Comparative Assessment of Fischer-Tropsch and Methanol-to-Jet Routes for Sustainable Aviation Fuel Production

Abstract

The transition to sustainable aviation fuels (SAF) is critical for reducing the environmental footprint of the aviation sector. This study presents a comparative analysis of two promising pathways for SAF production - One via Fischer-Tropsch (FT) synthesis and the second one via Methanol-to-Jet. The assessment includes technical, economic, and environmental aspects to provide a holistic evaluation of both routes, with a particular focus on the methanol route, using the FT route as a benchmark. The technical analysis examines feedstock flexibility, process efficiency and fuel quality and highlights key operational considerations and challenges. Economic feasibility is assessed based on capital and operating costs, while the environmental impact is assessed based on life cycle greenhouse gas emissions, energy requirements and potential sustainability benefits. A detailed study of the MTJ route explores its advantages in terms of reduced process complexity, potential for cost reduction and compatibility with existing methanol production infrastructure. The study includes detailed kinetic models for the main process steps in order to assess the composition of the fuel examines reaction conditions and integration strategies to optimize efficiency and output quality. Using FT-SAF as a benchmark, the research illustrates the comparative advantages and challenges of the MTJ route, highlighting its potential to become a leading SAF production pathway. Preliminary results indicate that both routes offer viable SAF production options, but MTJ offers specific economic and environmental advantages that merit further exploration. The study identifies key factors influencing the selection of SAF production routes and provides insights into optimizing process configurations for improved sustainability. For the data basis, the processes are modelled using the flowsheeting software AspenPlus® coupled via the in-house tool aspenparserDLR for automated data exchange between the simulation software and python. Additionally, the direct interaction allows to include own optimizer algorithms for reactor design and complex kinetic models while performing parameter variation to identify the ideal process designs. Combined with the python-based tool pyteea for techno-economic analysis (TEA) and life cycle assessment (LCA) a holistic evaluation of the production pathways is realized. This work contributes to the strategic decision-making process for SAF deployment, supporting the aviation industry's decarbonization goals. The findings offer valuable guidance for policymakers, industry stakeholders, and researchers seeking to advance sustainable fuel technologies.