XRD, BET, TEM, and UV–Vis DRS to confirm structural, textural, and optical properties. Photocatalytic performance was evaluated in a batch type reactor under simulated solar irradiation, with CO2 and water vapor as reactants. Product distribution was monitored using gas chromatography, focusing on short-chain hydrocarbons (C1–C3) as the primary reduction products.
The porous ceria-incorporated TiO2 photocatalyst exhibited measurable photocatalytic activity for CO2 reduction under simulated solar light. The incorporation of ceria enhanced light absorption in the visible region and promoted efficient charge separation, resulting in the formation of short-chain hydrocarbons. Gas chromatographic analysis confirmed the production of methane, ethane, ethylene, propene, and propane in the range of a few ppm, indicating selective C1–C3 hydrocarbon formation. These findings demonstrate the synergistic effect of ceria incorporation and porous structuring in driving CO2 reduction beyond CO and CH4, extending towards multi-carbon products.
This study highlights the potential of porous ceria-incorporated TiO2 as a promising photocatalyst for solar-driven CO2 reduction into short-chain hydrocarbons. Although current yields are in the ppm range, the selective generation of C1–C3 hydrocarbons under mild conditions demonstrates a critical step toward sustainable fuel production. The results provide valuable insights into catalyst design strategies that can bridge the gap between greenhouse gas mitigation and renewable fuel generation. Advancing such photocatalytic systems contributes to the long-term vision of a circular carbon economy, offering new opportunities for the petroleum and energy sectors to transition toward cleaner and more sustainable practices.
Geetali Kalita
Speaker
Deputy General Manager and Head-ESG
M/s Numaligarh Refinery Limited
Background:
Diversifying energy basket by integration with nearby Petrochemical and Fertilizer plant.
In the evolving energy landscape, diversification is crucial for sustainability. Downstream refineries can bolster their energy portfolio by integrating petroleum products and chemicals. Numaligarh Refinery Limited (NRL) is strategically positioned to capitalize on this opportunity, given its proximity to a Petrochemical plant and a Fertilizer plant approximately 200 km away.
Synergistic Collaboration for Value Creation:
NRL proposes to utilize Methanol from Assam Petrochemicals Limited (APL) and Ammonia from the Assam Fertilizer Plant to produce marketable-grade Dimethylamine (DMA) at 20KTPA . This collaboration addresses APL's current offtake capacity constraints, as NRL's utilization of 90 TPD Methanol will facilitate their plant expansion done recently at 500 TPD. The reaction involves 90 TPD methanol and 27 TPD ammonia processed over a silica-alumina catalyst to produce methylamine, which can be further converted into a family of methylamines, including mono-, di-, and trimethylamine.
Market Significance of Methylamines:
These methylamines are essential ingredients for various chemicals used in:
Solvents: Dimethylformamide and dimethylacetamide.
Pharmaceuticals: Active pharmaceutical ingredients (APIs).
Agrochemicals: Herbicides and pesticides.
Flocculants: Water treatment chemicals.
Surfactants: Detergents and cleaning agents.
Rubber Chemicals: Vulcanization accelerators.
Catalysts: Industrial processes.
Strategic Benefits
Product Diversification: Enhances NRL's product profile with a wider range of chemicals.
Energy Security: Contributes to stabilized energy security for the country by increasing self-reliance.
Sustainability Alignment: Supports the SDGs' 2030 targets by adopting sustainable energy practices.
Conclusion
This initiative not only fosters economic growth through value-added products but also aligns with global sustainability goals. By leveraging local resources and synergies, NRL can play a pivotal role in enhancing India's energy security while promoting a diversified and sustainable energy basket.
The paper shall talk about the opportunity to produce Mono methyl, di-methyl, trimethyl amine and its process and value creation through product diversification to meet demand and increase energy security for the country.
Diversifying energy basket by integration with nearby Petrochemical and Fertilizer plant.
In the evolving energy landscape, diversification is crucial for sustainability. Downstream refineries can bolster their energy portfolio by integrating petroleum products and chemicals. Numaligarh Refinery Limited (NRL) is strategically positioned to capitalize on this opportunity, given its proximity to a Petrochemical plant and a Fertilizer plant approximately 200 km away.
