Enabling sustainable aviation fuels through Power-to-X
Turning renewable electricity into scalable low-carbon fuels
Airborn Fuels Switzerland AG is developing a Power-to-e-Methanol project in Sisslerfeld, Switzerland, as a foundation for future production of sustainable aviation fuel (SAF).
The feasibility study, carried out by AFRY, supports the development of scalable solutions that convert renewable electricity and captured CO2 into low-carbon fuels for hard-to-abate sectors.
Project facts
Project name
Sisslerfeld Power-to-e-Methanol
Client:
Airborn Fuels Switzerland AG
Location:
Sisslerfeld, Canton Aargau, Switzerland
Project type:
Feasibility study
Core technologies:
Power-to-X, green hydrogen, e-Methanol
Objective:
Assess technical and commercial viability of e-Methanol production as a pathway to sustainable aviation fuels
Developing Power-to-X solutions to support the energy transition
The transition to climate-neutral energy systems requires scalable alternatives to fossil fuels, particularly in sectors where direct electrification is not feasible. Power-to-X technologies enable this shift by converting renewable electricity into energy carriers such as hydrogen and e-fuels.
In this project, renewable electricity is transformed into green hydrogen and further processed with captured CO2 to produce e-Methanol - a versatile, low-carbon fuel and chemical building block that can be stored, transported, and used across industries.
Creating a pathway from e-Methanol to sustainable aviation fuel
E‑methanol plays a key role in enabling sustainable aviation fuel production. It serves as an intermediate product in Power-to-Liquid processes, where renewable hydrogen and CO2 are converted into synthetic jet fuel.
This pathway offers significant potential to reduce lifecycle emissions in aviation while supporting fuel diversification and energy security. When produced from renewable electricity and non-fossil CO2, e-based SAF represents a near zero-carbon solution.
Reducing project risk through a phased development strategy
To address market and technology uncertainties, the project follows a staged approach:
- Phase 1: Deployment of a Power-to-Methanol (P2M) facility
- Phase 2: Development of methanol-to-SAF pilot
- Phase 3: Demonstration and scaling of SAF production
- Phase 4: Global roll-out through licensing of proven technology
This strategy ensures early commercial viability by leveraging the established global market for methanol, while keeping flexibility to scale SAF production as technologies mature and demand increases.
Strengthening local industry and energy resilience in Switzerland
The Sisslerfeld site in Canton Aargau is being developed as a strategic industrial hub. The project contributes to regional and national objectives by:
- Supporting decarbonization of industry through green fuels
- Reducing dependence on imported fossil energy
- Enabling sector-coupling across power, fuels, and industry
- Increasing the attractiveness of the site for high-value industries
Access to biogenic CO2 sources further enhances the sustainability of the project, enabling circular carbon use and supporting climate targets.
Delivering feasibility through integrated technical and commercial analysis
AFRY supports Airborn Fuels Switzerland AG with a comprehensive feasibility study that provides a robust basis for investment decisions. The scope includes:
- Definition of technical parameters and design assumptions
- Evaluation of site and infrastructure requirements
- Assessment of technology options and partners
- Conceptual design of the e-Methanol plant
- Cost estimation and business case development
This structured approach ensures that both engineering feasibility and commercial viability are addressed in a consistent and transparent way.
Navigating the SAF ecosystem
Building the foundation for future low-carbon aviation fuels
Methanol-based pathways to sustainable aviation fuel are advancing rapidly but are still at pilot and demonstration stage. Key industry players are progressing technologies towards certification and commercial scale.
By establishing a Power-to-e-Methanol plant today, the project creates a flexible platform that can adapt to future SAF market developments, enabling a gradual scale-up of low-carbon aviation fuels.
Power-to-X solutions such as e-Methanol and SAF are essential for enabling the energy transition in sectors where emissions are hardest to reduce, like within aviation. By combining engineering expertise with strategic insight, we support our clients in turning emerging technologies into viable, scalable solutions.
Amartya Mukherjee, Project Manager for PtX Projects, Thermal and Renewable Power at AFRY.
Did you know?
- Power-to-X enables long-term energy storage by converting renewable electricity into fuels and chemicals.
- E‑methanol is already traded globally and used across industries, making it a strong entry point for large-scale e-fuels.
- Sustainable aviation fuel can reduce lifecycle emissions while using existing fuel infrastructure.
