SPECIAL FEATURE

Driving demonstration of Vehicles Running on Synthetic Fuels at the Expo 2025 Osaka, Kansai, Japan

Synthetic fuels are a key option for achieving carbon-neutral mobility

“Synthetic fuels” are carbon-neutral fuels synthesized from hydrogen and carbon-dioxide(CO₂) derived as raw materials from renewable energy sources. It achieves carbon neutrality thanks to reduced CO₂ emissions throughout its entire lifecycle—from raw-material production to product use. Aiming to create a decarbonized society, we are developing technology for production of synthetic fuels, which represents a key part of our next-generation energy business. We are producing synthetic fuels at a plant completed at our Central Technical Research Laboratory in 2024 and supplying diesel and gasoline blended with these synthetic fuels during the Expo 2025 Osaka, Kansai, Japan (hereinafter “the Expo”). We promote the idea that engine-equipped vehicles running on synthetic fuels are a key mobility option on the path toward carbon neutrality. In addition, it will contribute to achieving the Expo’s sustainability mission as laid out in the EXPO 2025 Green Vision.

Steps leading up to the demonstration at the Expo

A shuttle bus running on synthetic diesel transports Expo visitors

One of the vehicles running on synthetic fuel at the Expo is a shuttle bus (hereinafter “Expo Shuttle Bus”) from the station to the Expo site. During the Expo, a direct shuttle bus running on synthetic diesel operates between Osaka Station (Umekita Green Place bus parking lot) and the Expo venue. This service is the first time in Japan that synthetic fuel produced entirely from hydrogen and CO₂ is used to operate a commercial vehicle. Our plan is to add a small amount of synthetic fuel to diesel initially and then gradually increase the proportion of synthetic fuel. Through the operation of the Expo Shuttle Bus, we hope passengers and everyone we encounter along the route will experience the potentials of future fuels and showcase a future in which synthetic fuels become widely adopted.
Partners: WEST JAPAN JR BUS COMPANY, and HINO MOTORS, LTD.

After dropping off the last passengers, the bus returns to the garage in the evening.

Refueling for tomorrow’s service.

The bus is cleaned inside and out every night.

The synthetic fuel dispenser is the same type as a conventional diesel dispenser.

Vehicles working on synthetic gasoline for guests and related parties

As well as demonstrating the Expo Shuttle Bus, we are providing gasoline blended with synthetic fuel for the vehicles used for transporting guests and related parties. Synthetic gasoline manufactured at the Central Technical Research Laboratory is being supplied to a total of eight passenger vehicles provided by five car manufacturers. Each manufacturer has confirmed that their vehicles can run on this synthetic fuel just like conventional gasoline. Another advantage of synthetic fuels is that they can be handled with the same facilities as used for storage and transportation of conventional petroleum-based products. During the Expo, synthetic fuel will also be provided at service stations in Osaka city via the same equipment and procedures used for petroleum-based gasoline.
Partners: Suzuki Motor Corporation, Subaru Corporation, DAIHATSU MOTOR CO., LTD. , Toyota Motor Corporation, and Mazda Motor Corporation

Toyota: Vellfire HEV Z PREMIER

MAZDA: CX-80 PHEV

Suzuki: SPACIA HYBRID X

Subaru: CROSSTREK S:HEV

DAIHATSU: ROCKY Premium G HEV

The process leading up to practical use of synthetic fuels

ENEOS’s demonstration plant for production of synthetic fuels primarily consist of three areas: a “Hydrogen production and CO₂ Capture area,” a “Synthetic gas production area,” and an “FT synthesis area.” In the Hydrogen production and CO₂ Capture area, hydrogen is produced by electrolyzing water with renewable electricity, and CO₂ is captured from factory emissions and collected directly from the atmosphere by using special equipment. In the “Synthetic gas production area,” synthetic gas composed of carbon monoxide (CO) and hydrogen is produced from CO₂ and hydrogen, facilitating reaction in subsequent processes. In the “FT synthesis area,” the Fischer-Tropsch (FT) synthesis reaction process is used to produce synthetic crude oil (artificial crude oil) from CO and hydrogen. The synthetic crude oil then undergoes the same processing steps as conventional crude oil in existing productization system to produce fuels such as gasoline, jet fuel, and diesel. Its quality is adjusted to meets the same standards as conventional fossil fuels before being supplied to vehicles.