Synergistic Collaboration for Value Creation:
NRL proposes to utilize Methanol from Assam Petrochemicals Limited (APL) and Ammonia from the Assam Fertilizer Plant to produce marketable-grade Dimethylamine (DMA) at 20KTPA . This collaboration addresses APL's current offtake capacity constraints, as NRL's utilization of 90 TPD Methanol will facilitate their plant expansion done recently at 500 TPD. The reaction involves 90 TPD methanol and 27 TPD ammonia processed over a silica-alumina catalyst to produce methylamine, which can be further converted into a family of methylamines, including mono-, di-, and trimethylamine.
Market Significance of Methylamines:
These methylamines are essential ingredients for various chemicals used in:
Solvents: Dimethylformamide and dimethylacetamide.
Pharmaceuticals: Active pharmaceutical ingredients (APIs).
Agrochemicals: Herbicides and pesticides.
Flocculants: Water treatment chemicals.
Surfactants: Detergents and cleaning agents.
Rubber Chemicals: Vulcanization accelerators.
Catalysts: Industrial processes.
Strategic Benefits
Product Diversification: Enhances NRL's product profile with a wider range of chemicals.
Energy Security: Contributes to stabilized energy security for the country by increasing self-reliance.
Sustainability Alignment: Supports the SDGs' 2030 targets by adopting sustainable energy practices.
Conclusion
This initiative not only fosters economic growth through value-added products but also aligns with global sustainability goals. By leveraging local resources and synergies, NRL can play a pivotal role in enhancing India's energy security while promoting a diversified and sustainable energy basket.
The paper shall talk about the opportunity to produce Mono methyl, di-methyl, trimethyl amine and its process and value creation through product diversification to meet demand and increase energy security for the country.
Emissions abatement is a critical pillar of global energy transition, with increasing pressure on industry to reduce its carbon footprint. A major source of greenhouse gas emissions (GHGs) is associated gases, primarily composed of light hydrocarbons such as methane which is over 80 times more potent than CO₂ over a 20-year period. These gases are often vented or flared, contributing to significant environmental impacts without any economic value. A more sustainable and economically viable alternative is to monetize these gases by converting them into low-carbon liquid fuels. This approach reduces GHG emissions while creating economic value, aligning profitability with environmetal compliance.
Herein, we present a modular and integrable solution that monetizes associated gases by converting them into low-carbon liquid fuels such as methanol, gasoline, diesel, or jet fuel. The gas is first conditioned and then catalytically reformed into syngas, which is subsequently processed via proven and commercially mature technologies to produce drop-in fuels. We describe the key aspects of the solution:
This solution offers a scalable and practical way to cut emissions and utilize associated gases. It also accommodates variable off-gas compositions, making it suitable for both upstream and downstream integration. The produced fuels are drop-in quality and compatible with conventional products and existing infrastructure.
Overall, this technology platform is a techno-economically viable and attractive solution to reduce industrial emissions while creating additional revenue streams by converting associated gases into certified low-carbon fuels. Its modular and adaptable desing allow alignment with local regulations, diverse feedstocks, and meet end-user requirements. This enables rapid deployment of the solution across various industrial settings, including brownfield sites with minimal retrofitting.
Herein, we present a modular and integrable solution that monetizes associated gases by converting them into low-carbon liquid fuels such as methanol, gasoline, diesel, or jet fuel. The gas is first conditioned and then catalytically reformed into syngas, which is subsequently processed via proven and commercially mature technologies to produce drop-in fuels. We describe the key aspects of the solution:
- Chemistry and process engineering desing of the solution.
- Modularization and process integration, especially for brownfield projects.
- Carbon intensity (CI) of end products, assessed by life cycle methodologies.
This solution offers a scalable and practical way to cut emissions and utilize associated gases. It also accommodates variable off-gas compositions, making it suitable for both upstream and downstream integration. The produced fuels are drop-in quality and compatible with conventional products and existing infrastructure.
