The UK government has revealed it expects the first-ever net zero transatlantic flight to take place as early as next year, with an aircraft to be powered solely by 100% sustainable aviation fuel. The announcement came during a visit to the US by Transport Secretary Grant Shapps, who during a meeting with airline executives invited the international sector to work closely with the government to deliver the demonstrator flight. The government says it is committed to drive forward the SAF industry, which had the potential to deliver significant carbon savings, improve domestic fuel security, support thousands of green jobs and put flying on a more sustainable path. It acknowledged that current jet fuel specifications do not allow flights to solely use 100% SAF but did not elaborate on how this would be overcome on the net zero flight beyond saying SAF use would need to be “complemented by additional decarbonisation measures to be fully net zero” and referenced greenhouse gas removals.

Currently one of the highest single emitters of greenhouse gases, the government said “aviation is one of our biggest challenges when it comes to making transport green, but the investment and innovations such as SAF are there to make guilt-free flying a reality.”

The new transatlantic initiative has resulted from the Jet Zero Council partnership between industry and government that aims to drive delivery of new technologies and innovative ways to cut aviation emissions, while supporting the UK economy. It is estimated a UK SAF industry could support up to 5,200 UK jobs directly, as well as a further 13,600 through global exports, with an annual turnover that could reach £2.3 billion ($2.8bn) by 2040.

“This trailblazing net zero emissions flight, a world first, will demonstrate the vital role that sustainable aviation fuel can play in decarbonising aviation in line with our ambitious net zero targets,” said Shapps. “That’s not just great news for the environment, it’s great news for passengers who will be able to visit the Big Apple without increasing damaging greenhouse gas emissions.”

The government said it was committed to accelerating the testing and approval of 100% SAF “to unlock the full decarbonisation potential of this technology.” It said delivering the transatlantic flight would help gather data needed to support ongoing and future work to test and certify SAF, “while exploring how engine efficiency improvements, flight optimisation and greenhouse gas removals can contribute to achieving net zero flights.”

Described as a “pioneering test flight”, the transatlantic initiative will be supported by up to £1 million of competition funding to help increase understanding of commercial flights using 100% SAF. It will be open to all airlines covering non-stop UK-US routes, “welcoming their collaboration with wider aviation and fuel stakeholders across the SAF supply chain.” After an initial expression of interest phase opening on May 14 and closing on June 12 2022, successful airlines will be invited to submit a full stage application, following which the funding will be made available competitively to support the testing, research and personnel costs of the initiative.

“This flight, driven through collaboration and bold ambition, is a perfect example of how innovation can and will shape our future lives,” said Indro Mukerjee, CEO of Innovate UK, which is running the competition with the Department for Transport. “It is only by working together that we will see the transformative change needed to deliver on the commitments to meet net zero.”

Aero engine manufacturer Rolls-Royce has been testing its large commercial engines on 100% SAF over the last year. “We have the technology to help the UK government achieve its objectives and we look forward to working closely with them to deliver this milestone transatlantic flight,” said Warren East, CEO of Rolls-Royce. “Just over 100 years ago, Rolls-Royce powered the first-ever transatlantic flight and now we have the innovation and expertise to power the next generation of sustainable aircraft.”

As well as the fuel specifications barrier, the government said it was working with industry on other challenges preventing a higher uptake of SAF, such as high fuel production costs, technology risk at commercial scale and feedstocks availability. It confirmed it was exploring a SAF mandate, supporting the UK SAF industry with £180 million ($220m) of funding over the next three years and establishing a fuel testing clearing house in the UK. In addition to the £180 million funding, £400 million of funding is being made available through a government partnership with Breakthrough Energy Catalyst to drive private sector investment into the next generation of green technologies, through which UK SAF projects can seek additional capital.

The government is aiming to confirm a SAF mandate, as well as specific targets, timescales and scheme design following a second consultation this year. At a fifth meeting of the Jet Zero Council last month, the government launched the Zero Emission Flight Delivery Group that is made up of aviation experts from across industry and government who will work together to realise zero emission flight.

