Advancing Sustainable Aviation via Power-to-Liquid & Direct Air Capture Study

Objective

To evaluate and develop a modular, integrated and mass-manufacturable e-fuels system capable of producing Sustainable Aviation Fuel (SAF) at scale, using a Power-to-Liquids (PtL) process and Direct Air Capture (DAC) technology. This study was funded by UK Government through the Advanced Fuels Fund (AFF) competition.

Project Scope

The Front-End Loading 1 (FEL1) phase of the Advancing Sustainable Aviation via Power-to-Liquid and Direct Air Capture (ASAP-DAC) project involved:

1. Hosting a Framing and Concept Identification Workshop to outline pathways for SAF production using DAC and PtL processes.
2. Conducting a techno-economic analysis to assess various SAF production concepts at both demonstration and commercial scales.
3. Reviewing key enabling technologies, including DAC systems, electrolyser types for syngas and hydrogen production, and Fischer-Tropsch (F-T) reactor systems.
4. Delivering preliminary technical designs, cost estimates, and economic evaluations to guide future project phases.

Findings & Recommendations

Findings

• Concept Selection: Five production concepts were evaluated, with Concept 1 (Reference Case) and Concept 5 (Commercial Scale Facility) emerging as the most feasible pathways for SAF production. Concept 1 utilized co-electrolysis of CO2 and H2O via Solid Oxide Electrolytic Cells (SOEC), while Concept 5 leveraged biogenic CO2 for cost efficiency.
• Technology Reviews:
  • DAC technology provided by Mission Zero Technologies demonstrated feasibility at demonstration scales but posed scaling challenges for commercial facilities.
  • SOEC electrolysers showed higher efficiency compared to PEM and alkaline technologies, particularly when integrated with downstream heat recovery.
  • F-T processes offered opportunities to enhance carbon conversion and SAF yields, though further vendor engagement is necessary.
• Economic Insights: Direct Air Capture and electrolysers accounted for the highest CAPEX and OPEX costs. Increased carbon and hydrogen conversion rates to SAF significantly reduced the Levelized Cost of SAF (LCOSAF).

Recommendations

1. Optimize DAC system designs to align with SAF facility capacities and address scalability challenges for commercial plants.
2. Engage key technology vendors to refine the technical definitions of SOEC electrolysers, F-T reactors, and hydrocrackers.
3. Explore biogenic CO2 as a primary feedstock for commercial facilities to mitigate costs associated with DAC.
4. Advance FEL2 with a focus on modular and factory-assembled designs for
   enhanced manufacturability and cost reductions.