Overall, this technology platform is a techno-economically viable and attractive solution to reduce industrial emissions while creating additional revenue streams by converting associated gases into certified low-carbon fuels. Its modular and adaptable desing allow alignment with local regulations, diverse feedstocks, and meet end-user requirements. This enables rapid deployment of the solution across various industrial settings, including brownfield sites with minimal retrofitting.
In the global trend toward carbon neutrality, circular carbon strategies where CO₂ is captured, converted, and reused, are gaining unprecedented momentum. Over US $28 billion has been collectively invested in circular‑carbon technologies to date, with US $6.6 billion entering the sector in 2024, reflecting escalating interest in CO₂ valorization. Concurrently, circular‑carbon systems are recognized as vital for achieving mid‑century climate targets and transitioning from linear fossil pathways to regenerative, decarbonized fuel cycles.
Against this backdrop, direct CO₂ Fischer-Tropsch synthesis emerges as a compelling route to e‑fuels-drop‑in replacements like synthetic diesel and kerosene-when supplied with renewable hydrogen. However, a persistent challenge in direct CO₂ FT using iron (Fe) catalysts is water (H₂O). H₂O accumulation induces Fe catalyst oxidation and deactivation, while also competing with CO₂ for adsorption sites, leading to suppressed conversion and lower hydrocarbon yields.
To address these bottlenecks, we introduce a membrane reactor design employing a high-temperature resistant ZSM-5 type zeolite membrane. This hydrophilic membrane selectively permeates H₂O, effectively reducing its partial pressure within the reaction zone. By maintaining a water-less environment, the membrane mitigates catalyst oxidation and restores active sites for CO₂ conversion, thus enhancing overall catalytic activity.
Our experimental evaluation reveals that the water‑selective membrane significantly boosts CO₂ conversion and hydrocarbon productivity across a broad temperature range. Remarkably, at 260oC-where conventional fixed‑bed reactors fail to initiate direct CO₂ FT-our membrane reactor sustains steady hydrocarbon synthesis. This low‑temperature performance underscores the membrane’s strong capacity to shift equilibrium by effective H₂O removal, enabling milder operational conditions and reduced thermal energy demand.
In the broader context, membrane reactors present a niche advantage. While scale‑up may be constrained by fabrication complexities and membrane area requirements, their modularity makes them well‑suited for small‑scale, local production of e‑fuels, ideal for integrating with distributed CO₂ and H₂ sources in industrial, agricultural, or residential settings.
This study thus demonstrates that integrating ZSM‑5 membranes into direct CO₂ FT aligns with the emerging paradigm of circular carbon economies, supporting local e‑fuel generation, enabling efficient CO₂ utilization, and contributing to decarbonization pathways. Our membrane offers a promising addition to the toolset: it enhances catalyst life, improves conversion under milder conditions, and supports resilient, decentralized fuel production.
Against this backdrop, direct CO₂ Fischer-Tropsch synthesis emerges as a compelling route to e‑fuels-drop‑in replacements like synthetic diesel and kerosene-when supplied with renewable hydrogen. However, a persistent challenge in direct CO₂ FT using iron (Fe) catalysts is water (H₂O). H₂O accumulation induces Fe catalyst oxidation and deactivation, while also competing with CO₂ for adsorption sites, leading to suppressed conversion and lower hydrocarbon yields.
To address these bottlenecks, we introduce a membrane reactor design employing a high-temperature resistant ZSM-5 type zeolite membrane. This hydrophilic membrane selectively permeates H₂O, effectively reducing its partial pressure within the reaction zone. By maintaining a water-less environment, the membrane mitigates catalyst oxidation and restores active sites for CO₂ conversion, thus enhancing overall catalytic activity.
Our experimental evaluation reveals that the water‑selective membrane significantly boosts CO₂ conversion and hydrocarbon productivity across a broad temperature range. Remarkably, at 260oC-where conventional fixed‑bed reactors fail to initiate direct CO₂ FT-our membrane reactor sustains steady hydrocarbon synthesis. This low‑temperature performance underscores the membrane’s strong capacity to shift equilibrium by effective H₂O removal, enabling milder operational conditions and reduced thermal energy demand.
