A Comparative Analysis of Conventional Thermal and Electrochemical Reforming Pathways for Hydrogen Production Towards Sustainable Aviation Fuels (SAF)

Leandro Hostert; Naiza Vilas-Bôas; Julio R. Meneghini; Edson A. Ticianelli; Hamilton Varela

doi:10.1016/j.eng.2025.10.028

Engineering ›› DOI: 10.1016/j.eng.2025.10.028

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A Comparative Analysis of Conventional Thermal and Electrochemical Reforming Pathways for Hydrogen Production Towards Sustainable Aviation Fuels (SAF)

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Abstract

H₂ is increasingly recognized as a cornerstone of global decarbonization strategies, including in hard-to-abate sectors, such as aviation. Its large-scale applicability remains limited owing to the limited diversity and maturity of low-carbon production pathways. Approximately 96% of global $H_{2}$ production originates from non-renewable sources, primarily through steam methane reforming (SMR), which remains the most commercially established route. Another critical barrier to the substitution of conventional aviation fuels lies in hydrogen storage, as the current volumetric energy density and cryogenic storage requirements render onboard integration impractical for most aircraft configurations. To address these challenges, this study developed a techno-economic and environmental benchmarking framework that compares conventional thermal reforming technologies (SMR, autothermal, and POX) with emerging electrochemical routes (water electrolysis and alcohol electro-oxidation), highlighting their potential roles in the transition toward sustainable aviation fuels (SAF). By normalizing efficiency, energy intensity, $C O_{2}$ emissions, and cost (USD ${k g}^{- 1}$ $H_{2}$ and USD $\cdot G J^{- 1}$ ), this study quantifies the trade-offs that define current and emerging pathways. SMR remains the industrial baseline (70%–85% thermal efficiency, 1–2 USD·kg⁻¹ H₂, 9–12 kg CO₂·kg⁻¹ H₂), whereas ethanol-based electrochemical reforming operates 0.3–0.9 V below conventional electrolysis, achieving up to 40% lower electrical energy demand (∼2.4 kW·h·(Nm³)⁻¹ $H_{2})$ with near-zero direct emissions. A sensitivity analysis demonstrates that a 60% reduction in catalyst cost or electricity prices below 0.03 USD·(kW·h)⁻¹ could make electrochemical reforming cost-competitive with SMR. This study consolidates fragmented knowledge into a comprehensive roadmap that links catalyst performance and technology readiness for aviation decarbonization by integrating engineering metrics with policy and infrastructure perspectives to identify realistic transition pathways toward sustainable hydrogen and hybrid aviation fuels.

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Green hydrogen production / Electrochemical reforming / Sustainable aviation fuel (SAF)

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Leandro Hostert, Naiza Vilas-Bôas, Julio R. Meneghini, Edson A. Ticianelli, Hamilton Varela. A Comparative Analysis of Conventional Thermal and Electrochemical Reforming Pathways for Hydrogen Production Towards Sustainable Aviation Fuels (SAF). Engineering DOI:10.1016/j.eng.2025.10.028

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