Sustainable Aviation
Recycling Plastic Waste for Sustainable Jet Fuel Additives

Recycling Plastic Waste for Sustainable Jet Fuel Additives
The aviation industry is one of the largest contributors to global carbon emissions, with traditional jet fuels accounting for a significant portion of greenhouse gas emissions. As the world moves toward sustainability, the need for eco-friendly alternatives has become paramount. One promising solution lies in the conversion of waste plastics, specifically polystyrene, into sustainable aviation fuel (SAF) additives. This innovative approach not only addresses the environmental impact of aviation but also tackles the growing problem of plastic waste.
Polystyrene, a common plastic used in packaging, disposable utensils, and insulation, is notoriously difficult to recycle. In the United States alone, approximately 2.5 million metric tons of polystyrene are produced annually, with most of it ending up in landfills. Researchers at the Illinois Sustainable Technology Center (ISTC) have developed a groundbreaking method to convert this waste into ethylbenzene, a key additive for sustainable aviation fuels. This breakthrough could revolutionize the aviation industry by providing a cost-effective and environmentally friendly alternative to fossil fuel-derived additives.
The significance of this development cannot be overstated. By repurposing waste polystyrene, the aviation industry can reduce its reliance on fossil fuels, lower carbon emissions, and contribute to a circular economy. This article explores the science behind this innovation, its potential impact, and the broader implications for sustainability in aviation and beyond.
The Science Behind Polystyrene-Derived Ethylbenzene
Conversion Process
The process of converting polystyrene into ethylbenzene involves two primary steps: thermal pyrolysis and hydrogenation. During pyrolysis, polystyrene is heated to high temperatures, breaking it down into a liquid rich in styrene. This liquid is then subjected to hydrogenation, a chemical reaction that converts styrene into crude ethylbenzene. Finally, distillation is used to purify the ethylbenzene, achieving a purity level of up to 90%.
This method is not only efficient but also cost-effective. Preliminary analyses suggest that producing ethylbenzene from polystyrene is cheaper than traditional methods that rely on crude oil. Additionally, the process reduces carbon emissions by 50% to 60% compared to fossil fuel-derived ethylbenzene, making it a more sustainable option.
“Planes will continue to burn fuel. To reduce carbon emissions associated with aviation fuel, sustainable aviation fuel is the only option. Landfill-bound waste plastic can be a source for sustainable aviation fuel.” – Hong Lu, Research Scientist at ISTC
Why Ethylbenzene Matters
Ethylbenzene is a critical component of sustainable aviation fuels due to its role as an aromatic hydrocarbon. Aromatic hydrocarbons are essential for maintaining the performance and safety of jet engines. They lubricate mechanical parts, prevent leaks by swelling seals, and ensure the fuel’s stability under varying conditions. Current sustainable aviation fuels contain only about 0.5% aromatic hydrocarbons, far below the 8.4% required by regulatory standards. The addition of ethylbenzene bridges this gap, enabling the use of higher proportions of sustainable fuels in aviation.
Moreover, ethylbenzene derived from polystyrene has a lower tendency to form soot upon combustion compared to other aromatic compounds. This characteristic makes it an ideal additive for reducing particulate emissions, further enhancing its environmental benefits.
Broader Implications for Sustainability
Aligning with Global Goals
The development of polystyrene-derived ethylbenzene aligns with global sustainability initiatives, such as the U.S. Department of Energy’s Sustainable Aviation Fuel Grand Challenge. This initiative aims to produce 3 billion gallons of sustainable aviation fuel annually by 2030 and meet 100% of projected domestic jet fuel demand by 2050. By providing a viable source of aromatic hydrocarbons, this innovation supports the aviation industry’s transition to renewable energy sources.
Beyond aviation, this research contributes to the broader goal of achieving a circular economy. By repurposing waste materials, it reduces the need for virgin resources and minimizes environmental pollution. This approach can inspire similar innovations in other industries, fostering a culture of sustainability and resource efficiency.
Economic and Environmental Benefits
The economic advantages of this method are significant. By utilizing waste polystyrene, the cost of producing ethylbenzene is reduced, making sustainable aviation fuels more accessible. Additionally, the reduction in carbon emissions contributes to climate change mitigation efforts, aligning with international agreements such as the Paris Accord.