In the broader context, membrane reactors present a niche advantage. While scale‑up may be constrained by fabrication complexities and membrane area requirements, their modularity makes them well‑suited for small‑scale, local production of e‑fuels, ideal for integrating with distributed CO₂ and H₂ sources in industrial, agricultural, or residential settings.
This study thus demonstrates that integrating ZSM‑5 membranes into direct CO₂ FT aligns with the emerging paradigm of circular carbon economies, supporting local e‑fuel generation, enabling efficient CO₂ utilization, and contributing to decarbonization pathways. Our membrane offers a promising addition to the toolset: it enhances catalyst life, improves conversion under milder conditions, and supports resilient, decentralized fuel production.
The increasing urgency to mitigate climate change has intensified the search for sustainable fuels, particularly in the aviation sector, where decarbonization remains a formidable challenge. Sustainable aviation fuels (SAFs), particularly e-fuels, present a promising avenue for reducing greenhouse gas emissions associated with air travel. However, the intrinsic variability in the chemical composition and properties of e-fuels poses substantial barriers to their widespread adoption. To overcome these hurdles, it is crucial to identify suitable additives that can augment critical fuel properties such as energy density, combustion efficiency, and thermal stability.
In response to this challenge, our research leverages the power of machine learning (ML) to predict and optimize the properties of SAFs. Utilizing the Chemical SuperLearner (ChemSL) framework, we demonstrate the effectiveness of ML models in estimating key aviation fuel properties, including density, net heat of combustion, cetane number, boiling point, and freezing point. The ChemSL framework integrates multiple molecular representations with a SuperLearner ensemble model, allowing for the construction of highly accurate and robust property prediction models.
Our results show that the ChemSL models achieve high predictive accuracy, as evidenced by low mean absolute errors and high R-squared values for all considered properties. Furthermore, the diversity of base learners included in the ChemSL models underscores the complexity of the prediction tasks and highlights the importance of employing ensemble methods to capture intricate relationships within the data.
This study paves the way for the rapid identification of suitable additives to enhance the performance of sustainable aviation e-fuels, thereby contributing to a more efficient and environmentally friendly transition towards sustainable aviation. Future research directions include expanding the molecular database to screen additives compatible with middle distillates and exploring the applicability of the ChemSL framework to other challenging problems in fuel design and optimization.
In response to this challenge, our research leverages the power of machine learning (ML) to predict and optimize the properties of SAFs. Utilizing the Chemical SuperLearner (ChemSL) framework, we demonstrate the effectiveness of ML models in estimating key aviation fuel properties, including density, net heat of combustion, cetane number, boiling point, and freezing point. The ChemSL framework integrates multiple molecular representations with a SuperLearner ensemble model, allowing for the construction of highly accurate and robust property prediction models.
Our results show that the ChemSL models achieve high predictive accuracy, as evidenced by low mean absolute errors and high R-squared values for all considered properties. Furthermore, the diversity of base learners included in the ChemSL models underscores the complexity of the prediction tasks and highlights the importance of employing ensemble methods to capture intricate relationships within the data.
This study paves the way for the rapid identification of suitable additives to enhance the performance of sustainable aviation e-fuels, thereby contributing to a more efficient and environmentally friendly transition towards sustainable aviation. Future research directions include expanding the molecular database to screen additives compatible with middle distillates and exploring the applicability of the ChemSL framework to other challenging problems in fuel design and optimization.
