ACT Group

13/11/2025

What is Synthetic Diesel? A Complete Guide
written by Amelia 02/23/2025

Synthetic diesel, also known as synthetic fuel or synfuel, is a type of fuel created through chemical processes that convert raw materials like natural gas, coal, or biomass into diesel-like hydrocarbons. Unlike conventional diesel fuel, which is derived from crude oil through refining processes, synthetic diesel is manufactured through various methods designed to replicate the properties of natural diesel while often providing enhanced efficiency and cleaner emissions.

In this article, we will explore what synthetic diesel is, the processes involved in its production, its benefits, and its potential role in the future of the energy sector.

What is Synthetic Diesel?
The concept of synthetic fuels has been around for over a century, with its origins traced back to the early 1900s. The invention of synthetic diesel can be attributed to the development of the Fischer-Tropsch (FT) synthesis in the 1920s. This process, developed by German chemists Franz Fischer and Hans Tropsch, enabled the conversion of coal or natural gas into liquid hydrocarbons.

Synthetic diesel became especially significant during World War II when Germany relied heavily on synthetic fuels to power its military machinery due to limited access to crude oil. This marked a turning point in the development of synthetic fuels, showcasing their ability to provide an alternative to conventional crude oil-derived fuels.

How is Synthetic Diesel Produced?
The production of synthetic diesel involves several advanced technologies that differ significantly from the traditional methods of diesel fuel production. The two primary methods used to produce synthetic diesel are:

1. Fischer-Tropsch Synthesis
The Fischer-Tropsch process is the most commonly used method for producing synthetic diesel. It involves the conversion of synthesis gas (a mixture of carbon monoxide and hydrogen) into liquid hydrocarbons using a catalyst, typically iron or cobalt-based. The key steps in this process include:

Gasification: The raw material, such as coal, biomass, or natural gas, is converted into synthesis gas through gasification. This is done by heating the raw material in the presence of oxygen or steam at high temperatures.

Synthesis Reaction: The synthesis gas is then fed into a Fischer-Tropsch reactor where it reacts with the catalyst. Under controlled conditions of pressure and temperature, the carbon monoxide and hydrogen atoms in the gas combine to form long-chain hydrocarbons.

Refining: After the Fischer-Tropsch process, the synthetic fuel is typically refined to remove impurities, improve its combustion properties, and make it suitable for use in diesel engines.

2. Biomass-to-Liquids (BTL) Technology
Biomass-to-liquids (BTL) technology is another method for producing synthetic diesel. It involves converting organic materials, such as agricultural waste or forest residues, into liquid fuels. The process is similar to Fischer-Tropsch, with biomass serving as the raw material. BTL technology is considered more sustainable because it utilizes renewable organic feedstocks instead of fossil fuels like coal and natural gas.

The general steps in BTL production are as follows:

Gasification: Biomass is gasified to produce synthesis gas (syngas), which is a mixture of carbon monoxide and hydrogen.

Fischer-Tropsch Synthesis: Similar to the traditional Fischer-Tropsch method, the syngas undergoes a synthesis reaction in the presence of a catalyst to produce liquid hydrocarbons.

Refining: The liquid synthetic diesel is then refined to meet fuel standards and specifications for diesel engines.

3. Coal-to-Liquids (CTL) Technology
Another approach for producing synthetic diesel is through coal-to-liquids (CTL) technology. This method is particularly prevalent in countries with abundant coal resources. Like the Fischer-Tropsch process, coal is first gasified to create syngas. The syngas is then converted into liquid fuels through the Fischer-Tropsch synthesis.

Types of Synthetic Diesel
Synthetic diesel is often classified into two primary types: Fischer-Tropsch diesel (FTD) and Hydrotreated Vegetable Oil (HVO).

1. Fischer-Tropsch Diesel (FTD)
Fischer-Tropsch diesel is the product of the Fischer-Tropsch synthesis, where syngas derived from coal, natural gas, or biomass is converted into liquid hydrocarbons. FTD is chemically similar to conventional diesel but with a higher cetane number, which results in improved combustion characteristics. This makes it ideal for use in modern diesel engines.

FTD is a clean-burning fuel with minimal sulfur and aromatic compounds, making it a more environmentally friendly option compared to traditional diesel fuel. However, FTD is often produced from non-renewable feedstocks, which limits its sustainability.

2. Hydrotreated Vegetable Oil (HVO)
Hydrotreated vegetable oil (HVO) is another type of synthetic diesel that is produced by hydrotreating vegetable oils or animal fats. This process involves reacting the oils or fats with hydrogen in the presence of a catalyst to produce hydrocarbons that can be used as diesel fuel. HVO is a renewable, biodegradable fuel that has similar properties to conventional diesel.

