Siemens and CAPHENIA Partner to Accelerate SAF Production Scale-Up

Industrial technology firm Siemens has entered into a strategic partnership with cleantech company CAPHENIA to accelerate the industrial-scale production of Sustainable Aviation Fuel (SAF). The collaboration will see Siemens provide its extensive portfolio of digitalization and automation technologies to optimize CAPHENIA's innovative synthesis gas production process, a critical step in creating synthetic fuels.

This partnership addresses one of the aviation industry's most significant challenges: the limited supply and high cost of SAF. By leveraging industrial automation, the companies aim to create a scalable and economically viable pathway for producing high-quality synthetic fuels from bio-methane and other renewable feedstocks. The successful scale-up of this technology could play a crucial role in helping the aviation sector meet its ambitious decarbonization targets.

The Technology Behind the Partnership

At the core of the collaboration is CAPHENIA’s proprietary plasma technology. The process involves converting bio-methane, renewable electricity, and carbon dioxide into a high-purity synthesis gas (syngas). This syngas, a mixture of hydrogen and carbon monoxide, serves as a versatile intermediate feedstock that can be further processed into various sustainable fuels, including e-Kerosene, which is chemically equivalent to conventional jet fuel.

CAPHENIA's method is designed to be highly efficient and modular, allowing for decentralized production facilities. However, transitioning from a successful pilot stage to large-scale industrial manufacturing requires precise process control, operational efficiency, and robust safety systems. This is where Siemens' expertise becomes essential.

Siemens will contribute its comprehensive Digital Enterprise portfolio, which includes solutions for process simulation, automation, and operational management. Key components include the Simatic PCS neo process control system, which allows for fully web-based plant management, and advanced simulation software that enables the creation of a "digital twin." This digital replica of the production plant allows for virtual testing, optimization, and operator training before the physical facility is even built, significantly reducing commissioning times and potential risks.

Strategic Implications for SAF Production

The aviation industry is under immense pressure to reduce its carbon footprint, with SAF widely regarded as the most viable near-to-mid-term solution for decarbonizing air travel. However, current global SAF production accounts for less than 1% of total jet fuel consumption. The primary obstacles to wider adoption are the lack of production capacity and the price premium over conventional kerosene.

Partnerships like the one between Siemens and CAPHENIA are critical for overcoming these hurdles. By applying proven industrial automation and digitalization techniques to novel fuel production methods, the collaboration aims to streamline manufacturing, improve yields, and ultimately lower the cost per gallon of SAF. This industrialization is a necessary step to move SAF from a niche product to a mainstream commodity.

For Siemens, this partnership reinforces its position as a key technology provider for the green transition, extending its expertise in industrial processes to the burgeoning sustainable fuels market. For CAPHENIA, access to Siemens' global reach and technological suite provides a clear pathway to commercialization and helps de-risk the complex process of scaling up its innovative technology.

Future Outlook

The immediate focus of the partnership will be on optimizing the design and engineering of CAPHENIA's first commercial-scale production plants. Using Siemens' digital twin technology, the companies will simulate and refine the entire process chain, from feedstock intake to syngas output, ensuring maximum efficiency and reliability.

Following the digital design phase, Siemens' automation hardware and software will be integrated into the physical plants. This includes instrumentation for monitoring and control, electrification infrastructure, and advanced software for process analytics and predictive maintenance. The goal is to create highly automated facilities that can operate continuously with minimal human intervention, ensuring consistent quality and high output.

While specific timelines for the first commercial plant were not disclosed, the partnership signals a clear intent to move rapidly from development to deployment. The success of this collaboration will be measured by its ability to deliver a replicable, scalable blueprint for SAF production that can be deployed globally.

Why This Matters

This partnership represents a critical convergence of innovative chemistry and industrial technology. By combining CAPHENIA’s novel plasma process with Siemens’ proven automation and digitalization platforms, the collaboration directly tackles the industrialization gap that has hindered widespread SAF adoption. The outcome could provide a scalable model for producing cost-competitive SAF, a vital component for the aviation industry's pursuit of net-zero emissions.

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