In efforts to reduce the impact of anthropogenic CO2 emissions, green hydrogen and captured CO2 have recently become key components in producing a range of synthetic chemicals, including e-kerosene, a sustainable aviation fuel. E-kerosene can be blended with conventional jet fuel to decrease its carbon footprint. Although e-kerosene can reduce CO2 emissions in a closed cycle, the current methods for e-kerosene production are prohibitively expensive, mainly due to the high cost of water electrolysis. This study has developed a techno-economic model to analyze the effects of different processes used to produce E-kerosene. The findings indicate that several parameters affect the cost of E-kerosene, including the type of electrolyzer and the pathways used to convert CO2 and hydrogen into kerosene-range molecules, such as Fischer-Tropsch or methanol-to-jet. The results also show that the operating cost of electrolyzers has a notable contribution to the cost of E-kerosene, highlighting that the cost of renewable electricity is a crucial factor in determining E-kerosene’s price. Process intensification techniques, such as the co-electrolysis of CO2 and H2O in solid oxide electrolyzers to produce syngas directly, can eliminate the need for the reverse water-gas shift reaction. This could reduce the cost of e-kerosene. However, achieving this cost reduction depends on lowering the capital and operational costs associated with co-electrolysis in solid oxide cells, as well as increasing their lifespan. Similarly, developing efficient catalysts for the Fischer-Tropsch reaction using a CO2 and H2 mixture could reduce the cost of e-kerosene by eliminating the need for reverse water-gas shift reaction. With predictions of lower prices for renewable electricity and advancements in solid oxide electrolyzer technology, the cost of e-kerosene may become competitive with conventional kerosene under optimized conditions by 2050.
Fatemeh Parvizi
Speaker
Senior Research Scientist
Research Institute of Petroleum Industry
Sustainable Aviation Fuel (SAF) is appearing as a critical solution to decrease greenhouse gas emissions from the aviation sector, which is heavily reliant on fossil-based fuels, by providing (through the adoption of) low-carbon, renewable fuels compatible with current engines. This paper describes the situation of SAF developments in total, in terms of their production methods, emerging technologies, and challenges. The paper first presents the principal pathways of SAF, including bio-based and power-to-liquid (PtL) technologies. Bio-based SAF, derived from biomass such as oilseed crops, agricultural residues, and waste oil, has played a basic role in the development of sustainable fuel. Although it stands out due to its technological readiness and low carbon emissions, particularly apparent in the Hydroprocessed Esters and Fatty Acids (HEFA) pathway, its widespread use has limited its application due to sustainability concerns associated with biomass resources, land use change environmental issues and competition with the food industries. The PtL technologies differ as they convert renewable electric energy to liquid hydrocarbons using water electrolysis and carbon capture as pathways to offer a new way of producing low-carbon fuels with potentially better benefits for environmental impacts. Yet, the high capital cost and technological complexities currently restrict PtL’s commercial feasibility. Achieving large-scale production and ensuring a continuous renewable energy supply also pose ongoing challenges. A main focus of the paper is the methanol-to-jet (MTJ) pathway, where methanol is reacted as an intermediate and converted to jet fuel through the methanol-to-olefins (MTO) pathway and subsequent olefin oligomerization and hydroprocessing. The MTJ pathway has the added bonus of feedstock flexibility, including renewable methanol that can be produced from biomass in addition to green electricity. Furthermore, the MTJ pathway can produce sustainable aviation fuel that meets international fuel specifications and reduces CO2 emissions. The paper further explores the integration of SAF production with renewable energy systems and outlines how this integrated approach can form the basis of a more sustainable and financially viable industry. This is based on life cycle assessments (LCA) and techno-economic assessments (TEA) to quantify environmental impacts and main cost factors. In summary, SAF plays an essential role in achieving a sustainable and low-carbon aviation future. The MTJ pathway, among others, is highlighted as a practical, scalable, and cost-effective approach that can significantly support worldwide climate goals. Continued research, industrial collaboration, and strong policy supports are needed to address the associated challenges with feedstock sustainability, process efficiency, and regulatory alignment.
The mobility sector is a significant contributor to global greenhouse gas emissions, accounting for 23% of these emissions, which necessitates urgent decarbonization efforts. Green hydrogen and its derived fuels are seen as crucial solutions for reducing emissions in this sector. The International Maritime Organisation (IMO) has committed to halving greenhouse gas emissions from shipping by 2050, based on 2008 levels, to meet Paris Agreement targets. Similarly, the International Air Transport Association (IATA) aims to halve net emissions by 2050 compared to 2005 levels, which would mean a 65% reduction compared to 2019.
E-fuels, such as e-methanol and sustainable aviation fuels (SAF), are pivotal in this transition. In 2022, SAF production tripled to approximately 300 million liters, with over 130 renewable fuel projects announced by more than 85 producers across 30 countries. Despite this growth, SAF production remains a small fraction of total jet fuel consumption, highlighting the need for further scaling. E-methanol is also gaining traction, with over 200 methanol-fueled ships ordered globally. By 2035-2040, e-methanol is expected to reach price parity with traditional fuels like VLSFO, driven by regulatory penalties on fossil fuel use.
