Efficient conversion of syngas into sustainable aviation fuel

Fischer−Tropsch synthesis to paraffinic kerosene is a crucial pathway to obtain sustainable aviation fuel (SAF), but a more efficient catalyst is needed for practical applications. Here, we report a cobalt-manganese catalyst supported on tetrapropylammonium hydroxide-etched Beta zeolites that breaks the long-standing activity-selectivity trade-off. The obtained catalyst achieves 82.8% CO conversion and 67.5% C8−16 selectivity, yielding a high productivity. It also exhibits remarkable stability and strong tolerance to CO2-rich feeds, thus enabling it to process real-world syngas feedstocks. The observed Co0−isolated Mnδ+ dual-site configuration identified by operando spectroscopies, along with the support’s hierarchical porosity and moderate acidity, is responsible for the highly efficient synthesis of jet fuel. In our pilot-scale test, the shaped pellet catalyst delivers a productivity of 5.154 g gCo−1 h−1 with 78.9% C8−16 hydrocarbons in liquid products. Excellent performance in industrial test and techno-economic analysis further demonstrates the strong potential of this catalyst for scalable production of SAF. Fischer−Tropsch synthesis to paraffinic kerosene is a crucial pathway to obtain sustainable aviation fuel, but a more efficient catalyst is needed for practical applications. Here, the authors report a cobalt manganese catalyst supported on tetrapropylammonium hydroxide-etched Beta zeolites that addresses the long-standing activity-selectivity trade-off.