The Potential of SAF Catalyst Technology in Boosting Biochemicals Production

The recent landmark achievement of the inaugural transatlantic flight powered entirely by sustainable aviation fuel (SAF) not only highlights the potential of this technology in the aviation industry, but also its capability to revolutionize biochemical production. The catalyst technology employed in the historic Flight100, if afforded the opportunity for commercial scale up, could unlock various applications in the chemicals production sector.

The SAF utilized in the Flight100 consisted of a blend of 88% HEFA hydroprocessed esters and fatty acids provided by AirBP, and 12% SAK synthetic aromatic kerosene supplied by Virent, a subsidiary of Marathon Petroleum Corporation. Virent, in collaboration with Johnson Matthey, developed the SAK using proprietary BioForming sugars to aromatic process, which harnesses feedstocks such as sugar beet, sugar cane, and corn, and is also capable of handling cellulosic sugars as feedstock.

In contrast to current forms of SAF that require conventional jet fuel blending to achieve the optimal fuel burning balance, the BioForming sugars to aromatics process yields bio-based aromatics in the SAK, eliminating the necessity for blending with conventional jet fuel. This offers the potential to elevate the overall SAF content in the fuel mix, a crucial factor in meeting the aviation sector’s emission reduction targets.

The International Civil Aviation Organization (ICAO), the EU, the US Department of Energy (DOE), and the OneWorld airline alliance have all established ambitious targets for SAF blending, underscoring the global drive for a more sustainable aviation industry. Nonetheless, SAF currently constitutes just over 0.1% of the global aviation fuel mix, which continues to be dominated by fossil-based jet kerosene. Johnson Matthey, in its endeavours to scale up the BioForming technology, must draw lessons from the hurdles encountered by other companies in similar ventures to ensure success.

One potential application of this technology lies in the production of biochemical feedstock. Virent, in a statement, emphasized the diverse feedstocks that this technology can utilize, including lignocellulosic sugars from woody biomass or agricultural residues. One-third of the output from the process can be utilized for chemical production, a fact demonstrated by Virent’s collaborations with companies such as Coca Cola and Japan’s Toray Industries in the production of biobased packaging materials and polymers, respectively.

According to David Kettner, President and General Counsel at Virent, this technology has the capacity to produce chemical feedstock closely resembling mixed xylenes, making it suitable for polymer applications. Virent’s demonstration plant currently produces approximately one barrel/day of bio-reformate, with potential to comfortably scale up to commercial levels. Johnson Matthey, in partnership with Virent, is diligently working towards commercializing the technology and is confident in scaling up production to hundreds of thousands of tonnes per year.

The potential of this catalyst technology to not only revolutionize the aviation industry but also contribute to biochemical production presents an exciting prospect for the sustainable energy and chemicals sectors. The successful commercial scale-up of this technology could serve as the transformative force that these industries have been eagerly anticipating.

In conclusion, the opportunities presented by the utilization of this catalyst technology in both the aviation and chemicals sectors hold promise for a more sustainable future. As the industry continues its efforts towards reduced carbon emissions and increased use of SAF, it is imperative to persist in the development and investment in innovative technologies that can pave the way for a greener and more sustainable future.