UK start-up develops hydrogen-based synthetic fuel designed to replicate Jet A-1

British start-up Zero Petroleum says it has successfully developed and validated a synthetic aviation fuel made using green hydrogen and carbon dioxide that it claims is a “100% replica” of standard aviation fuel Jet A-1.

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The Oxford-based company said its latest development represents a step towards producing a synthetic sustainable aviation fuel (e-SAF) that could be used as a direct alternative to conventional aviation fuel, without requiring changes to aircraft engines or fuel infrastructure.

Zero’s process uses renewable hydrogen and captured carbon dioxide to manufacture hydrocarbons. Unlike many current SAF pathways, which use biological feedstocks such as used cooking oil or animal fats, power-to-liquid e-SAF uses renewable electricity to produce hydrogen, which is combined with a carbon source to make synthetic hydrocarbons.

The company said its fuel has been validated against the properties of conventional Jet A-1, including its chemical composition and performance characteristics. Zero has previously described its approach as producing “whole-blend” synthetic fuels rather than fuels that need to be blended with conventional kerosene.

The development follows earlier work by Zero to progress its synthetic Jet A-1 towards formal aviation fuel approval. In 2025, the company said it was working with the UK SAF Clearing House on testing and qualification, with the aim of progressing its fuel through the ASTM process used to approve new SAF production pathways.

However, validation of a fuel's properties is not the same as certification for commercial aviation. New SAF production routes have to undergo technical assessment and approval before they can be used within the relevant aviation fuel standards. Once an approved SAF meets the required blending conditions, it can be treated as Jet A/Jet A-1 under the applicable specifications.

Synthetic fuels are attracting particular interest because they can potentially be produced without relying on limited biological feedstocks. The International Civil Aviation Organization identifies power-to-liquid e-SAF as a potentially high-emissions-reduction pathway, although it also describes the technology as requiring significant capital investment and longer-term scaling.

The technology faces substantial challenges beyond proving that the fuel can replicate conventional kerosene. Large-scale production requires significant quantities of renewable electricity, green hydrogen and sustainable sources of carbon dioxide. Production costs and the availability of renewable energy are also major considerations.

The commercial challenge is particularly significant for e-SAF with airlines questioning whether sufficient e-SAF production will be available to meet forthcoming targets.