Yield optimization of power-to-liquid kerosene via Fischer-Tropsch synthesis

Abstract

Sustainable aviation fuels (SAFs) are considered a key enabler for reducing the greenhouse gas emissions from the aviation sector, and supporting long-term climate neutrality targets. Among the approved SAF pathways, Power to Liquid (PtL) pathway via Fischer-Tropsch (FT) route offers a scalable route for converting the renewable electricity and carbon dioxide into drop-in aviation fuels. However, the broad hydrocarbon spectrum produced during FT synthesis necessitates extensive downstream hydrocarbon upgrading to maximize the kerosene yield as well as to meet the ASTM D7566 specifications. This could be achieved with the optimization of both FT synthesis and hydrocarbon upgrading operating conditions. While previous studies have primarily focused on either individual process step or analyzed alternative process configurations, limiting the identification of their combined impact on kerosene production. This study presents an integrated techno-economic assessment of kerosene production via the PtL FT pathway using a detailed Aspen Plus®-Python simulation framework. The simulation model incorporates validated Python-based kinetic models for FT synthesis and hydrocracking within a PtL process chain, enabling a systematic evaluation of their influence on the kerosene selectivity, process efficiencies and production costs. The results shows that optimization of FT synthesis and hydrocracking conditions enables a kerosene yield of 87.6 % while meeting the ASTM D7566 fuel specifications. Despite the high kerosene yield, the process remains energy intensive, exhibiting a Power-to-Fuel efficiency of 36.9 %. Furthermore, the economic analysis demonstrates that maximizing kerosene yield does not inherently minimize the production cost, as profitability strongly depends on the market value of by-products.