“UK airlines strongly support the development of a UK SAF industry, which will play a vital role in helping our sector deliver net zero emissions by 2050, as we are committed to doing,” commented Tim Alderslade, Chief Executive of trade body Airlines UK, on the transatlantic initiative. “This announcement will provide additional momentum and, alongside the recent £180 million in Treasury support for the development of new UK SAF plants, demonstrates the commitment of government to making SAF a key part of the decarbonisation of aviation. We now need to turbocharge production in order to build the initial three SAF plants by 2025 and UK airlines have shown real commitment to making this happen with our partnerships with Phillips 66, Velocys and LanzaTech.

“We look forward to working with ministers through the Jet Zero Council to continue to explore mechanisms to attract the required private investment – in addition to a planned mandate – so we can help deliver the government’s 10% SAF uptake goal by 2030.”

Photo: Rolls-Royce

The demand for SAF is high but supply remains limited as facilities are still under construction, and production in many cases is years away. But since last year, several oil companies have started producing SAF through co-processing, which is giving SAF supply a boost. In July 2021, NetJets Europe became the first customer to purchase Air bp’s ISCC PLUS certified SAF produced through co-processing of waste fats and used cooking oil in bp’s Castellon refinery in Spain. Other oil companies have followed in rapid succession to announce SAF production through co-processing, including Phillips 66 (UK), TotalEnergies (France), OMV (Austria), Eni (Italy) and bp (Germany). Phillips 66 has just supplied British Airways with a first batch of SAF produced at its Humber Refinery in the UK under a multi-year agreement. Why are the big oil companies choosing this route? Susan van Dyk takes an in-depth look at co-processing, what it means, who is doing it and what volumes of SAF are produced this way.

Andreea Moyes, Air bp’s Global Aviation Sustainability Director, explains her company’s rationale for co-processing: “As an integrated energy company, our ambition is to be a net-zero company by 2050 or sooner and to help the world get to net zero. Part of this is cutting the carbon intensity of the products we sell, such as jet fuel. We believe that all technologies and pathways, including co-processing, are needed to help the industry decarbonise.”

Co-processing is the simultaneous processing of biobased material, such as fats, oils and other feedstocks, with fossil-based feeds in refinery infrastructure. Using an existing refinery can offer benefits in terms of cost savings and carbon reduction as it removes the need to build dedicated processing units. The high market demand for SAF is playing a role in refinery decisions to co-process.

Explained Fabian Wedam, Head of Aviation at OMV Group: “Market demand for sustainable products is increasing sharply in the short to mid term and large scale dedicated SAF production units require a significant lead time for construction.” Co-processing is a stepping stone since existing assets can be used and only limited investments are needed, he said. Co-processing allows OMV to access the growing market for sustainable products in the short term using existing assets and infrastructure in OMV’s refineries. Last December, OMV signed an agreement to supply Austrian Airlines with 1,500 tonnes of SAF produced at its Schwechat Refinery during 2022.

Oil companies have the resources and expertise to produce SAF through co-processing using existing refinery infrastructure and limited investment. “Utilising the existing refinery infrastructure and their links to existing supply networks play an important role in increasing the supply of SAF,” said Moyes. The bp refinery in Lingen has started production of SAF from used cooking oil, marking the first industrial production facility in Germany using co-processing to produce SAF from waste and residues.

Co-processing enables an oil company to quickly become relevant in a net-zero world. According to Bernardo Fallas, Director of Corporate Communications at Phillips 66, “co-processing is one of the ways the Humber Refinery is positioning itself as a refinery of the future.” Phillips 66 believes markets for lower-carbon products are growing, he said. The agreement with British Airways demonstrates its Humber Refinery’s ability to supply them. The airline has just announced it has taken delivery of the first batch of SAF produced by the refinery, which it says is the first commercial-scale SAF to be supplied in the UK (see article). The blended fuel will be supplied by pipeline to several UK airports, including London Heathrow.

