CARE-O-SENE achieves milestone in the commercialisation of sustainable aviation fuels

Researchers in the CARE-O-SENE project prove that a yield of over 80% for sustainable kerosene is achievable.

Hamburg/Berlin, 1.10.2024 – Intensive testing in the CARE-O-SENE project confirms that the new CARE-O-SENE catalysts can achieve kerosene yields in excess of 80%. This significantly improves the economic viability of power-to-liquid (PtL) processes and accelerates the commercialisation of Sustainable Aviation Fuel (SAF).

This is a significant progress in the development of more efficient catalysts for the Fischer-Tropsch process, a central step in PtL processes for the production of sustainable aviation fuels (SAF). The German-South African CARE-O-SENE consortium, which includes the Fraunhofer Institute (IKTS), the Helmholtz Centre Berlin (HZB), INERATEC, the Karlsruhe Institute of Technology (KIT), University of Cape Town (UCT) and Sasol, is making an important contribution to the goal of decarbonising aviation with this success.

Using the established Fischer-Tropsch process, green hydrogen and carbon dioxide can be converted into synthetic fuels. The catalysts developed in the CARE-O-SENE project increase the efficiency of the overall process, so that fuel production can be significantly increased while using the same resources.

The positive results from the project team's internal tests in a special laboratory in South Africa have now been confirmed by external experts from the Danish company Topsoe: ‘At our pilot plant in Denmark we have tested several product samples that Sasol produced for the CARE-O-SENE project in its semi-commercial plant in South Africa. We were able to increase the yield in kerosene production to over 80 percent,’ explains Sandra Winter-Madsen, Product Line Director from Topsoe.

‘We are pleased that we have been able to confirm the 80% yield target of the CARE-O-SENE project,’ says Tobias Sontheimer, co-project manager and head of the Strategy Department for Energy and Information at HZB. ’This is another important milestone on the road to the production of SAF suitable for mass production.’

The next step is now a scientifically sound life cycle analysis (LCA): ‘The product processing data is a crucial building block for the ongoing LCA, which we intend to use, among other things, to better quantify the positive impact of the new catalysts on the viability of PtL projects,’ explains Toine Cents, work package leader in the CARE-O-SENE project and Senior Manager Engineering Research at Sasol. ‘We expect the results of the LCA at the end of 2024.’

Further details on the current state of research in the CARE-O-SENE project and insights into how international collaboration can help to meet the challenge of decarbonising aviation can be found in the webinar: Innovate to Elevate: A CARE-O-SENE Event on International Collaboration to Decarbonise Aviation. Further information can be found at this Link.

*Technical term for the effectiveness of multi-stage chemical processes

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Press contact:
Torsten Titze, Communications Manager Advanced Materials, Sasol
Mobile telephone: +49 173 66 800 90
Torsten.Titze@de.sasol.com

CARE-O-SENE initiative introduced during Chilean
President's visit to Helmholtz-Zentrum Berlin

At the beginning of June, the President of Chile, Gabriel Boric Font, visited the Helmholtz Centre Berlin (HZB). He was accompanied by an official delegation of 50 members, including representatives from national authorities, parliamentarians, business leaders, scientists and researchers. Among the delegation were the Chilean Minister of Science and four other ministers from various sectors.

During the visit, discussions focused on the development of innovative catalytic materials crucial for achieving a climate-neutral industry. HZB is collaborating with Sasol on an international research project called CARE-O-SENE (Catalyst Research for Sustainable Kerosene). The project aims to develop new Fischer-Tropsch catalysts to optimise the production of sustainable kerosene on an industrial scale. The Helmholtz Centre Berlin (HZB) plays a significant role in this initiative.

Chile and Germany currently co-chair the Climate Club, an alliance of 38 countries working together to address climate change.

Young Sasol Scientist's Trip to Helmholtz Zentrum Berlin (HZB)
Supported by CARE-O-SENE Mentorship Program)

Dr Jerry Lamola, a rising Scientist-in-Training (SIT) at Sasol in Sasolburg, embarked on a remarkable journey to Helmholtz Zentrum Berlin (HZB) for just over a week in June. This opportunity was facilitated by his mentor, Dr Tobias Sontheimer, who co-leads the CARE-O-SENE program. The trip was organized and mostly sponsored through the CARE-O-SENE mentorship program, established just last year.

“This trip proved incredibly fruitful, enhancing both technical prowess and soft skills development for Jerry”, says Dr Denzil Moodley, Senior Scientist at Sasol. “He gained valuable insights into the HZB structure, discussing with experts on key areas like research strategy, funding proposals, staying abreast of current research trends, and evaluating technology readiness levels. Additionally, Jerry participated in technical discussions with investigators involved in the CARE-O-SENE project.”

During his stay, Jerry visited one of the world’s largest and most in-demand synchrotron facilities, BESSY II, and had the opportunity to take part in night-shift experiments performed on some of the catalyst systems in the CARE-O-SENE program, under the guidance of WP 1 leader, Dr Catalina Jimenez.

He contributed to the “Long Night of the Sciences” which is a popular science exhibition for the general Berlin community, where the two South African-German projects GreenQuest and CARE-O-SENE were showcased.

