Professor Mohamed Pourkashanian recently spoke to Cirium, suppliers of aviation analytics, about the innovative SAF pathways we’re establishing at the EIC – particularly using the next-generation MCFC technology. You can read the full interview below:
The CO2 to SAF pathway winning over investors
In the crowded field of SAF innovation, every producer claims their pathway is the mostviable. But Professor Mohamed Pourkashanian, director of the Energy Innovation Centre(EIC) at the UK’s Sheffield University, believes his team’s approach stands apart for its practicality, cost-effectiveness, and investor appeal.
As an academic group looking at the area, including operating the UK’s only SAF clearing house, “we’ve seen all the different production routes,” he tells Cirium.
“Many companies, especially [small and medium-sized enterprises], come up with great ideas, but they don’t think about feedstock availability or supply chain logistics. You can’t have one solution globally – you need to tailor it to the infrastructure, policy, and economics of each location,” he explains.
Instead Pourkashanian makes a compelling case for a SAF production method that integrates carbon capture, hydrogen generation, and power production from one modular system.
Carbon capture twist
At the heart of the EIC’s SAF pathway is the molten carbonate fuel cell (MCFC), a technology that captures carbon dioxide from industrial emissions, and generates power and hydrogen at a relatively low cost. The captured gases – CO2, hydrogen, and carbon monoxide – are then fed into a Fischer-Tropsch reactor to produce liquid hydrocarbons,which can be refined into SAF.
“You’re not just capturing carbon,” Pourkashanian explains, which in itself is a necessary and costly process for industrial users. “You’re turning it into something valuable. For industries like glass or cement manufacturing, this means decarbonising their operations while producing a sellable product.”
The system’s flexibility is key. Companies can choose to benefit from subsidies for carbon capture, hydrogen production, or SAF – whichever suits their business model best. According to Pourkashanian, the integrated approach reduces SAF production costs by 20-25% compared to conventional methods.
Plug and play
Unlike some SAF technologies that remain theoretical, the EIC’s system uses commercially available components. MCFC units can be purchased from the USA, CO2 conversion electrolysers from Toshiba, which is a partner in the project and the Fischer-Tropsch reactor from a UK firm, he explains.
The goal is to offer industrial clients a plug-and-play solution. A glass manufacturer, for example, could install a compact unit on-site to capture emissions and produce hydrocarbons, which could then be sent to a refinery for SAF conversion or processed on-site if infrastructure allows. “The novelty is in the integration,” Pourkashanian says, with the intellectual property tied into bringing the technology together. “We’re using AI to optimise how these units worktogether, managing different response times and purity requirements.”
Attracting investors
The EIC is already producing 200 litres of SAF per day at its pilot facility. A full-scale demonstration plant is planned, while a commercial facility capable of producing 170 kilotonnes annually is slated to be built in North Tees, UK, where existing fuel infrastructure can support distribution. “We’re not just talking theory,” Pourkashanian says. “We’ve built it. Investors see that and their trust in the process increases.”
Pourkashanian notes that the model is attracting more investor interest than the university can currently manage. That’s because it’s not just a concept but a functioning system with real-world potential. “If you go to investors with an idea and a few millilitres of fuel, the risk is high,” he says, adding: “But when they see 200 litres a day, it’s a different story.” The project is also attracting interest from a wide range of stakeholders. UK power producer DRAX is exploring how to convert its biomass-derived CO2 into SAF, and Leeds Bradford airport is assessing on-site feasibility.
Aerospace majors Boeing and Airbus haveexpressed support, with Qatar Airways offering a letter of intent to purchase fuel once production scales. “They visited us, saw the setup, and said they’d negotiate once we reach demonstrationstage,” Pourkashanian explains. While SAF is often framed as a climate solution, Pourkashanian argues its role in energy security is equally vital. He points to the UK Ministry of Defence’s 2023 strategy on sustainable aviation fuel, which views domestic SAF production as a national security asset.
“Most airports rely on pipeline supply,” he says. “Producing SAF locally reduces dependence on fossil fuel imports and strengthens defence readiness.” With modularity, cost savings, and strategic flexibility baked into the design, Pourkashanian believes this SAF pathway could be the one that finally bridges the gap between innovationand industrial adoption.
