Researchers at KAUST, working with Aramco, have achieved a major milestone in the push for cleaner aviation: a system that converts captured CO₂ into jet‑fuel‑range hydrocarbons with the highest efficiency reported to date. Around 75% of the liquid output falls directly within the range needed for aviation fuel .
The team used machine‑learning optimisation to identify an unconventional copper‑rich catalyst that outperformed traditional formulations, producing the heavier, energy‑dense molecules required for long‑haul flight rather than lighter by‑products . Crucially, the catalyst ran for more than 1,000 hours without interruption, a key requirement for real‑world use .
After upgrading through hydrogenation and distillation, the resulting fuel passed early ASTM D4054 prescreening tests, including flash point, volatility and energy content, indicating it could one day meet full aviation certification standards .
Why it matters for travel
Aviation is one of the hardest sectors to decarbonise because long‑haul aircraft still rely on dense liquid fuels. Current sustainable aviation fuel (SAF) supply is limited and depends heavily on waste oils and biomass, which cannot scale fast enough to meet global demand .
CO₂‑derived fuel components could:
- expand future SAF supply,
- reduce lifecycle emissions by using captured carbon, and
- support long‑haul decarbonisation without changing aircraft or infrastructure.
Commercial use is still years away and will require scale‑up, cost analysis and full certification . But the breakthrough sets a new benchmark and offers a promising pathway for powering future flights with recycled carbon rather than fossil fuels.