From an environmental perspective, diverting polystyrene from landfills reduces plastic pollution and its associated hazards. This dual benefit—addressing both aviation emissions and plastic waste—makes this innovation a game-changer in the fight against climate change.
Conclusion
The conversion of waste polystyrene into sustainable aviation fuel additives represents a significant step forward in the quest for greener aviation. By addressing the dual challenges of plastic waste and carbon emissions, this innovation offers a practical and scalable solution for the aviation industry. The development of ethylbenzene from polystyrene not only meets regulatory requirements but also provides economic and environmental benefits, making it a cornerstone of sustainable aviation fuel production.
Looking ahead, further research and investment are needed to scale up production and refine the process. As the aviation industry continues to embrace sustainability, innovations like this will play a crucial role in shaping a cleaner, greener future. By turning waste into a valuable resource, we can pave the way for a more sustainable world.
FAQ
Question: What is ethylbenzene, and why is it important for sustainable aviation fuels?
Answer: Ethylbenzene is an aromatic hydrocarbon that improves the performance and safety of jet fuels. It is essential for meeting regulatory standards and enabling the use of higher proportions of sustainable aviation fuels.
Question: How does the conversion of polystyrene into ethylbenzene reduce carbon emissions?
Answer: The process reduces carbon emissions by 50% to 60% compared to traditional methods of producing ethylbenzene from crude oil. It also repurposes waste polystyrene, preventing it from ending up in landfills.
Question: What are the economic benefits of using polystyrene-derived ethylbenzene?
Answer: Producing ethylbenzene from polystyrene is cheaper than traditional methods, making sustainable aviation fuels more cost-effective. It also reduces the need for virgin resources, contributing to a circular economy.
Sources: Technology Networks, Bioengineer.org
Sustainable Aviation
American Airlines Completes First eSAF Commercial Flight
American Airlines and Infinium completed the first commercial passenger flight on electro sustainable aviation fuel on August 6, 2026.

On August 6, 2026, American Airlines and Infinium completed the first commercial passenger flight powered by electro sustainable aviation fuel (eSAF), marking the initial delivery of a non-biobased sustainable aviation fuel to a United States commercial airport. The flight operated from Corpus Christi International Airport (CRP) to Dallas Fort Worth International Airport (DFW).
In a joint press release issued on August 6, the companies confirmed that the eSAF was produced at Infinium’s Pathfinder facility in Corpus Christi, Texas. The operation demonstrates the real-world compatibility of next-generation, drop-in synthetic fuels with existing aviation supply chains and aircraft engines. The fuel was blended with conventional JetA aviation fuel and tested to meet ASTM International specifications, certifying its use without requiring modifications to current fueling infrastructure or aircraft.
Scaling synthetic fuel production
Infinium has been operating its Pathfinder facility since 2023, functioning as the first commercial-scale power-to-liquids eFuels production site globally. The facility utilizes waste carbon and renewable energy to produce scalable, drop-in synthetic fuels. According to Infinium, its eSAF can deliver an estimated reduction in lifecycle greenhouse gas (GHG) emissions of over 90 percent compared to conventional petroleum-based jet fuel.
“Since 2023, we have been producing scalable, drop-in eDiesel and eNaphtha at our Pathfinder facility from waste carbon and renewable energy for use in commercial trucks and plastics processing,” said Infinium CEO Robert Schuetzle in the press release.
American Airlines CEO Robert Isom emphasized the necessity of transitioning these technologies from the investment phase to operational reality. Isom stated that scaling sustainable aviation fuel (SAF) production at lower prices is essential for reducing emissions, strengthening long-term competitiveness, and maintaining the connectivity that passengers rely on.
Corporate partnerships and future offtake agreements
The August 6 flight serves as a precursor to larger commercial agreements between the two companies. American Airlines holds an existing offtake agreement for commercial volumes of eSAF from Infinium’s upcoming Project Roadrunner facility, which is currently under construction. Production and deliveries from Project Roadrunner are expected to begin in 2027.
