Green Hydrogen-driven Synthetic Aviation Fuel Demonstration Plant Debuts at PSI

When you think of jet fuel, it’s easy to picture crude oil as the go-to source. But let me tell you, things are changing over at the Paul Scherrer Institute in Villigen, Switzerland. There’s a new player in town—the aerobrew demonstration plant. Thanks to support from Metafuels AG and the Swiss Federal Office of Energy, this facility is now cranking out synthetic kerosene made from green methanol, hydrogen, and captured CO₂. Sure, it’s starting small with an output of just 50 liters a day, but this plant marks a significant milestone in creating a seamless methanol-to-jet integration all under one roof, bringing us closer to commercial-scale e-SAF (sustainable aviation fuel).

Aerobrew Moves Beyond the Bench

Founded back in 2021 by Saurabh Kapoor, Leigh Hackett, and Ulrich Koss, Metafuels teamed up with PSI in 2023 to put their proprietary methanol-to-jet process, known as “aerobrew,” to the test. After going through a pilot phase with some seed funding, they landed a cool $9 million in 2024, plus a 4.4 million CHF grant to set up their pilot plant at PSI. And it doesn’t stop there; they secured a whopping $24 million Series A round led by UVC Partners, which helped build a three-story demo hall where all the magic happens—everything from conversion to upgrading and fractionation—all seamlessly working together.

Integrated Methanol-to-Jet under One Roof

Most Power-to-Liquid test facilities require various modules located in separate buildings for things like methanol synthesis and fuel upgrading. But in Villigen, the aerobrew plant is breaking that mold by bringing all those steps together in one spot. This approach not only cuts down on logistical headaches but also allows researchers to keep an eye on things like heat flows and reaction efficiencies in real-time. According to the folks working on this project, this kind of integration is a game changer for methanol-to-jet e-SAF.

How the Aerobrew Process Works

So, how does this aerobrew process actually work? Well, renewable electricity powers electrolysers that split water into green hydrogen and oxygen. The CO₂ captured—either from the air directly or through biogenic sources—feeds a reverse water-gas shift reactor, which creates a syngas that gets transformed into green methanol. The real highlight here is when that methanol flows through reactors that stitch together one-carbon units into longer hydrocarbon chains. After some additional hydro-isomerisation and fractionation, the end product meets aviation fuel standards, giving us a drop-in e-SAF that can seamlessly blend with conventional Jet A-1 fuel.

Swiss Policy and Industry Momentum

Switzerland isn’t just sitting on the sidelines; they’ve aligned with Europe’s ReFuelEU Aviation framework, kicking in some SAF blend mandates at Zurich and Geneva airports starting in early 2026. And with synthetic fuel mandates coming into play from 2030, they’re paving the way for more Power-to-Liquid pathways like aerobrew. On the airline side, Swiss International Air Lines and the Lufthansa Group have already struck deals with Metafuels to look into long-term e-SAF procurement. With traditional bio-SAF sources being limited, e-SAF from green hydrogen is looking like a smart move to hit those tightening decarbonization targets.

Environmental and Lifecycle Insights

One of the biggest draws of hydrogen-based e-SAF is its impressive lifecycle emissions profile. Metafuels, along with independent assessments, suggests that this new approach can lead to a reduction of greenhouse gas emissions by 70-90% compared to fossil kerosene, particularly when powered by low-carbon electricity and sustainable CO₂. To track all this, PSI’s Technology Assessment group is diving deep into lifecycle studies right on site, verifying energy inputs, carbon balances, and any potential environmental trade-offs. This real-world data is crucial for refining Switzerland’s roadmaps towards achieving carbon-neutral aviation by mid-century.

De-risking the Scale-Up

Now, 50 liters a day might not sound like much, but every drop counts when it comes to gathering insights on catalyst longevity, energy integration, and maintenance needs. This small-scale output allows operators to test continuous runs, pinpoint fouling issues, and optimize energy recovery—all of which feed directly into the architecture for future commercial plants. And guess what? Metafuels is already on the fast track to developing their first commercial e-SAF facility in Rotterdam, aiming for initial production in the lower five-digit liters per day, with plans to ramp it up from there.

Financing the Path to Commercial Scale

Getting Power-to-Liquid projects off the ground isn’t cheap, so a solid mix of public and private funding is key. Metafuels’ journey from seed funding to federal grants and a successful Series A round showcases how investors, industry partners, and energy agencies can share in the risks. Plus, with backing from the Netherlands Enterprise Agency (RVO), the proposed Turbe facility at the Port of Rotterdam serves as a great example of how cross-border partnerships can help ramp up green hydrogen-derived e-SAF.

What’s on the Horizon

Looking ahead, PSI’s demonstration plant is set to undergo a series of performance trials, catalyst screenings, and lifecycle validations over the next year. The findings from these tests will help shape everything from feedstock sourcing to energy optimization and design plans for larger facilities. As Metafuels secures offtake agreements with airlines and establishes low-carbon grid connections, Villigen is primed to serve as a blueprint for future Power-to-Liquid installations, setting the stage for green hydrogen and synthetic aviation fuel to make a real impact in the global jet fuel market.