The aviation industry accounts for roughly 2–3% of global CO₂ emissions, and sustainable aviation fuel (SAF) is widely seen as the most promising near-term solution to bring those numbers down. Now, a new catalyst technology from the United States could make SAF production significantly cheaper and more efficient — a development with important implications for the broader Power-to-X landscape.

A Single Step Instead of Many

In early April 2026, Gevo, a Colorado-based advanced biofuels company, announced that it had licensed two patented catalyst technologies from the U.S. Department of Energy’s Oak Ridge National Laboratory (ORNL) for use in sustainable aviation fuel production.

The key innovation: ORNL researchers have developed a catalyst that enables a single-step conversion of ethanol into olefins — the chemical building blocks needed to produce jet fuel. Traditionally, this transformation requires multiple processing stages, each adding cost and complexity. By collapsing those steps into one, the new technology promises to reduce both capital and operating expenses.

Why This Matters for Power-to-X

Power-to-X refers to a family of technologies that convert renewable electricity into storable fuels, chemicals, or other energy carriers. In the context of aviation, Power-to-X pathways — particularly Power-to-Liquid (PtL) — are essential for producing synthetic fuels that can replace fossil-based jet fuel without requiring changes to existing aircraft or airport infrastructure.

Ethanol, which can be produced from agricultural waste, cellulosic biomass, or even captured CO₂ combined with green hydrogen, serves as a versatile intermediate in several Power-to-X value chains. Making the conversion from ethanol to jet fuel more efficient directly strengthens the economic case for these pathways.

From Lab to Industrial Scale

Through the U.S. Department of Energy’s Technology Commercialization Fund, Gevo and ORNL have secured support for a three-year cooperative research and development agreement (CRADA). The goal is to advance the catalyst technology from laboratory scale to pilot-scale reactors and, ultimately, to industrial commercialization.

ORNL will also leverage its Center for Nanophase Materials Sciences to better understand how the catalyst performs in larger reactors — a critical step in ensuring the technology works reliably at commercial volumes.

Beyond Jet Fuel: Multiple Applications

The olefins produced through this process are not limited to aviation fuel. They can also be used to manufacture plastics, solvents, and surfactants — markets worth well over a trillion dollars globally. This versatility could help improve the business case for investing in the technology and provide additional revenue streams for Power-to-X producers.

The Bigger Picture: SAF Needs to Scale Fast

The International Air Transport Association (IATA), which represents more than 80% of global air traffic, considers SAF the most important lever for achieving net-zero emissions in aviation by 2050. According to IATA, SAF could contribute around 65% of the emissions reductions the industry needs.

However, scaling up SAF production remains a major challenge. A recent study published in Nature Communications found that by 2024, only about 24% of announced global SAF production capacity had actually been realized on schedule. Global demand for jet fuel is projected to reach approximately 230 billion gallons by 2050, underlining the urgency of cost-effective production technologies.

Breakthroughs like the ORNL/Gevo catalyst could play a pivotal role in closing this gap — especially when combined with other recent advances, such as Washington State University’s work on aromatic kerosene from vegetable oils, which could enable SAF to fully replace conventional jet fuel rather than just being blended with it.

What This Means for Switzerland and Europe

For the European Power-to-X sector, these developments provide both opportunity and competitive pressure. The EU’s ReFuelEU Aviation regulation, which entered into force in January 2025, mandates increasing shares of SAF at European airports. Technologies that can lower production costs will be critical for meeting these mandates without placing an excessive burden on airlines and passengers.

Switzerland, with its strong innovation ecosystem and SPIN driving collaboration between industry, research, and policy, is well positioned to benefit from — and contribute to — the global push for more efficient SAF production.

Sources: Oak Ridge National Laboratory / Newswise, April 6, 2026; BioEnergy Times, April 8, 2026; Nature Communications, November 2025