The development of e-fuels faces several challenges, including high initial investment costs due to the energy and capital-intensive nature of projects. The lack of standardized definitions for hydrogen and its derived fuels across regions could limit the global trade of e-fuels. Additionally, the absence of long-term offtake commitments creates uncertainty, delaying final investment decisions. To overcome these hurdles, a holistic approach involving incentives and support mechanisms is necessary to ensure sustained e-fuel production on scale.
Siemens Energy is actively involved in scaling e-fuels, contributing through system optimization, scaling and standardization of e-fuel plants, and highly automated mass manufacturing. The company is also engaged in several projects worldwide, such as the Haru Oni Pilot Project in Chile, which integrates wind energy for e-fuel production. Other projects include the Kassø Power-to-X initiative in Europe, which focuses on large-scale e-methanol production.
The Elyzer P-300 platform is designed for large-scale deployment, offering customized solutions with high plant efficiency and optimized design for fast installation and low maintenance costs. Siemens Energy's capacity growth plan includes ramping up electrolyser manufacturing to deliver large-scale electrolysis systems, with a target of 3 GW annual production capacity.
The market outlook for e-fuels is promising, but progress is needed. Leadership from governments and authorities is crucial for establishing regulations, quotas, and incentives. Attractive project financing conditions and binding commitments to mid/long-term offtake agreements are also essential. A globally agreed framework for certifying the source of e-fuel and risk-sharing mechanisms among green hydrogen ecosystem actors would further support the scaling of e-fuels.
E-fuels, such as e-methanol and sustainable aviation fuels (SAF), are pivotal in this transition. In 2022, SAF production tripled to approximately 300 million liters, with over 130 renewable fuel projects announced by more than 85 producers across 30 countries. Despite this growth, SAF production remains a small fraction of total jet fuel consumption, highlighting the need for further scaling. E-methanol is also gaining traction, with over 200 methanol-fueled ships ordered globally. By 2035-2040, e-methanol is expected to reach price parity with traditional fuels like VLSFO, driven by regulatory penalties on fossil fuel use.
The development of e-fuels faces several challenges, including high initial investment costs due to the energy and capital-intensive nature of projects. The lack of standardized definitions for hydrogen and its derived fuels across regions could limit the global trade of e-fuels. Additionally, the absence of long-term offtake commitments creates uncertainty, delaying final investment decisions. To overcome these hurdles, a holistic approach involving incentives and support mechanisms is necessary to ensure sustained e-fuel production on scale.
Siemens Energy is actively involved in scaling e-fuels, contributing through system optimization, scaling and standardization of e-fuel plants, and highly automated mass manufacturing. The company is also engaged in several projects worldwide, such as the Haru Oni Pilot Project in Chile, which integrates wind energy for e-fuel production. Other projects include the Kassø Power-to-X initiative in Europe, which focuses on large-scale e-methanol production.
The Elyzer P-300 platform is designed for large-scale deployment, offering customized solutions with high plant efficiency and optimized design for fast installation and low maintenance costs. Siemens Energy's capacity growth plan includes ramping up electrolyser manufacturing to deliver large-scale electrolysis systems, with a target of 3 GW annual production capacity.
The market outlook for e-fuels is promising, but progress is needed. Leadership from governments and authorities is crucial for establishing regulations, quotas, and incentives. Attractive project financing conditions and binding commitments to mid/long-term offtake agreements are also essential. A globally agreed framework for certifying the source of e-fuel and risk-sharing mechanisms among green hydrogen ecosystem actors would further support the scaling of e-fuels.
