Sustainable Aviation Fuel from CO₂, Green Hydrogen, and Byproduct Valorization: An Integrated Circular Economy Approach

This project aims to develop a sustainable alternative to fossil-based kerosene by advancing Sustainable Aviation Fuels (SAF) while integrating plastic waste valorization to establish a circular carbon economy. Aviation remains one of the hardest sectors to decarbonize, and Electro-jet (e-jet) fuel, produced from CO₂ and renewable hydrogen, presents a scalable near-term solution. However, current e-jet production methods require multiple conversion steps and significant renewable electricity. To improve efficiency, this project will develop a direct dimethyl ether (DME) conversion route, reacting DME with fossil hydrocarbon refinery cuts, reducing OPEX and CAPEX while achieving a 50% reduction in carbon emissions. A key component of this project is the valorization of SAF byproducts, including captured CO₂, unconverted hydrocarbons, and oxygenated compounds, as inputs for advanced chemical recycling technologies. This approach repurposes single-use plastic waste into carbon-neutral aviation fuels, API Grade III+, IV, and V base oils, and specialty chemicals, reinforcing a closed-loop carbon system. The project will also explore CO₂ co-utilization to enhance process efficiency and minimize emissions. Additionally, Sulzer’s methane pyrolysis technology will be assessed for sustainable hydrogen production, further supporting SAF synthesis. Key activities include catalyst development, Life Cycle Assessment, techno-economic analysis, and pilot-scale validation of the integrated SAF and plastic recycling processes. This project will reduce GHG emissions, lower costs, and position Qatar as a leader in sustainable aviation fuels. Collaboration with Qatar’s Ministry of Environment and Climate Change (MOECC) will ensure alignment with the country’s net-zero emissions goal by 2050. Expected outcomes include technology breakthroughs, catalyst prototypes, and potential IP filings.

Hamad Bin Khalifa University (HBKU)