A team of engineers has unveiled a novel approach to producing sustainable aviation fuel (SAF) that could significantly reduce dependence on used cooking oil, currently a dominant feedstock in the UK. The work, led by researchers at the University of Sheffield, introduces a process that captures carbon dioxide directly from the air, combines it with hydrogen, and uses concentrated solar energy to generate fuel.
Detailed in a study published in Nature Communications, the research relies on advanced modelling and simulation to assess how the technology might perform at an industrial level. The findings indicate that large-scale production facilities could be viable in regions with strong sunlight and relatively low hydrogen or land costs, with the United States, Chile, Spain, South Africa, and China identified as particularly promising locations.
The development comes at a time when recent data from the UK’s SAF mandate highlights a heavy reliance on used cooking oil for fuel production, raising concerns about long-term scalability. The newly proposed method seeks to address these limitations by offering an alternative pathway that does not depend on finite or competing waste resources.
“Decarbonising the aviation industry is key to slowing global warming and achieving net zero. SAF has emerged as a promising solution to meet energy needs while reducing greenhouse gas emissions, as it works in existing engines, potentially allowing for sustainable air travel without major mechanical changes to aeroplanes. However, a major challenge in switching to SAF is ensuring that we have enough feedstock to produce the huge amount of fuel that the industry needs and also making the fuel in a way that doesn’t require fossil fuels.
“The process we have proposed has the potential to address key challenges in scaling up SAF. It’s a renewable energy-powered way of capturing CO₂ from air and making SAF that is cost-effective and can be scaled to industrial levels. It also reduces electricity consumption in the production process and can fit within a circular economy.”
– Professor Meihong Wang, Professor of Energy Systems at the University of Sheffield.
The technique was developed in partnership with the East China University of Science and Technology and builds upon an existing concept known as Direct Air Capture and CO₂ Utilisation (DACCU). While DACCU also combines captured carbon dioxide with hydrogen, it typically relies on natural gas to generate the heat required for chemical reactions—something the researchers argue undermines its sustainability credentials.
By contrast, the Sheffield-led approach replaces fossil fuel heating with concentrated solar power, achieving the high temperatures necessary for fuel synthesis while lowering projected costs. Estimates suggest production could reach around $4.62 per kilogram, compared to approximately $5.60 for conventional DACCU methods.
“The innovation lies in a hydrogen-fluidised calciner. This is a specialised reactor that uses a field of mirrors to focus sunlight, eliminating the need for onsite fossil fuel combustion. By using hydrogen to circulate the carbon particles, the system also streamlines production as it serves as the medium to circulate the carbon particles while simultaneously providing the essential feedstock for fuel synthesis.
This dual-purpose design allows us to bypass traditional, complex steps like syngas production and CO₂ purification, resulting in a much more streamlined and cost-effective production cycle. By converting atmospheric carbon into SAF directly onsite, we transform CO₂ from a waste product into a valuable resource, fostering a circular economy that eliminates the need for the expensive pipeline networks and geological reservoirs required by traditional carbon capture and storage.”
– Professor Meihong Wang.
The study represents a collaborative effort involving researchers from the University of Sheffield, the University of Manchester, and the East China University of Science and Technology. Funding support was provided through the EU RISE project OPTIMAL and the National Natural Science Foundation of China.
The findings highlight how this emerging technology could play a role in reducing aviation emissions while supporting more sustainable industrial practices. The research also reflects the University of Sheffield’s broader focus on tackling global challenges through innovation and interdisciplinary collaboration.
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