The expansion of Infinium’s production capacity is supported by significant financial partnerships. Project Roadrunner is financed by Breakthrough Energy Catalyst and Brookfield Asset Management, with nonrecourse project debt provided by HSBC.
The American Airlines offtake agreement is partially supported by a separate arrangement with Citi, designed to enable Scope 3 emissions reductions from employee travel. Edward Skyler, Head of Enterprise Services and Public Affairs at Citi, noted that the first-of-its-kind flight represents a critical step for lower-carbon aviation, adding that the financial institution looks forward to efforts aimed at scaling SAF production.
AirPro News analysis
The successful deployment of eSAF on a commercial passenger flight represents a technical milestone for the aviation industry, which has historically relied on biobased feedstocks like used cooking oil or agricultural waste for SAF production. Because biobased feedstocks face inherent scalability and land-use constraints, power-to-liquid synthetic fuels offer a theoretically limitless production pathway, provided there is sufficient access to renewable electricity and captured carbon. We view the involvement of major financial institutions like Citi, Brookfield, and HSBC as a strong indicator that capital markets are beginning to validate the commercial viability of eFuels. The primary hurdle remains the unit cost of production. The transition from the Pathfinder facility’s initial output to the larger-scale Project Roadrunner in 2027 will be a critical test of whether eSAF can achieve the price parity necessary for widespread airline adoption.
Sources: American Airlines and Infinium
Photo Credit: American Airlines
Sustainable Aviation
KBR Selected for Asia’s First Ethanol-to-Jet SAF Plant in Singapore
KBR will provide PureSAF technology licensing and FEED services for a 100,000-ton/year SAF facility on Jurong Island, Singapore.

On June 29, 2026, KBR announced its selection by Keppel Ltd. and Aster Chemicals and Energy to provide technology licensing and Front-End Engineering Design (FEED) services for a proposed 100,000-ton-per-year SAF (SAF) facility on Jurong Island, Singapore.
The planned facility is envisioned as Asia’s first commercial-scale ethanol-to-jet (EtJ) SAF plant. According to the KBR press release, the project will utilize the company’s PureSAF technology to produce a 100% drop-in jet fuel, supporting Singapore’s national mandate to increase sustainability usage across the aviation sector.
PureSAF technology and project scope
The Jurong Island facility will leverage PureSAF, a technology originally developed by Swedish Biofuels AB and engineered for commercial-scale production by KBR, which holds the exclusive global license. The process is designed to convert ethanol into aviation fuel that requires no blending with conventional Jet A or Jet A-1 before use.
In a statement accompanying the announcement, KBR President and CEO Stuart Bradie highlighted the system’s flexibility.
“KBR’s PureSAF is a feedstock-flexible, bankable technology that is designed to deliver a 100% drop in jet fuel, ready to power aircraft without blending. We are constantly innovating our SAF solution to make it compatible with feedstock availability in different regions and to enable the aviation industry to transition to low-carbon jet fuel with a cost-optimized approach.”
The FEED study will determine the technical configuration and project capital expenditure required for the facility. The development remains subject to regulatory approvals and a final investment decision (FID) by the project partners.
Aligning with Singapore’s aviation mandates
The selection of KBR follows a January 28, 2026, agreement between Keppel’s Infrastructure Division and Aster to jointly assess the development of the Jurong Island site. Aster operates as a joint venture between Indonesian petrochemical company Chandra Asri and Swiss commodities trader Glencore.
The proposed 100,000-ton annual production capacity aligns directly with targets set by the Civil Aviation Authority of Singapore (CAAS). Starting in 2026, the CAAS mandates a 1% SAF uplift for all departing flights from the country, with a stated goal of increasing that requirement to between 3% and 5% by 2030.
Alongside the SAF plant contract, KBR and Keppel signed a Memorandum of Intent to collaborate on broader energy transition initiatives. The companies plan to explore technologies related to waste-to-energy, plastic recycling, biofuels, and artificial intelligence-driven digitalization.