The visit wasn’t just focused on CARE-O-SENE but gave Jerry a wider exposure to the HZB facilities. A visit to the HZB Wannsee campus allowed him a tour of multiple labs and provided him with a high-level overview of their techniques and other types of research which included water-splitting, electrocatalysis, photocatalysis and fundamental understanding of electrons.

Reflecting on his experience, Jerry said:

"The trip was exceptionally well-rounded and full of many incredible experiences. I’m grateful to Tobias and CARE-O-SENE for the opportunity, as well as all the HZB colleagues who welcomed me so warmly. The biggest highlight is seeing how the power of fundamental science is used to address societal and industrial challenges, as evidenced by the impact of the CARE-O-SENE and GreenQuest projects."

Apart from his scientific pursuits, in his free time Jerry enjoyed the German summer, exploring some Berlin's cultural offerings and soaking in the excitement and atmosphere of the Euro 2024 football championship which was hosted in Germany. This visit highlights the benefits of the CARE-O-SENE mentorship program, especially in terms of talent development, scientific exchange and exposure of young scientists to world class research facilities.

The pressing question of whether sustainable aviation is achievable took center stage at the recentZeit für Klimaevent under the motto "Aviation and Climate Neutrality: Can We Fly Sustainably?” in Frankfurt.

The event brought together experts from various fields to discuss innovative solutions for a greener future. Among the notable contributors was Dr. Tobias Sontheimer, co-lead of the #CAREOSENE consortium, who shared his insights on the path towards climate-neutral aviation.

During the panel discussion titled “Innovative Technologies and Quick Wins on the Way to Climate-Neutral Aviation,” Dr Tobias Sontheimer delved into the role of innovative catalyst technologies in the production of Sustainable Aviation Fuel (SAF). He explained how these catalysts are crucial in minimizing resource consumption during fuel production. “The existing fleet of aircraft will need to be supplied with fuel for several more decades,” Sontheimer noted, emphasizing the need for efficient and sustainable fuel solutions. “At the same time, the blending rates of SAF will change significantly over the next few years, necessitating advancements in fuel technology.”

The panelists highlighted the key role of SAF for decarbonizing the aviation sector and stressed the importance of international projects such as CARE-O-SENE to accelerate innovation cycles and the speed up commercialization. It was common sense between all panelists to achieve or even exceed these SAF blending mandates. “To achieve this”, stated Tobias Sontheimer, “we do not have the time to allow ourselves development cycles of 10 to 15 years. We have to scale the production of SAF short-term”, which the CARE-O-SENE project is aiming for.

The event was also a great networking opportunity, which allowed, Dr Dirk Schär, the other co-lead, to highlight the mission of CARE-O-SENE, that aims to contribute to making sustainable flying more cost-effective. The consortium’s research and innovations in catalyst technology are poised to play a pivotal role in the energy transition within the aviation sector. By enhancing the efficiency and reducing the environmental impact of SAF production, CARE-O-SENE is setting the stage for a future where flying can be both eco-friendly and economically viable.

The discussion at “Zeit für Klima” underscored the urgency and feasibility of transitioning to sustainable aviation practices.

After his recent presentation at the 5th Iceland Geothermal Conference (IGC2024), Dr Dirk Schaer, Technical Manager of Marketing and Sales Catalysts at Sasol Germany and co-lead of the CARE-O-SENE project, took time to answer three questions. He explained why the combination of Fischer-Tropsch (FT) technology and geothermal energy is ideal for the economically efficient production of sustainable aviation fuel, especially when the new catalysts developed by the German-South African CARE-O-SENE project are used:

What are the primary advantages that FT technology delivers in SAF production?

Fischer-Tropsch technology stands out in SAF production due to several key advantages over alternatives:

First, FT is commercially proven and a widely used technology.

Secondly, it’s feedstock agnostic. FT technology is remarkably versatile, capable of utilizing various feedstocks efficiently.

Thirdly, it produces the highest kerosene yields, which ensures optimal utilization of limited renewable resources and has the highest GHG elimination potential.

Finally, the FT-derived route to jet fuel is already ASTM approved and Sasol have many years’ of experience in production, marketing and working with aviation authorities.

Why is it important to develop new catalysts for SAF production?

Today, we face two primary obstacles to producing SAF at scale. SAF requires a substantial amount of energy to manufacture, and more efficient FT catalysts can help us reduce those requirements – making SAF both less expensive and more sustainable.

We also need to decrease the dependence on precious metals and cobalt in the production process, and advanced catalysts can help here, too. Mitigating the need for these elements will help address concerns related to resource scarcity and cost fluctuations.

Why is the combination of FT and geothermal energy sources so beneficial?

The integration of FT technology with geothermal energy sources offers compelling advantages.

Chemical processes, including the FT process, often face challenges with dynamic operations, necessitating intermediate storage. Geothermal energy – by the way also hydropower – provides a stable energy source, circumventing these operational hurdles.

This results in significant lower investment costs and further to this reduced operational stress, positively influencing the catalyst lifetime, contributing to the overall sustainability and viability of SAF production.