Mitsubishi Heavy Industries (MHI) has completed a pilot demonstration of an integrated production route for liquid synthetic fuel, combining co-electrolysis of CO2 and steam with downstream fuel synthesis.
The trial, carried out at the company’s research center in Nagasaki, produced liquid hydrocarbons with properties suitable for use in sustainable aviation fuel (SAF), underscoring growing industrial momentum behind e-fuels as a long-term decarbonization option for aviation.
The process converts CO2, water and electricity into syngas (a blend of hydrogen and carbon monoxide) which is then upgraded into liquid fuels through Fischer-Tropsch synthesis.
By integrating the two stages into a single production chain, MHI aims to demonstrate a pathway that could eventually be scaled for commercial SAF production, provided low-carbon power and concentrated CO2 streams are available.
From Lab-Scale Integration to Industrial Ambition
At the core of the system is solid oxide electrolysis cell (SOEC) technology that performs co-electrolysis of steam and carbon dioxide in one step. MHI is developing a proprietary tubular SOEC stack designed to increase efficiency while simplifying plant configuration, a factor the company says could help narrow the cost gap between synthetic fuels and fossil-based alternatives.
The demonstration aligns with the aviation sector’s long-term climate trajectory set by the International Civil Aviation Organization (ICAO), which targets net-zero emissions from international aviation by mid-century.
Under current scenarios, SAF and other low-carbon fuels are expected to deliver the majority of emissions reductions, driving demand for scalable production technologies beyond conventional bio-based routes.
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Beyond aviation, the syngas produced through SOEC co-electrolysis could be directed into a wider portfolio of carbon-neutral fuels, including synthetic diesel, gasoline, methanol and methane for maritime transport, road mobility and gas networks.
That flexibility positions the technology as a potential platform for multiple hard-to-abate sectors, rather than a single-use SAF solution.
While commercial deployment remains dependent on cost reductions, renewable power availability and CO2 sourcing, MHI says the pilot has helped de-risk the technical integration of electrolysis and fuel synthesis. The company plans to build on the results to accelerate development of modular, high-efficiency e-fuel systems that could support industrial decarbonization strategies in the 2030s and beyond.
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