Norway-based recycler Wastefront will begin construction on one of Europe’s largest tyre-to-fuel facilities at the Port of Sunderland, UK, which will convert waste tyres into tyre-derived oil (TDO), and subsequently process TDO into Sustainable Aviation Fuel (SAF). Wastefront intends to begin TDO production in 2026.
The firm employs a process that involves heating tyres to 500 degrees C in pyrolytic modules without the presence of oxygen. This thermal decomposition breaks down the tyres into oil, soot, and gas. The oil extracted serves as a vital feedstock for SAF production, while the generated gas powers the process, enhancing its energy efficiency.
Wastefront adds that a single plant can process 80,000 tonnes of tyres/year. If this process were scaled across the UK, it could consume the nation’s entire stock of used tyres, producing 110,000 tonnes of SAF each year. This output would meet 1% of the UK’s aviation fuel demand, a tenfold increase over the current volume of SAF available in the country.
The UK Government has set an ambitious target to ensure that 10% of all jet fuel used in flights departing from the UK comes from SAF by 2030. Wastefront’s initiative aligns perfectly with this objective, contributing significantly to the country’s sustainability goals. By converting waste tyres into valuable aviation fuel, Wastefront can play a crucial role in meeting this target, demonstrating the viability and scalability of innovative SAF production methods, it adds.
The environmental benefits of converting tyres into SAF are manifold. This process significantly reduces carbon emissions in the aviation sector, aligning with the industry’s goal of achieving net-zero carbon emissions by 2050. Additionally, it provides a sustainable solution for tyre waste management, preventing the incineration of tyres in highly polluting cement plants or their disposal in landfills.
SAF produced from tyre pyrolysis oil can be used in gas turbine engines, either in its pure form or blended with conventional jet fuel. Its high heating value makes it suitable for use without significant modifications to existing engines. However, challenges remain, such as higher fuel consumption compared to conventional jet fuel and increased NOx emissions. Despite these hurdles, the emissions of carbon monoxide (CO) and total hydrocarbons (THC) are comparable to those of traditional jet fuel.
Recent changes in regulations, such as the UK’s renewable transport fuel obligation, have created a favourable market environment for tyre-to-oil producers. The International Air Transport Association (IATA) has expressed support for the inclusion of additional feedstocks for SAF production, recognising the strategic value in Wastefront’s innovative approach.
Wastefront’s pioneering efforts in producing SAF from recycled tyres represent a promising convergence of environmental sustainability and industrial innovation. By addressing both waste management and renewable fuel production, this initiative holds significant promise for future development within the aviation sector. The tyre industry, with its critical role in this process, stands to benefit from the advancements and opportunities presented by this sustainable technology. As the UK aims to achieve its SAF usage goals by 2030, Wastefront’s contribution could be instrumental in shaping a greener future for aviation.