Siemens and cleantech startup CAPHENIA have entered a strategic partnership to accelerate the global scale-up of sustainable aviation fuel, with Siemens taking on the role of preferred automation and digitalization partner for CAPHENIA’s plasma-based SAF technology.
At the heart of the collaboration is CAPHENIA’s Plasma Boudouard Reactor (PBR) — a globally unique 3-in-1 zone reactor that uses plasma to split bio-methane into synthesis gas at temperatures of around 1,500°C. The process integrates three established chemical reactions into a single system, achieving a process efficiency of more than 86 percent. The synthesis gas produced can then be processed into SAF, renewable diesel, or chemical products, with no by-products and minimal energy losses.
Under the agreement, Siemens will supply solutions from its Siemens Xcelerator portfolio — including process control systems, drive technology, and process simulation software — to help standardize and digitalize CAPHENIA’s reactor plants. Digital twins will allow operating parameters to be optimized before physical commissioning, enabling faster and more consistent rollout across future sites.
“Decarbonizing aviation cannot be achieved without synthetic fuels. Demand for SAF is growing exponentially, yet production capacity urgently needs to be ramped up,” said Christian Gückel, Head of Vertical Chemicals at Siemens Digital Industries.
Dr. Mark Misselhorn, founder and CEO of CAPHENIA, added: “The market for sustainable aviation fuels will not grow evenly — it will fragment. Those who scale quickly, those who are industrial-ready, those who have the right partners will lead.”
Siemens is supporting CAPHENIA from its pilot plant at industrial park Höchst in Frankfurt through to commercial scale-up, with the goal of a modular, standardized automation template adaptable to different locations globally.
The urgency is clear: the EU Renewable Energy Directive mandates binding SAF blending quotas, and by 2050 the aviation industry will require an estimated 500 million tonnes of SAF annually. Today, SAF accounts for less than one percent of global kerosene demand.
