10-02-2025

Topsoe and Sasol demonstrating synthetic fuel production

The FrontFuel SynFuels demonstration project has achieved a major milestone in demonstrating synthetic fuel production from biogenic resources. At the project site in Foulum, Denmark, the team has successfully converted biogas and CO₂ to a synthetic crude by integrating Topsoe’s eREACT™ technology with Sasol’s Fischer-Tropsch (FT) technology.

This achievement is significant in advancing an integrated eFuel process as it goes towards demonstrating bio/eSaf can be derived from existing demonstrated chemicals technology knowhow and processes. The FrontFuel project is a collaboration between the University of Aarhus, Topsoe and Sasol and is funded by the Energy Technology Development and Demonstration Programme (EUDP).

The FrontFuel demo is intended to both de-risk and lower the technological barriers for eFuels production by proving that the solid oxide electrolyzer cell/SOEC-eREACT™-FT combination can create a synthetic hydrocarbon crude (syncrude) feedstock viable for refining into fuel. As an industry first, this test configuration involved blending biogenic CO₂, biogas, and hydrogen to create a synthesis gas (syngas) stream, which is then processed into syncrude. This syncrude represents the early stages of what could become a sustainable jet fuel, setting a strong foundation for bio-/e-Fuels in commercial applications.

Next step for FrontFuel is to refine this syncrude into a final synthetic paraffinic kerosene product (ASTM D7566). This process will allow the further integrated testing and development as the project moves closer to a final eFuels process (feeding only CO₂ and H2). "We have always been confident that this process would be successful," explained Sandra Winter-Madsen, Product Line Director. "It's a step-by-step de-risking approach where we've combined Topsoe and Sasol's established technologies in an integrated setup to make something tangible. We have demonstrated to the market that this integrated process works - and that it will lay the groundwork for bio-/e-Fuels production at scale".  

Topsoe and Sasol's collaboration under G2LTM bio-/e-Fuels envisages offering an attractive path in renewable synthetic fuel production, through an integrated and scalable model based on best-in-class energy and carbon-utilization process. Under the single-point license, Sasol and Topsoe offer a full technology bundle from feed in, to product out.  

"This wax symbolizes progress towards actual sustainable chemical products. As it is produced from renewable inputs like CO2 and biogas, it proves that the integrated process chain is working and that the known fossil-driven processes can be pivoted to sustainable feedstocks", says Peter Mølgaard Mortensen, Lead Scientist. "The next phase involves making jet fuel with actual carbon accounting, which we hope may qualify it as SAF. In the next phase, the interchangeable nature of biogas, biomethane and CO2 feedstocks will be demonstrated even further".  

As the project progresses, FrontFuel's development team is working on optimizing the front-end processes, intending to refine the first synthetic kerosene batch – a potential milestone for both the industry and the future of sustainable aviation.