“We were the first in the UK to co-process waste oils to produce renewable fuels and now we will be the first to produce SAF at scale,” said Darren Cunningham, Lead Executive UK and General Manager for Phillips 66’s Humber Refinery. “We’re currently refining almost half a million litres of sustainable waste feedstocks a day, and this is just a start.”

Fallas added the Humber Refinery recently increased renewable fuel produced through co-processing from 1,000 bpd to 3,000 bpd, and the refinery aims to expand renewable fuels capacity to 5,000 bpd by 2024.

So what are the current volumes of SAF supplied through co-processing by others in the market? Air bp’s Moyes indicated her company has already produced more than 5,000 barrels per day (bpd) of biofuels (approximately 200-250 million litres total volume of biofuel, although SAF is not the only product) at three refineries through co-processing and aims to triple production by 2030 across these sites. According to Wedam, the planned production of SAF by the OMV Group for 2022 will be 2,000 tonnes, or about 2.3 million litres, of co-processed SAF.

The potential volumes of SAF that a refinery can produce through co-processing is currently limited by ASTM D1655. The standard only permits co-processing of 5% vegetable oils or waste oils and fats, and Fischer-Tropsch synthetic liquids for SAF production. Although 5% may seem a small amount, it could still be considerable if the scale of refinery operations is considered. Bp’s Castellon and Lingen refineries each have a capacity of about 100,000 barrels per day, so 5% amounts to 5,000 bpd (about 200-250 million litres per year).

However, indicated Steve Csonka, Executive Director of the Commercial Aviation Alternative Fuels Initiative (CAAFI) in the US, the 5% “current maximum co-processing volumetric limits are being assessed by a standing ASTM Task Force for possible increase, with broader voting to be accomplished upon the Task Force’s completion in the coming months.”

Moyes confirmed: “Air bp is leading the Task Force seeking to increase the sustainable aviation fuel content of traditional jet available from refineries co-processing renewable feedstocks. The hope is to raise the limit from 5% to 30% to benefit customers and global supply.” Increasing the feedstock limits for co-processing are likely to have a significant impact on the volumes of SAF that could be supplied via this route.

SAF produced through co-processing can be certified as sustainable and is also recognised under CORSIA as an eligible fuel. According to Air bp, the SAF produced through co-processing and supplied to Netjets received ISCC PLUS certification. The SAF had an attributed saving of around 80% carbon emissions over its lifecycle compared with conventional jet fuel based on a mass balance approach. It should be noted that this value is only calculated based on the renewable content in the finished fuel. ISCC has developed a guidance document on the certification of co-processing to assist companies. Various methods or a mixture of methods are permitted to calculate the bio-yield, including radiocarbon 14 analysis, to ensure that only the renewable content is counted.

All the co-processing activities mentioned used fats and oils feedstocks, in most cases waste fats and used cooking oils (UCO). The types of feedstock are currently restricted under ASTM D1655 and limited to fats and oils, and Fischer-Tropsch synthetic liquids. FT syncrude is not currently used in co-processing as it is not commercially available at this time. Other feedstocks may be permitted in future if ASTM certification is achieved, usually a very rigorous process.

“Feedstock availability, as well as reliability of supply and quality, will be one of the key challenges in the future,” said OMV’s Wedam. “Already today, the market for SAF-suitable feedstock is very competitive. Lipid feedstocks will not be sufficient once the aviation industry moves further towards carbon neutrality.”

Feedstock challenges

The challenge with future availability of waste oils and fats feedstock for SAF production has been confirmed in an ICF report, ‘Fueling net zero’. Renewable diesel and biodiesel compete for the same feedstock, and significant expansion of renewable diesel facilities will soon place a constraint on supply.

According to Moyes, bp recognises that “increasing feedstock availability is an important part of increasing overall SAF production and there are two elements to this. Firstly, as most commercial production today uses HEFA feedstocks, increasing these in the short-term is key. In support of this, bp recently entered into a 10-year strategic agreement with Nuseed enabling Nuseed to accelerate the expansion of its Carinata sustainable production programme.

