RuAviation

Researchers at the Boreskov Institute of Catalysis, part of the Federal Research Center of the Siberian Branch of the Russian Academy of Sciences (SB RAS), in cooperation with the Russian Science Foundation, are developing catalytic systems for converting used cooking oils into sustainable aviation fuel (SAF) components. The project targets a reduction in aviation’s carbon footprint through the incorporation of biogenic components into jet fuel blends.

The combustion of conventional jet fuel releases millions of metric tons of carbon dioxide and other emissions into the atmosphere each year. In 2024, global aviation-related CO₂ emissions exceeded 940 million metric tons. Against this backdrop, the production of SAF from renewable feedstocks is gaining practical importance. While tailpipe emissions from bio-based fuels are comparable to those of conventional kerosene, lifecycle assessments indicate a carbon footprint reduction of up to 80%. Current global SAF production stands at approximately 2 million metric tons per year, with major airlines targeting output levels of up to 500 million metric tons by 2050.

A wide range of feedstocks can be used for SAF production, including biomass, animal fats, cellulose, and waste cooking oils. The latter are particularly attractive due to their relatively low cost compared with petroleum-based raw materials; the global market for used cooking oils is estimated at around USD 7 billion. One of the most widely applied conversion pathways is the HEFA process (Hydroprocessed Esters and Fatty Acids). This technology involves hydrodeoxygenation to remove oxygen and form straight-chain alkanes, followed by hydroisomerization to improve cold-flow and performance characteristics. The resulting products can be used to produce aviation fuel components as well as renewable diesel and gasoline.

Two main HEFA process configurations are currently employed. The two-step route separates hydrodeoxygenation and hydroisomerization into consecutive stages. The single-step route integrates hydrodeoxygenation, hydroisomerization, and partial hydrocracking within a single reactor using one catalyst. The latter approach offers advantages in terms of cost efficiency and process simplicity. The Boreskov Institute of Catalysis is focusing on catalyst development for the single-step HEFA process, with particular attention to performance, stability, and operational reliability.

The research centers on shaped catalyst supports based on zeolites and the deposition of active metal components onto these structures. This approach allows researchers to establish clear correlations between catalyst preparation methods and functional properties. The use of nickel–molybdenum systems on zeolitic matrices promotes the formation of isomerized alkanes and enhances the efficiency of converting vegetable lipids into aviation-grade fuel components.

According to project leader Roman Kukushkin, PhD in Chemistry, the key objective is to develop catalysts that not only remove oxygen effectively but also facilitate complex reaction pathways, ensuring that the resulting hydrocarbons meet the stringent requirements of aviation fuel blending.

One of the anticipated outcomes of the project is a reduction in SAF production costs combined with improved environmental performance, while maintaining the operational characteristics required for aviation use. The research is supported by a grant from the Russian Science Foundation (No. 25-23-01310), enabling further optimization work and future scale-up of the technology.