AirPro News analysis
We view the progression of the Jurong Island project to the FEED stage as a critical indicator of the Asia-Pacific region’s readiness to scale SAF production. While North America and Europe have led early SAF capacity investments, Singapore’s firm regulatory mandate provides the demand certainty required to underwrite commercial-scale facilities in Southeast Asia. The choice of an ethanol-to-jet pathway is particularly notable, as it allows operators to bypass the constrained supply of fats, oils, and greases that limit hydroprocessed esters and fatty acids (HEFA) production volumes. The project’s ultimate realization hinges on the upcoming final investment decision, which will test the commercial viability of the EtJ process in the current economic environment.
Sources: KBR
Photo Credit: KBR
Sustainable Aviation
NGO Coalition Pushes EU to End Aviation ETS Exemption
The SASHA Coalition urges the EU to end its ETS exemption for international flights ahead of the July 2026 legislative review.

A coalition of environmental and industry non-governmental organizations is urging the European Commission to end the European Union Emissions Trading System exemption for international flights, a move proponents estimate could generate €130 billion in carbon market revenues between 2027 and 2035.
In a campaign coordinated by the SASHA Coalition, groups including Opportunity Green, Transport & Environment, and Carbon Market Watch are targeting the upcoming legislative revision of the European Union Emissions Trading System (EU ETS) scheduled for July 2026. The coalition argues that integrating extra-EEA flights into the carbon pricing mechanism is necessary to fund clean aviation technologies, specifically electro-Sustainable Aviation Fuel (eSAF) and Direct Air Capture (DAC) infrastructure.
The financial and environmental cost of the exemption
The European Union initially included aviation in the ETS on January 1, 2012, but introduced a stop-the-clock mechanism exempting extra-EEA flights following international pressure. According to a policy briefing from the SASHA Coalition, this exemption left an estimated 1.1 billion tonnes of carbon dioxide emissions unregulated between 2012 and 2023. The coalition calculates this resulted in €26 billion in uncollected carbon market revenues during that period.
If the exemption is maintained after its scheduled expiration in 2027, the coalition projects that 1.3 billion tonnes of carbon dioxide emissions will go unregulated through 2035. A full-scope ETS could generate an estimated €14 billion in annual revenue for European Union member states by 2030.
Industry perspectives on carbon pricing and CORSIA
The debate centers on the effectiveness of the United Nations Carbon Offsetting and Reduction Scheme for International Aviation (CORSIA). The European Commission is required to assess by mid-2026 whether CORSIA delivers sufficient environmental ambition. Environmental groups argue the UN scheme is structurally unfit because it relies on offsetting rather than absolute emissions reduction and targets only emissions above a high baseline. Conversely, Airlines and industry groups have historically opposed extending the EU ETS to international flights, citing concerns over market distortions, potential violations of international law, and competitive disadvantages for European hubs.
Clean technology providers argue that a strong regulatory framework is required to drive investment. During a June 9, 2026 roundtable event at the European Parliament convened by the SASHA Coalition, NEG8 Carbon Head of Business Development Dr. David Mulrooney emphasized the necessity of the ETS for commercial strategy.
“To answer your question directly: the EU ETS is foundational to our commercial strategy. NEG8 supplies atmospheric CO2 capture. The stronger and more consistent the carbon price signal, the stronger the investment case for the infrastructure we sell into. ETS is not a policy backdrop for us. It is the market mechanism our business is built on,” Mulrooney stated.
Mulrooney advocated for directing ETS revenue into DAC and eSAF to drive down costs, similar to historical cost curves for solar power and batteries. Member of the European Parliament Cynthia Nà Mhurchú also spoke at the event, noting that regulatory certainty is critical for future planning.
AirPro News analysis
The July 2026 review of the EU ETS represents a critical juncture for European aviation policy. We observe that the European Commission is caught between two competing pressures: the mandate to meet aggressive decarbonization targets and the risk of triggering international trade disputes if it unilaterally prices emissions on extra-EEA flights. The SASHA Coalition focus on revenue generation for eSAF and DAC is a strategic pivot, framing the ETS not just as a punitive tax but as a necessary funding mechanism for the aviation industry transition. Overcoming airline opposition to overlapping carbon pricing regimes will require the Commission to clearly articulate how the EU ETS and CORSIA can coexist without creating prohibitive administrative and financial burdens for operators.
Sources: SASHA Coalition
Photo Credit: SASHA Coalition
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