“Secondly, bp plays an ongoing role in researching and developing the technologies required to bring the different SAF production technology options to commercial production. This widens the feedstocks that can be used. For example, bp and Johnson Matthey have developed a simple-to-operate and cost-advantaged Fischer-Tropsch technology that can operate both at large and small scale to economically convert synthesis gas, generated from sources such as municipal solid waste and other renewable biomass, into long-chain hydrocarbons suitable for the production of SAF. Using all technology options, we believe there is enough feedstock availability to meet the industry’s SAF requirements.”

Other feedstocks that have great potential for co-processing are bio-oils/biocrudes produced through technologies such as fast pyrolysis (bio-oils), catalytic pyrolysis or hydrothermal liquefaction (HTL, biocrudes). Unlike fats and oils, these biocrudes can be produced from wastes such as forest or agricultural residues that are available in far greater volumes. However, these technologies are at various stages of technology readiness.

The recently completed Pyrocell plant in Sweden, using BTG Bioliquids’ fast pyrolysis technology, has started producing bio-oil, which will be co-processed by Preem at the Lysekil refinery in Sweden to produce renewable diesel and gasoline. Note that the feedstock limitations under ASTM D1655 for SAF production do not apply to other fuel products. Preem, considered the leader in co-processing activities, has co-processed 30% tall oil methyl esters into drop-in fuels for more than a decade. Following a revamp last year, Preem’s Gothenburg refinery is currently able to co-process 95% tall oil methyl esters and tallow, according to Fredrik Hellesöy, Strategic Business Development Manager at Preem. This highlights the unlimited potential of co-processing to produce significant volumes of low-carbon intensity fuels.

Due to the current feedstock limitations under ASTM D1655, Preem is not producing SAF, but if the 5% limit is increased to 30%, SAF production will become economically feasible, said Hellesöy. For Preem, co-processing is just a step on the way to full conversion, he stated.

Co-processing can increase the supply of sustainably certified SAF in the short-term at current co-processing limits and could become more significant if these limits are increased, and other feedstocks are certified under ASTM. Using existing refinery infrastructure allows for more rapid production of SAF as construction of new facilities proceed. At the same time, it is part of the long-term business strategies of oil companies for a net-zero future.

“This strategy secures long-term business in an ever-changing world and supports the company’s commitment to a sustainable energy future,” said Fallas at Phillips 66.

Added Martin Thomsen, CEO, Air bp: “We believe SAF is one of the aviation industry’s key routes to reducing carbon emissions, and ISCC PLUS certified SAF is the first step towards developing new refining and commercial solutions, including those that achieve CORSIA certification, to keep decarbonising our offers for our aviation customers. Co-processing is an important step in replacing fossil fuel with renewable feedstocks within refineries.”

Photo: The bp refinery in Lingen, Germany (© bpPLC)

Susan van Dyk

GreenAir Correspondent

www.svdconsulting.ca

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British Airways has taken delivery from oil major Phillips 66 of an initial batch of the UK’s first commercial-scale production of sustainable aviation fuel. The fuel is being produced through co-processing at the Phillips 66 Humber Refinery in northeast England from sustainable waste feedstocks under a multi-year purchase agreement signed late last year for “thousands of tonnes” of SAF. Blended with conventional jet fuel, the fuel is added to the existing pipeline infrastructure that directly feeds several UK airports, including London Heathrow. The SAF is being produced from waste gases, crop and forestry residues, household and commercial waste, and used cooking oil, and, according to the partners, can lower lifecycle CO2 emissions by over 80% compared to traditional jet fuel. The airline says the purchased fuel will reduce lifecycle CO2 emissions by almost 100,000 tonnes, enough to power 700 net zero CO2 emission flights between London and New York on its Boeing 787 aircraft.

“Being the first airline to source sustainable aviation fuel produced at commercial scale in the UK is another breakthrough moment for us and the airline industry,” commented British Airways’ Chief Executive Sean Doyle. “Progressing the development and commercial scale-up of SAF will be a game-changer and crucial to reducing the aviation sector’s reliance on fossil fuels and improving the UK’s energy supply resilience.