This project is conducted under the “Green Innovation Fund Project / Fuel Production Technology Development Using CO₂, etc.” of the New Energy and Industrial Technology Development Organization (NEDO).

My Duties

As a staff member of the Operations Department, I planned equipment startup schedules, managed their execution, adjusted operations, investigated the causes of problems, and formulated countermeasures.

Episodes that left an impression up to the provision of synthetic fuels

There were times when operations did not go according to simulations creating many problems, and the entire team was not sure what to do. When the process/operations department pulled together as one, pooling our wisdom to find solutions, it brought an indescribable sense of accomplishment. Given all these hardships, the emotion that I felt when we achieved the “first drop” of synthesized oil is still vivid in my mind.

Project Expectations

We firmly believe that “synthetic fuels will be the normal in the future,” and I will strive to make this a reality every day in my research.

Pilot Testing Group S.K.

My Duties

I am in charge of the section that converts artificially produced crude oil called “synthetic crude oil” into fuels (operations planning and execution of productization facilities, product analysis, and quality management).

Episodes that left an impression up to the provision of synthetic fuels

I was in charge of the process of converting synthetic crude oil into finished products, focusing on planning and adjusting distillation and bench-scale equipment operations. While I was happy that we were producing one barrel (159 L) of synthetic crude oil daily, it was difficult to process large amounts of oil, something that really couldn’t be experienced in the research laboratory. Nevertheless, I worked together with colleagues in other departments and made steady progress in the productization step. On actually witnessing the blending of diesel oil for EXPO 2025, I felt that the fruits of our work were finally getting out into society, and I was overwhelmed with emotion.

Project Expectations

I will make every effort to see that synthetic fuels become the “normal energy” and not just an “energy of the future”!

Synthetic Fuels & Process Group N.T.

My Duties

I am in charge of manufacturing the catalyst used in Fischer-Tropsch (FT) synthesis reaction system and I conduct research and development to make the manufacture of synthetic crude oil more efficient.

Episodes that left an impression up to the provision of synthetic fuels

Until just before the completion of the demonstration plant's construction, we were unable to produce catalysts with the targeted performance, and at that time, we faced the risk of project delays. What stands out to me is how the team persistently analyzed the causes and countermeasures, adjusted the catalyst manufacturing conditions, and successfully collected the first drop as planned using a catalyst that performed as intended.

Project Expectations

There are still challenges to be solved in putting synthetic fuels to practical use. Going forward, I will make every effort in research and development to overcome each and theses challenges.

Synthetic Fuels & Process Group T.S.

My Duties

I was in charge of the productization of synthetic fuels and managed the blending of synthetic fuels as well as their quality, delivery, and supply and demand. For fossil fuels, these supply chain tasks are usually split between refineries and service stations, but I managed the entire process myself.

Episodes that left an impression up to the provision of synthetic fuels

I studied manufacturing conditions nearly from scratch to adjust the quality of synthetic fuels so that they could be used in the same way as conventional fossil fuels.
Using our demonstration facilities, I established a production system comparable to a refinery and adjusted the amount of supply and the delivery schedule according to usage conditions. I am grateful for the assistance that I received from many colleagues inside, of course, the Central Technical Research Laboratory and other departments within the company, and finally from people at a variety of companies, all of which led up to this provision of synthetic fuels.

Project Expectations

I will take on the challenge of achieving carbon neutrality by leveraging not only synthetic fuels but also other approaches, such as biofuels.

Fuels R&D Group Y.K.