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Sustainable Aviation Fuels: Concrete Chemicals Joint Venture Gets Off The Ground

Berlin, Dauerthal, Germany / Johannesburg, South Africa - The partner companies Enertrag, Cemex and Sasol ecoFT have founded "Concrete Chemicals GmbH", which is planning a pioneering project on the Cemex site in Rüdersdorf near Berlin to produce sustainable aviation fuel that will simultaneously contribute to the decarbonization of the cement industry.

Both the cement and aviation industries are considered the sectors with the greatest challenges in reducing greenhouse gas emissions. The international Concrete Chemicals consortium is setting the course for more climate-friendly cement production by capturing CO2 and converting it into Sustainable Aviation Fuel (SAF) using hydrogen. To implement the project, the consortium is preparing funding applications to be notified at the European level.

SAF production uses a power-to-liquid (PtL) process that utilizes carbon, such as that from unavoidable industrial sources of CO2, and renewable, green hydrogen produced by electrolysis. The carbon and hydrogen are converted into a synthesis gas consisting of a mixture of carbon monoxide and hydrogen. This syngas is then converted into longer chain hydrocarbons for the production of e-kerosene or SAF using the Fischer-Tropsch (FT) process.

To advance this process flow, the three partners are pooling their technical expertise in Germany: Enertrag will produce green hydrogen exclusively with energy from regional wind and PV plants. Cemex will capture the CO2 produced during cement production on site. Sasol ecoFT will also contribute its Fischer-Tropsch technology to the production of SAF.

The e-kerosene is to be certified for use in aircraft, which includes its chemical properties such as composition and purity. In addition, the project partners intend for the e-kerosene to meet EU RED II criteria and thus allow it to be accounted for in the greenhouse gas reduction quota and the mandatory minimum blending quota for PtL kerosene.

Two scaling stages: Expansion to annual production of up to 35,000 metric tons of e-kerosene planned

The project comprises two scaling stages. First, the hydrogen is to be produced on site using electricity from regional renewable energy plants. Thus, in the first phase, 15,000 tons of e-kerosene are to be produced annually. For this purpose, 100 tonnes of CO2 per day are to be captured at the Rüdersdorf site, combined with 12 tonnes of H2 per day and used for PtL production.

In the second stage, larger quantities of hydrogen are to be delivered by pipeline. The green hydrogen will be produced as part of the Enertrag-IPCEI project "Electrolysis Corridor East Germany" with an electrolysis capacity of 210 MW. This section of the project also uses only renewable electricity to produce 40 tons of green hydrogen per day. In parallel, CO2 capture will increase by another 300 tons per day. In total, the production of 35,000 tons of e-kerosene per year should be possible in the second project phase.



Source: IWR Online, 14 Apr 2022