“I’m confident that Britain can take a leading role on the global stage in this space, creating green jobs and export opportunities, if industry, developers and government continue to collaborate and make it a key focus area.”

Headquartered in Houston, Texas, Phillips 66 processes, transports, stores and markets fuels and products globally, and had $56 billion of assets as of the end of 2021.

“We were the first in the UK to co-process waste oils to produce renewable fuels and now we will be the first to produce SAF at scale,” said Darren Cunningham, Lead Executive UK and General Manager for Phillips 66’s Humber Refinery. “We’re currently refining almost half a million litres of sustainable waste feedstocks a day, and this is just a start.

“The strategic collaboration and supply agreement confirm each companies’ commitment to a lower carbon future. The production of SAF is just one of a number of decarbonisation projects we are currently progressing, and we are excited by the role we play in supplying the UK with the fuels it needs, both now and in the future.”

The two companies said they are supporting UK government plans for a future SAF mandate and a business model for investing in advanced waste-to-jet fuel projects through participation in the Department for Transport’s Jet Zero Council Delivery Group. “British Airways also continues to work with government on ways to provide certainty for investors to help the UK be a leader in SAF production,” said the airline.

Transport Secretary Grant Shapps welcomed the UK’s first commercial-scale production and supply of SAF. “The fact it’s being produced here is a perfect demonstration how Britain continues to be a pioneer in developing green aviation technology. We can create thousands of green jobs while reducing the impact that flying has on the environment, so we can continue to connect and travel in a greener way.”

British Airways’ parent company, International Airlines Group, is investing $400 million over the next 20 years into SAF development and BA has existing partnerships with several companies, including LanzaTech, LanzaJet, Nova Pangaea Technologies and Velocys, to develop plants and purchase the sustainable fuel.

British Airways has just published its 2021 Sustainability Report. The airline has also announced a new way for customers on its short-haul European flights to help fund carbon reduction projects around the world. Through its onboard Speedbird Café menu app, a new category can be found on the BA Better World tab labelled ‘Contribute to Carbon Offsets’. The £2.50 ($3) contribution represents the carbon compensation of an average BA European return flight per customer, it says, with the funds invested in verified CO2 emissions reduction and avoidance projects.

Photo: British Airways

British Airways has launched a new sustainability docuseries, with the first video focusing on SAF:

British Airways could be using sustainable aviation fuel produced in the UK within the next few months following an agreement with one of world’s biggest oil refiners, Phillips 66. It will be produced and blended at Phillips 66’s Humber Refinery in north-east England from waste cooking oils, and supplied to London airports via the existing pipeline infrastructure. The SAF is expected to reduce lifecycle emissions by over 80% compared to the traditional jet fuel it replaces. Phillips 66 has 13 refineries in the United States and Europe, with a global refining capacity of 2.2 million barrels of crude oil per day. It is transitioning to a low-carbon future and last year announced plans to convert its Rodeo refinery in California into the world’s largest renewable fuels plant. The Humber Refinery, which employs over 1,000 workers, started production of renewable diesel in 2018, becoming the first in the UK to convert waste oil into road fuel. In November 2020 it took delivery of a new processing unit to convert used cooking oil (UCO) into low-carbon fuel. The refinery is situated very close to the proposed Velocys facility that will convert municipal solid waste to jet fuel for British Airways.

The airline said the purchase agreement of 36,000 tonnes of SAF with Phillips 66 Limited, a wholly-owned UK subsidiary of Phillips 66, would reduce lifecycle emissions by almost 100,000 tonnes, the equivalent of powering 700 net zero CO2 emissions flights between London and New York on its Boeing 787 aircraft.

The Humber Refinery’s UCO module increased renewable diesel capacity this year to 3,000 barrels per day (BPD) from 1,000 BPD and the company plans to further expand capacity to 5,000 BPD by 2024.

Added a spokesperson for Phillips 66: “While the UCO module will be an important part of our SAF supply, we will also be producing SAF via other production pathways at the refinery.”

