Synthetic fuels for renewable energy generators

Confirmed top 3 late-stage and top 3 early-stage partners that are developing cost-effective scalable Power-to-X methods.

The client has setup partnerships with the 3 suggested early-stage groups and has launched a pilot with one of the late-stage companies.

Provided clarity on which chemical pathways are scalable to the industrial level, ensuring the $5 million investment is wisely spent.

What is Power-to-X?

Power-to-X refers to a range of technologies that convert electricity into other forms of energy or materials, ideally from renewable sources. This includes Power-to-Gas (e.g. hydrogen, methane), Power-to-Liquids (e.g. synthetic fuels like methanol or ammonia), and Power-to-Chemicals (e.g. feedstocks for industry). These processes enable the storage, transport, and industrial use of renewable electricity.

• Power-to-Hydrogen (PtH₂): Converts renewable electricity and water into hydrogen via electrolysis. Hydrogen is a versatile energy carrier. It can be used directly as fuel, in fuel cells, or as a feedstock in industrial processes. It’s foundational to many other Power-to-X routes, including ammonia and methanol synthesis.
• Power-to-Ammonia (PtNH₃): Combines green hydrogen with nitrogen (from air) to produce ammonia via the Haber-Bosch process. Ammonia is easier to transport and store than hydrogen, making it a practical hydrogen carrier. It can be used directly as a carbon-free fuel in shipping and power generation, and as a fertiliser in agriculture.

• Power-to-Methanol (PtMeOH): Synthesising methanol by combining green hydrogen with captured CO₂. Methanol is a key chemical feedstock and a liquid fuel. It allows for direct CO₂ recycling, creating a carbon-neutral fuel that fits into existing infrastructure, including for maritime transport and chemical manufacturing.

• Power-to-Liquid Fuels (PtL): Produces synthetic hydrocarbons (e.g. diesel, kerosene) using hydrogen and captured CO₂ via Fischer-Tropsch or similar processes. These fuels are drop-in replacements for fossil-based jet fuel and diesel, making them vital for decarbonising aviation and long-haul transport where battery solutions are impractical.

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Why is Power-to-X important?

As economies accelerate toward net-zero targets, sectors that are hard to electrify—like aviation, shipping, and heavy industry—remain major emitters. Power-to-X (PtX) technologies offer a pathway to decarbonise these sectors by converting renewable electricity into energy carriers such as hydrogen, synthetic fuels, and ammonia. This flexibility is increasingly seen as essential for system-wide decarbonisation.

• Enables indirect electrification: Power-to-X extends the reach of renewables into sectors where direct electrification is not feasible, allowing for lower emissions without redesigning entire energy systems.
• Converts surplus renewable energy into usable fuels: PtX technologies help balance the grid by storing excess electricity as synthetic fuels, which can be deployed on demand.

• Supports decarbonisation of heavy transport and industry: Sectors such as steelmaking, maritime transport, and long-haul aviation can use PtX-derived fuels to reduce emissions without relying solely on batteries.

• Utilises existing infrastructure: Many PtX fuels, including e-methanol and e-kerosene, can be integrated into current storage, distribution, and engine systems, accelerating adoption.

• Aligns with growing policy and regulatory support: National hydrogen strategies and international climate agreements are increasingly prioritising PtX solutions, creating favourable conditions for investment and deployment.

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What opportunities does Power-to-X enable?

As global decarbonisation targets intensify, Power-to-X (PtX) technologies are set to become central to the energy transition. Over the next decade, PtX will unlock high-value opportunities across sectors by enabling the large-scale conversion of renewable electricity into green fuels, chemicals, and feedstocks.

• Expansion of green fuel markets: PtX will support the growth of global markets for hydrogen, e-methanol, e-kerosene, and ammonia, which are projected to exceed $300 billion by 2035.
• New infrastructure and services: Widespread deployment will create demand for electrolysers, modular reactors, CO₂ capture systems, and fuel blending logistics, especially in regions with abundant renewables.

• Decarbonisation of global trade and transport: PtX fuels will be crucial for enabling net-zero supply chains across shipping, aviation, and heavy industry, positioning early movers to dominate clean export markets.

• Acceleration of industrial innovation: PtX will drive R&D in next-generation catalysis, flexible process engineering, and high-efficiency conversion systems that can scale up production while managing variable power inputs.

• Regulatory and financial advantages: Companies investing early in PtX will benefit from tightening emissions regulations, cross-border carbon pricing, and green industrial subsidies, gaining both compliance and competitive advantage.

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What technologies are driving the advancements in Power-to-X?

The Power-to-X shift is powered by advances in electrolysis (for green hydrogen), catalytic conversion systems (to synthesise fuels like methanol and ammonia), carbon capture technologies, and modular reactor designs. Improvements in system efficiency, material durability under dynamic load, and the ability to scale down for localised production are also accelerating adoption.

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Core Conversion Technologies

These are the foundational systems that enable Power-to-X transformations:

• Electrolysers (for green hydrogen production):
• PEM (Proton Exchange Membrane) – high purity, fast response to variable loads
• Alkaline – mature, lower cost but less dynamic
• Solid Oxide Electrolyser Cells (SOECs) – high efficiency, suitable for integration with industrial heat
• Haber-Bosch synthesis (for ammonia):
• Conventional with green H₂ input; emerging interest in modular/micro-scale Haber-Bosch systems
• Methanol synthesis reactors :
• Catalytic CO₂ hydrogenation systems using copper or zeolite-based catalysts
• Fischer-Tropsch synthesis (for Power-to-Liquids):
• Converts syngas (H₂ + CO) into hydrocarbons; often used in combination with gasification or reforming units

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Catalysis and Process Optimisation

Technologies that enable higher efficiency and selectivity in chemical reactions:

• Advanced catalysts for ammonia, methanol, and hydrocarbon production
• Modular micro-reactors for distributed or off-grid fuel synthesis

• Dynamic catalysis systems that perform well under intermittent renewable energy input

• AI-enhanced process control to optimise energy usage and output yield

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Carbon Capture and Utilisation (CCU)

Essential for turning CO₂ into a feedstock:

• Direct Air Capture (DAC) – capturing atmospheric CO₂ for methanol or synthetic fuel production
• Point-source CO₂ capture – from industrial plants, to feed into synthesis pathways

• CO₂ conditioning and purification units – necessary for catalyst compatibility and synthesis quality

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System Integration & Flexibility Tools

Technologies that support operation under variable loads and grid integration:

• Hybrid energy management systems – for balancing input from solar, wind, and grid
• Thermal and electrical energy storage – e.g. molten salt, batteries, supercapacitors

• Dynamic load-following in electrolyser systems – ensures efficient operation with intermittent power

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Monitoring, Control & Digital Tools

These support scale-up, safety, and efficiency:

• IoT and sensor networks – for monitoring pressure, temperature, and catalyst health
• Digital twins and simulations – for modelling PtX plant operations and cost projections

• Machine learning for predictive maintenance and yield optimisation

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Balance-of-Plant & Infrastructure

Supporting systems that ensure deployment viability:

• Gas purification units – critical for both hydrogen and CO₂
• Compression, liquefaction, and storage systems – particularly for hydrogen and ammonia

• Retrofitting existing transport infrastructure – pipelines, bunkering systems, etc., for new fuels