HVO is gaining popularity because it is considered a drop-in fuel, meaning it can be used in existing diesel engines and infrastructure without modifications. It also produces lower emissions of carbon monoxide, particulate matter, and hydrocarbons compared to traditional diesel.

Benefits of Synthetic Diesel
The development and use of synthetic diesel offer numerous advantages, especially when compared to conventional diesel fuels. Some of the key benefits of synthetic diesel include:

1. Cleaner Emissions
One of the most significant benefits of synthetic diesel is its potential to reduce harmful emissions. Synthetic diesel, particularly FTD, contains very low levels of sulfur, nitrogen, and aromatic compounds. This makes it burn cleaner than traditional diesel, resulting in fewer particulate emissions and lower levels of carbon dioxide (CO2) and nitrogen oxides (NOx).

2. Improved Fuel Efficiency
Synthetic diesel often has a higher cetane number than conventional diesel. A higher cetane number improves the fuel’s combustion efficiency, resulting in smoother engine operation and better fuel efficiency. This can lead to lower fuel consumption and, consequently, reduced greenhouse gas emissions.

3. Reduced Dependence on Crude Oil
Synthetic diesel offers a potential solution to the global challenge of reducing reliance on crude oil. By utilizing feedstocks such as natural gas, coal, and biomass, synthetic diesel can be produced from a variety of sources. This reduces dependence on oil imports and can enhance energy security, especially in regions with limited access to crude oil resources.

4. Renewable Options
Biomass-to-liquids (BTL) technology offers a renewable alternative to traditional diesel. By converting biomass, such as agricultural residues, into synthetic diesel, BTL provides a sustainable fuel option that helps mitigate the environmental impact of fossil fuels.

5. Versatility and Compatibility
Synthetic diesel can be produced to meet the same specifications as conventional diesel, making it fully compatible with existing diesel engines, infrastructure, and distribution systems. This allows for a seamless transition to synthetic diesel without requiring significant changes in infrastructure or vehicle fleets.

Challenges of Synthetic Diesel
While synthetic diesel offers many advantages, there are several challenges that need to be addressed to make it a more viable and widespread option. These challenges include:

1. High Production Costs
The production of synthetic diesel, especially through processes like Fischer-Tropsch and BTL, requires significant energy and advanced technology, which can make it more expensive than conventional diesel. The cost of raw materials and the complexity of the synthesis processes also contribute to high production costs.

2. Limited Availability of Feedstocks
The availability of suitable feedstocks for synthetic diesel production can be limited. For example, coal is a finite resource, and while biomass is renewable, it may not be available in sufficient quantities to meet global demand. Furthermore, the environmental impact of sourcing these feedstocks can vary depending on the method used.

3. Energy Intensity of the Process
Producing synthetic diesel requires a substantial amount of energy, particularly in the gasification and synthesis stages. The carbon footprint of synthetic diesel production can be high if the energy used in the process comes from non-renewable sources. To fully realize the environmental benefits of synthetic diesel, efforts must be made to use renewable energy sources in its production.

Conclusion
Synthetic diesel is an innovative alternative to conventional diesel fuel, offering a cleaner and more sustainable option for powering modern diesel engines. Through processes like Fischer-Tropsch synthesis and biomass-to-liquids technology, synthetic diesel can be produced from a variety of feedstocks, including coal, natural gas, and renewable biomass.

While synthetic diesel offers numerous benefits, including reduced emissions, improved fuel efficiency, and reduced reliance on crude oil, challenges remain in terms of production costs, feedstock availability, and energy intensity. However, as technology continues to evolve, synthetic diesel has the potential to play a key role in the future of global energy systems, providing a cleaner, more sustainable alternative to fossil-based fuels.

As the world moves toward decarbonizing its energy systems, synthetic diesel could serve as an important bridge between current fossil fuel reliance and a future powered by renewable energy.

17/06/2024

Forsale: Australia has been able to read about the R&D project for our portable 523kw biomass container boiler which comes complete with a 20' walking floor feed storage delivery system and an indirect heat exchange transfer for the boiler heated water to process heated wash down, building or swimming pool applications.
We have operated the plant for a combined period of only a few thousand hours in NSW and South Australia using many varied fuel mixes with amazing documented results, including 3rd party user reviews.
Our focus has been on Abattior applications but the veriaty of applications are so much broader than this.
Make contact and we can discuss how owning this Italian plant can reduce you fuel bills to as low as $2 per gj.