This paper is concerned with a comprehensive analysis of selected non-edible feedstocks in a co-process for the production of advanced biofuels. The research was aimed to study the co-process of standard refinery gasoil with the addition of vegetable oils (camelina, carinata, karanja, post-fermentation corn oil, spent coffee ground oil) and UCO. Their effect on NiMoP/Al2O3 catalyst activity and product properties was evaluated. Hydrotreating co-processing experiments were performed in a trickle bed bench-scale stainless steel tubular reactor (ø78x500 mm, total volume 250 mL) with an effective catalyst bed volume of 150 mL. The co-process was operated at hydrogen pressure 5 MPa, LHSV=1h-1, hydrogen to feedstock ratio 350 NL/L.h and with addition of 2.5 and 10 % by volume of different bio-oils.
Much attention has been paid to pretreatment of the feedstocks as they have significant catalyst deactivation potential. There was necessary to remove unwanted phospholipids and reduce the content of metal cations present in the oil prior to the. Degumming was done with citric acid at 50 °C. The washed degummed oil was dried and refined on silica gel column.
In the measured range of pressure and temperature parameters in the co-process, complete deoxygenation of free fatty acids and glycerides to alkanes (acid number and simdist) occurred. The cracking rate was minimal. The yield of C5+ was above 97.5 %.
From the distribution of n-alkanes in the product, it is evident that the proportion of C15-C19 n-alkanes increased which resulted in a marked increase in the cetane index from 54.1 to 59.6-62.2. The low-temperature properties met the normalized values for the summer season when 2, 5 and 10 % by volume of bio-oils were injected. The aromatic content was significantly reduced (7.9 % wt.), especially di-and polyaromatics. At the operating conditions tested, co-processing of the bio-oils used did not have a significant effect on the efficiency of hydrodesulphurization or hydrodenitrogenation of the catalyst and the low-temperature properties of the diesel.
Acknowledgment:
This work was supported by the Research and Development Agency under contracts APVV-18-0348 and APVV-16-0097.
Co-author/s:
Jozef Mikulec, Project Manager, VÚRUP.
András Peller, Scientific and Technical Worker,Slovak technical university, Faculty of Chemical and Food Technology.
Dr. Ladislav Danč, Head of Laboratory Development Department, VÚRUP.
Much attention has been paid to pretreatment of the feedstocks as they have significant catalyst deactivation potential. There was necessary to remove unwanted phospholipids and reduce the content of metal cations present in the oil prior to the. Degumming was done with citric acid at 50 °C. The washed degummed oil was dried and refined on silica gel column.
In the measured range of pressure and temperature parameters in the co-process, complete deoxygenation of free fatty acids and glycerides to alkanes (acid number and simdist) occurred. The cracking rate was minimal. The yield of C5+ was above 97.5 %.
From the distribution of n-alkanes in the product, it is evident that the proportion of C15-C19 n-alkanes increased which resulted in a marked increase in the cetane index from 54.1 to 59.6-62.2. The low-temperature properties met the normalized values for the summer season when 2, 5 and 10 % by volume of bio-oils were injected. The aromatic content was significantly reduced (7.9 % wt.), especially di-and polyaromatics. At the operating conditions tested, co-processing of the bio-oils used did not have a significant effect on the efficiency of hydrodesulphurization or hydrodenitrogenation of the catalyst and the low-temperature properties of the diesel.
Acknowledgment:
This work was supported by the Research and Development Agency under contracts APVV-18-0348 and APVV-16-0097.
Co-author/s:
Jozef Mikulec, Project Manager, VÚRUP.
András Peller, Scientific and Technical Worker,Slovak technical university, Faculty of Chemical and Food Technology.
Dr. Ladislav Danč, Head of Laboratory Development Department, VÚRUP.
Mehdi Tanha Ziyarati
Speaker
Head of Environmental Department, Pars Special Economic Energy Zone
National Iranian Oil Company
Pars Special Economic Energy Zone (PSEEZ) as a megascale gas industries region located in Asaluyeh County, southwestern Iran, faces serious challenges in sustainable waste management. For many years, the waste generated in this zone, including urban, rural, and municipal waste from petrochemical and gas refining industries, has been primarily collected and disposed of in a rudimentary manner at an open dumping site near the city of Kangan. The present feasibility study was conducted with the aim of identifying and evaluating optimal options for establishing a modern waste management complex in PSEEZ to acheive resource and energy recovery, as well as reduce the environmental, health and social impacts of waste disposal.
