Aircela Converts Air to Synthetic Gasoline Without Petroleum
Key Takeaways:
- Aircela’s system captures CO2 from ambient air and combines it with hydrogen to produce synthetic gasoline.
- The process uses a KOH water solution for direct-air capture, electrolysis for hydrogen, and methanol-to-gasoline (MTG) catalysis.
- Current prototype makes roughly one gallon of gasoline per day and can run in homes or small facilities; scaling depends on clean electricity.
- The liquid sorbent is recycled in the process, but fully low-carbon fuel requires renewable power to run the system.
How the Air-to-Gasoline Process Works
Aircela’s device pulls carbon dioxide directly from the atmosphere using a water-based liquid sorbent that contains potassium hydroxide (KOH). The CO2 chemically binds in the solution and is then concentrated for downstream chemistry.
Carbon capture and sorbent recycling
The company says the liquid sorbent is recycled continuously, reducing the need for consumables. That closed-loop sorbent handling is key to keeping operational costs and waste low.
Hydrogen production by electrolysis
Aircela produces hydrogen onsite by electrolysis of water. The oxygen byproduct is released, while hydrogen is stored and combined with the captured carbon to form intermediate molecules.
From CO2 + H2 to gasoline: MTG conversion
Captured carbon and hydrogen are first converted to methanol. That methanol then goes through a methanol-to-gasoline (MTG) catalytic process to produce a liquid fuel chemically similar enough to conventional gasoline to run in existing internal-combustion engines.
Practical performance and deployment
In demos, Aircela’s prototype creates up to about one gallon of synthetic gasoline per day. The company highlighted a rooftop demonstration that showed the system can operate in small footprints — small enough for homes, businesses, and distributed industrial settings.
Energy and emissions considerations
Electrolysis and the MTG steps consume electricity, so the lifecycle carbon impact depends on how that electricity is generated. When powered by grid electricity with fossil inputs, the fuel’s climate benefits shrink. Paired with solar or other renewables, the system can deliver much lower net emissions compared with petroleum-derived gasoline.
Scalability challenges
Scaling from a one-gallon-per-day unit to community or commercial production will require larger or many modular units, significant renewable power, and capital investment in reactors and catalysts. Aircela must demonstrate sustained operation, cost per gallon, and supply-chain readiness before broad adoption.
Why it matters
Aircela’s approach sits at the intersection of direct-air capture, electrolysis, and established MTG chemistry. If costs fall and renewable electricity is available, synthetic gasoline made from air could provide a drop-in fuel for existing vehicles while reducing dependence on petroleum.