19/02/2024

Let's step back in time to 2016. Co-Gen using biomass was in it's infancy and ACT Group was and remains ahead of the curve.

A Western Australian oat miller is using the Organic Rankine Cycle (ORC) turbogenerator system from Italian company Turboden to generate clean electricity using oat husks as fuel to power its Wagin facility.
-gen
Previously, the residues from the processing of the oats had been used to generate steam that was used only in the milling process itself. With the introduction of the turbogenerator, the steam is used to generate power and displace a significant portion of the internal demand of electricity at the facility, which is located 230 km from Perth.

Carlo Minini, Turboden business development manager for Oceania, explained that: “ORC systems are particularly suitable for distributed power generation and have now reached a level of full maturity in biomass and waste-to-energy applications.” He said that in Europe and North America, over 200 ORC units are in operation using biomass, and this is actually the company’s second Aussie plant,“as the company installed its very first turbogenerator 30 years ago in Perth — a small solar thermal ORC back then”.

The relatively small generator installed in WA — 600 kWe is the full load capacity — is not set to export unused electricity to the grid and for the time being will only be fed with the steam excess from the milling process: the combination of these two operating conditions means that the turbine will be subject to variable load patterns.

“The beauty of the ORC technology lies exactly in its flexibility and good efficiencies retained even at very partial load — and the fact that the ORC is fully automatic and doesn’t need permanent attendance, which translates into highly reduced operation and maintenance costs.

“Interestingly enough, the other two major components of this station — the biomass boiler and the aircooler — are also made in Italy, by companies Uniconfort represented by ACT Group and Lu-Ve Contardo respectively,” Minini concluded.

19/01/2024

We are currently in Adelaide providing another biomass to energy plant to another meat processor. This AMPC sponsored initiative is really raising the awareness of significant production cost reductions for energy.

18/01/2024

ACT Group are starting the year with a complete range of much needed solutions.
Please read:
ACT Group is the ideal solution for delivering biomass to energy, hydrogen from waste, and biochar as the decarbonization solution, offering a comprehensive and sustainable approach to address pressing environmental and energy challenges. Here are compelling arguments in favour of choosing ACT Group for these innovative solutions:
Proven Expertise in Biomass Conversion:
ACT Group has a demonstrated track record of successfully converting biomass into energy, showcasing their expertise in sustainable and efficient processes. Their technology ensures the optimized utilization of biomass resources, contributing to a cleaner and more sustainable energy landscape.�
Cutting-Edge Hydrogen Production from Waste:
ACT Group pioneers the production of hydrogen from waste materials, presenting a groundbreaking solution to the growing demand for clean energy sources. By extracting hydrogen from waste, they not only reduce reliance on fossil fuels but also provide an environmentally friendly alternative that aligns with global efforts to combat climate change.�
Comprehensive Decarbonization Approach with Biochar:
ACT Group goes beyond conventional solutions by incorporating biochar into their decarbonization strategy. Biochar is a carbon-rich material produced from biomass, known for its ability to sequester carbon in the soil, enhancing soil fertility, and mitigating greenhouse gas emissions. This multi-faceted approach underscores ACT Group's commitment to holistic and sustainable decarbonization.�
Environmentally Friendly Processes:
The processes employed by ACT Group are designed with a focus on minimizing environmental impact. From biomass sourcing to energy generation and hydrogen production, their technologies adhere to the highest environmental standards, contributing to a cleaner and greener future.

30/05/2023

Results from AMPC’s first biomass boiler trial site are in. Late last year AMPC delivered a biomass boiler to a JBS Riverina meat processing facility as part of its investment into sustainable fuel options.
The pilot demonstrated how different types of biomass, sourced through a circular economy approach, contributed to lowering energy costs, energy emissions, and achieving energy reliability.
JBS Sustainability Engineer Michael Lang said, “During the trial we monitored the feasibility of various blends of available biomass. We successfully used paunch materials (usually identified as a waste stream) in multi-fuel biomass blends of up to 80 per cent paunch / 20 per cent woodchip.
“The ability to use this site generated biomass together with externally sourced biomass such as wood chips has provided energy to the plant at sub $2/GJ. Costs to supply thermal energy to the site have substantially increased with both natural gas and coal prices rising sharply over the last 12–18 months. The ability to replace these fossil fuels with a lower carbon emission biomass alternative, using purpose-built boilers is now a genuine possibility.”
The pilot system has been operating in NSW and will now move to other sites throughout Australia.

30/11/2022