Municipal waste in the special zone is mainly generated from three primary sources: urban and rural areas (approximately 33 tpd), PSEEZ organization (approximately 5 tpd), and the industrial sector (approximately 40 tpd). In addition, nearly 15 tonnes per day of green waste is also generated in the PSEEZ. Physical analysis of the generated waste indicated a significant composition of compostable organic matter (39%), combustible materials (41%), and recyclables (20%), demonstrating a high potential for resource recovery.
Considering population growth rates and per capita waste generation, the municipla waste generation in a 10-year horizon is predicted to be around 105 tonnes per day, and green waste around 25 tonnes per day. For the processing and disposal of this waste, six combined options involving material recovery facilities, composting, production of solid recovered fuel (SRF), and incineration in combination with landfilling were technically, economically, and environmentally evaluated. Comparison results showed that options 1 (dry recycling and landfilling) and 2 (dry recycling, composting, and landfilling) had the lowest costs but were excluded due to the need for land area exceeding 6 hectares (which is a limitation of the designated complex site). Among the remaining options, those based on SRF production (3 and 4) were superior to incineration-based options (5 and 6) in terms of water and energy consumption, complexity, and final cost, although the incineration-based options were more effective in landfill diversion. Given the significant cost difference (incineration options were 4 times more expensive) and operational complexity, SRF-based options were prioritized. Finally, option four, which includes a material recovery facility, biodrying of compostable and green waste, production of SRF from combustible and dried waste, and landfilling of remaining waste, was selected as the optimal option. This option had the highest diversion rate among SRF-based options, required less land, offered higher energy efficiency, and posed lower risk in the final product market compared to option 3. Successful implementation of this option requires resolving challenges such as securing long-term cooperation from the Kangan cement factory and ensuring the desired quality of the produced SRF.
Co-author/s:
Sakhavat Asadi, The CEO of the Pars Special Economic Energy Zone, National Iranian Oil Company.
Mahdi Jalili Ghazizade, Associate Professor, Department of Environmental Technologies, Environmental Sciences Research Institute (ESRI), Shahid Beheshti University.
Municipal waste in the special zone is mainly generated from three primary sources: urban and rural areas (approximately 33 tpd), PSEEZ organization (approximately 5 tpd), and the industrial sector (approximately 40 tpd). In addition, nearly 15 tonnes per day of green waste is also generated in the PSEEZ. Physical analysis of the generated waste indicated a significant composition of compostable organic matter (39%), combustible materials (41%), and recyclables (20%), demonstrating a high potential for resource recovery.
Considering population growth rates and per capita waste generation, the municipla waste generation in a 10-year horizon is predicted to be around 105 tonnes per day, and green waste around 25 tonnes per day. For the processing and disposal of this waste, six combined options involving material recovery facilities, composting, production of solid recovered fuel (SRF), and incineration in combination with landfilling were technically, economically, and environmentally evaluated. Comparison results showed that options 1 (dry recycling and landfilling) and 2 (dry recycling, composting, and landfilling) had the lowest costs but were excluded due to the need for land area exceeding 6 hectares (which is a limitation of the designated complex site). Among the remaining options, those based on SRF production (3 and 4) were superior to incineration-based options (5 and 6) in terms of water and energy consumption, complexity, and final cost, although the incineration-based options were more effective in landfill diversion. Given the significant cost difference (incineration options were 4 times more expensive) and operational complexity, SRF-based options were prioritized. Finally, option four, which includes a material recovery facility, biodrying of compostable and green waste, production of SRF from combustible and dried waste, and landfilling of remaining waste, was selected as the optimal option. This option had the highest diversion rate among SRF-based options, required less land, offered higher energy efficiency, and posed lower risk in the final product market compared to option 3. Successful implementation of this option requires resolving challenges such as securing long-term cooperation from the Kangan cement factory and ensuring the desired quality of the produced SRF.
Co-author/s:
Sakhavat Asadi, The CEO of the Pars Special Economic Energy Zone, National Iranian Oil Company.
Mahdi Jalili Ghazizade, Associate Professor, Department of Environmental Technologies, Environmental Sciences Research Institute (ESRI), Shahid Beheshti University.