The refinery, which Phillips 66 says is one of the most complex in its portfolio and one of the most sophisticated in Europe, has a crude oil processing capacity of 221,000 BPD. It produces some 14 million litres of fuel per day, some of which is sold at its JET branded petrol stations and also jet fuel to airlines, as well as raw materials that can be transformed into a range of other products, including into essential components for electric vehicle batteries.

“The refinery was the first in the UK to co-process waste oils to produce renewable fuels and now we will be the first to produce SAF at scale, and we are delighted British Airways is our first UK customer,” said Humber Refinery General Manager Darren Cunningham. “We are currently refining almost half a million litres of sustainable waste feedstocks a day, and this agreement demonstrates our ability to supply them.”

The Humber Refinery is one of three investment partners in the Humber Zero project for large-scale decarbonisation in the immediate region and incorporates a cluster of local energy-intensive industries that make up more than 20% of the local economy and one in 10 jobs, and lie 1km from the North Sea coastline on the south bank of the River Humber. By 2030, Humber Zero aims to remove up to 8 MT/CO2 annually by integrating carbon capture and storage, alongside green and blue hydrogen production, into these existing, co-dependent industries. As well as decarbonising local industry, it is expected to provide hydrogen power for over one million local homes.

“This agreement with British Airways aligns with our strategy to create a refinery of the future, where we’re producing fuels from waste, being a critical part of the electric vehicle supply chain, reducing the carbon intensity of our processes through carbon capture and using hydrogen to power the refinery,” said Cunningham. “It secures long-term business in an ever-changing world.”

British Airways and Phillips 66 are members of the UK Department for Transport’s Jet Zero Council Delivery Group, with both supporting government plans for a future SAF blending mandate and a business model for investing in advanced waste-to-jet fuel projects.

“The UK has the resources and capabilities to be a global leader in the development of SAF and scaling up the production of SAF requires a truly collaborative approach between industry and government,” said British Airways Chief Executive Sean Doyle.

“We are excited to develop our relationship with Phillips 66 Limited further with a view to growing production capacity and using a wider range of sustainable waste feedstocks to supply our future flights. The development of SAF is a major focus for us and forms part of our commitment to achieving net zero carbon emissions by 2050 through a series of short, medium and long term initiatives.”

BA’s parent company IAG pledged two years ago to invest a total of $400 million on alternative sustainable fuel development over the following 20 years. Its Altalto Immingham project with Velocys aims to convert over 500,000 tonnes each year of non-recyclable household and commercial solid waste into sustainable aviation fuel, which would be supplied via the same pipeline as for the Phillips 66 fuel. According to an investor statement from Velocys last month, depending on progress of UK government policy and the project going ahead, commissioning and startup would commence in 2027, with full-scale commercial operation to follow that same year.

In February, British Airways announced it was to invest in SAF technology provider and SAF producer LanzaJet’s first commercial-scale Freedom Pines Fuels facility in Georgia, USA. The deal includes purchase of SAF to power a number of BA flights from the US from late 2022 and early-stage planning of a potential commercial-scale biorefinery in the UK. This would be produced using LanzaJet’s alcohol-to-jet process, which can use any source of sustainable ethanol, including, but not limited to, ethanol made from non-edible agricultural residues such as wheat straw and recycled pollution. LanzaJet, which is involved in three UK projects, and British Airways are also partnering with Nova Pangaea Technologies on ‘Project Speedbird’ to develop the first SAF facility in the UK to utilise woody residues from the UK, which aims to produce 100 million litres of SAF per year by 2025.

The purchase agreement with British Airways follows a Phillips 66 memorandum of understanding signing with Southwest Airlines in April this year “to advance the commercialisation of sustainable aviation fuel, focusing on public awareness and research and development.” The MoU also includes both sides exploring a future SAF supply agreement involving Phillips 66’s renewable fuels Rodeo Renewed project in California. The facility is expected to be capable of producing an initial 800 million gallons per year of renewable fuels and, subject to permits and approvals, could be completed in early 2024.

Photo: The Phillips 66 Humberside Refinery

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