Synfuels

Definition

Synfuels are fuels that are synthetically produced using renewable energy from carbon dioxide (CO₂) and water or renewable raw materials. They replace conventional fossil fuels such as petrol, diesel or kerosene. A key technology for the sustainable synthesis of synfuels is sophisticated catalytic processes. 

Catalysis accelerates a chemical reaction with the help of specific substances – also known as catalysts – that are not consumed during the process. However, they reduce the pressure and temperature requirements of the reaction and thus lower its overall energy requirements. At the same time, the catalysts increase the yield of the products and minimise the formation of by-products. This enables industrial production with lower energy and resource consumption. 

Current applications and opportunities

Catalysis plays a key role in many industrial processes, for example in the production of fuels from fossil sources, in the synthesis of plastics, medicinal ingredients, edible oils or nitrogen fertilisers, and in the neutralisation of environmental toxins such as pollutants in vehicle exhaust gases. However, new catalytic processes also enable synfuels to be produced efficiently from renewable raw materials such as vegetable oils, pyrolysis oils, CO₂, sunlight and water. 

The technology for producing synthetic fuels from biomass already exists and is technically feasible. However, the supply of the necessary renewable raw materials is still insufficient and expensive. One possible alternative on a large scale is Fischer-Tropsch synthesis, in which synthesis gases are converted into synfuels or other high-quality chemicals in a catalytic polymerisation process. In order to obtain the desired products, more stable and highly selective catalysts must be developed. In addition, the synthesis gases used as feedstock are still predominantly produced by reforming methane from fossil fuels. A sustainable alternative is the production of synthesis gases by means of dry reforming or the use of exhaust gas methane. However, the catalysts used in these processes are still not stable enough. 

The catalytic conversion of CO₂ and hydrogen into methanol and other chemicals is becoming increasingly important. One challenge here is capturing and separating CO₂ and ensuring a sustainable supply of green hydrogen. In addition, new highly selective catalysts need to be developed that convert CO₂ not only into methanol, but into a wider range of high-quality chemical products. 

Synthetic fuels have the advantage that they can be seamlessly integrated into existing transport and storage infrastructures, facilitating the transition to sustainable mobility. This is particularly beneficial in sectors that are difficult to decarbonise, such as aviation and shipping. Synfuels offer a direct alternative to fossil fuels.  

Switzerland is at the forefront of catalysis research. But while the technology is already widely used in the pharmaceutical and biotech sectors, it is still insignificant in the production of synthetic fuels in Switzerland, despite a vibrant start-up ecosystem. However, with targeted support for catalysis, materials science and AI-driven, automated laboratory infrastructures, Switzerland can also assume a leading position in this field. 

Challenges

In the energy sector, catalysts have so far been used primarily for the production of products from fossil raw materials. These catalysts are often neither selective nor stable enough to convert renewable and complex feedstocks such as CO₂ or pyrolysis oils. The highly selective catalysts required for this purpose are usually still based on rare and expensive metals such as platinum, palladium or iridium. In order to reduce dependence on these limited resources, new catalysts ought to be developed based on abundant materials such as iron, cobalt or nickel. 

The conventional development of new catalysts in the laboratory was largely based on the labour- and resource-intensive principle of trial and error. Today, however, labs are increasingly making use of AI and automation: AI analyses complex data sets and suggests optimal test conditions, reducing the number of experiments and speeding up successful tests. Robot platforms also synthesise and test compounds around the clock with high reproducibility. Advanced analytical and computational tools are essential to understand the reaction mechanisms at the atomic level. The SwissCAT+ platform, which is funded by the ETH Domain, provides Swiss researchers with the resources and infrastructure needed to develop highly selective catalysts. 

In order to transfer the results achieved in the laboratory to industrial applications, scaling platforms tailored to start-ups and research institutions are needed. These are still lacking in Switzerland for catalysis research. However, building and continuously upgrading such platforms and state-of-the-art laboratories requires significant financial investment.  

Focus on industry

Companies that produce and use synfuels with advanced catalytic technologies are considered to be pioneers of the Green Deal. These processes not only reduce energy consumption and the costs of chemical production processes but also increase the yield and thereby offer significant competitive advantages in sustainable markets. 

However, the development of highly selective catalysts requires significant investment in modern research and production infrastructures and in the extraction or recycling of materials such as cobalt, nickel and platinum. In addition, the production of synthetic fuels depends on securing large quantities of renewable energy and raw materials – including biomass, CO₂ and hydrogen. 

And finally, companies rely on employees with in-depth expertise in chemistry, chemical engineering and material sciences, who are also well-versed in AI-assisted experiments, laboratory automation, programming, robotics and statistical data analysis. 

International perspective 

Switzerland has strong international networks, particularly in the field of research. Research groups from ETH Zurich and EPFL are part of European consortia such as Horizon Europe and international research networks. Numerous internationally oriented projects have also been launched as part of national initiatives such as the National Centre of Competence in Research “Sustainable chemical processes through catalyst design” (NCCR Catalysis for short) and the Swiss CAT+ platform, to advance the development of catalysts for sustainable fuels. 

Future applications

New catalysts will deliver a major boost to the efficient production of sustainable fuels and chemicals. Highly selective catalysts can be used to produce ethanol, aviation fuels and aromatic compounds from greenhouse gases. Energy-efficient catalysts enable the cost-effective production of sustainable ammonia, which can be used both as a fertiliser and for storing renewable energy. Electrocatalytic processes will play an increasingly important role in converting CO₂ into synfuels and other high-quality chemicals, as they offer even greater selectivity and energy efficiency. Finally, selective catalysts also convert pyrolysis oil from biomass or plastics into high-quality fuels and base chemicals. 

The further development of catalysis strengthens the chemical and pharmaceutical industry in Switzerland and enables more environmentally friendly production processes along the entire value chain. It contributes to Switzerland’s net-zero target for 2050 and boosts energy independence and overall economic performance. However, political awareness of the benefits of this technology still needs to be raised further. A global private or public investment fund could provide the necessary capital to drive research and subsequently scale up the corresponding facilities.