The CO2SAF project focused on developing a one-stage syngas-to-Sustainable Aviation Fuel (SAF) unit, integrating Fischer-Tropsch synthesis and hydrocracking catalytic processes. By utilizing electro-reduced CO₂ as the carbon feedstock, the project aimed to produce low-carbon aviation fuels, addressing the challenges of decarbonizing the aviation sector. This approach provides a pathway for directly converting CO₂-enriched syngas into kerosene-range hydrocarbons, aligning with the growing need for sustainable aviation solutions.

One of the key outcomes was the development of an optimized electro-catalytic process for the reduction of CO₂ to CO. Advanced electrode materials and cell designs, informed by multi-physics computational simulations, achieved current densities of 150 mA/cm², Faradaic efficiencies exceeding 90%, and CO₂ conversion rates over 40%. The process demonstrated stable operation for extended durations, representing an important step toward reliable electrochemical CO₂ utilization technologies. The project also advanced the development of catalysts for hydrocracking, particularly through the shaping of zeolite-based materials, by combining zeolite with boehmite and using acetic acid as a peptizing agent. Additionally, the incorporation of PMMA as a pore-forming agent increased macroporosity, while mesoporosity played a critical role in enhancing the dispersion and availability of active sites. These features significantly improved the catalysts’ performance in hydrocracking reactions, demonstrating their potential for producing kerosene-range hydrocarbons.

The integration of advanced catalytic materials and processes enabled the production of SAF with a focus on the kerosene fraction (C₉-C₁₆). Fischer-Tropsch synthesis was successfully performed under high CO₂ concentrations without the need for extensive gas conditioning. ALD-promoted ceria catalysts improved product selectivity, with over 40% of hydrocarbons in the kerosene range and a 10% increase in selectivity compared to conventional cobalt-based catalysts. This work highlights the role of tailored catalytic materials and zeolite-based supports in advancing sustainable aviation fuels, contributing to the broader decarbonization goals of the aviation sector.

Acknowledgements (in Spanish)

CO2SAF (TED2021-132365B-I00) es un proyecto financiado por MCIN/AEI/10.13039/ 501100011033 y por la Unión Europea “NextGenerationEU”/PRTR.