In Spain, a significant part of the surplus forest biomass It ends up accumulating in hills, ditches and hard-to-reach areas, increasing the risk of forest fires and wasting a prime energy resource. Faced with this scenario, a group of research centers and companies is making a strong commitment to a specific approach: transforming these plant remains into sustainable fuels for sectors where electrification is not yet easily implemented.
This commitment materializes in Pyrofuel, a state project which seeks to convert forestry and pruning waste into high-quality liquid biofuels, suitable for aviation and heavy road transport. With public funding, new pyrolysis technologies, and advanced catalysts, the initiative aims to demonstrate that the intelligent management of forest waste can translate into fewer fires, lower COâ‚‚ emissions, and more renewable energy produced locally through valorization of wood waste.
Pyrofuel: from the Spanish mountains to the aircraft and truck depot
The Institute of Chemical Technology (ITQ), a joint center of Consejo Superior de Investigaciones CientÃficas (CSIC) and the Polytechnic University of València (UPV)[Company Name] plays a prominent role in Pyrofuel. The project focuses on valorize biomass originating from pruning and cleaning waste from Spanish roads and forests, which until now in many cases had no clear use or ended up being burned without efficient energy use.
Pyrofuel is funded by the Ministry of Science, Innovation and Universities With over 1,5 million euros, this investment aims to tackle several fronts simultaneously: reducing the risk of forest fires, decreasing the waste of plant resources (wood, agricultural residues, scrubland, and other byproducts), and significantly improving the efficiency of biomass conversion processes into fuel, moving towards the circular bioeconomy.
One of the most ambitious technical objectives is increase efficiency by around 30% from thermal pyrolysis applied to forest waste. This leap would allow obtaining more useful product from the same amount of biomass, improving economic viability and reducing the environmental impact of the entire biofuel production chain.
According to the researchers involved, the project is not limited to producing just any biofuel, but rather aims to develop fuels that comply with kerosene and diesel specifications currently used in aviation and heavy transport. Therefore, integration into the existing refueling infrastructure and engines would be much simpler, without requiring major technological changes to the vehicle fleet.
The potential impact goes beyond the laboratory: the CSIC emphasizes that this type of renewable fuel can become a key component for the decarbonization of freight and long-distance transport in Spain and the rest of Europe, especially in those segments where, to this day, full electrification encounters technical or operational limitations.
How thermal pyrolysis of forest waste works
The technological heart of the project is the thermal pyrolysis of biomassBiochemical combustion is a thermochemical process by which organic matter decomposes in the total absence of oxygen, at temperatures that are normally between 400°C and 600°C. Without oxygen, the material does not burn as in conventional combustion, but rather decomposes into different fractions: gases, carbonaceous solids, and especially bioliquids.
At Pyrofuel, we work with a system of advanced rapid pyrolysisDesigned to minimize biomass loss and maximize bioliquid production, this technology, in addition to increasing energy efficiency, is geared towards generating a liquid stream with characteristics suitable for subsequent catalytic refining, the key step in transforming it from a simple pyrolysis oil into a high-quality transportation fuel.
The research team has set itself the goal of improving the overall efficiency of this process by around 30% compared to reference technologies, which implies not only optimizing the operating conditions (temperature, residence time, heating rate), but also adjust the logistics of biomass collection and preparation to ensure a constant and homogeneous flow of waste towards the pyrolysis units.
In addition to this performance increase, the models developed in the project point to a reduction of up to 17% in COâ‚‚ emissions associated with fuel production, when compared to conventional processes derived from fossil fuels. This environmental improvement is based both on the renewable nature of the biomass used and on the optimization of the conversion chain.
The direct result of pyrolysis is a bioliquid which, on its own, is not yet a fuel ready for commercial use. like other biofuelsIt is an oil with high chemical complexity, the presence of oxygen, and unstable compounds that require a subsequent stage of catalytic hydrotreating to purify it, stabilize it and adapt it to current quality regulations for aviation and road transport fuels.
Catalytic hydrotreating: from bioliquid to sustainable fuel
Once the bioliquids from the pyrolysis of forest waste have been obtained, the refining phase begins using different techniques grouped under the term catalytic hydrotreatingThe objective of this stage is to eliminate impurities, reduce oxygen content, and improve the physical and chemical properties of the final product, until it is compatible with the specifications of conventional kerosene and diesel.
This phase combines several chemical processes. Among them, the hydrogenation and hydrodeoxygenationThese processes use hydrogen and solid catalysts to transform the organic molecules present in the bioliquid, eliminating oxygen and modifying its structure. Thanks to these reactions, a more stable fuel is obtained, with better calorific value and less tendency to degrade during storage.
Another key piece is the hydrocrackingThis is a reaction in which large hydrocarbon molecules are broken down into smaller, more manageable ones. This stage allows for better adjustment of the molecular weight distribution of the final product, so that it falls within the desired ranges for specific uses, such as aviation fuel or diesel for heavy vehicles.
Processes of deoxygenation Additional modifications are designed to reduce the percentage of oxygen typically present in vegetable-based pyrolysis oils. By eliminating this oxygen, a fuel is obtained that is more similar in behavior and characteristics to petroleum derivatives, simplifying its blending with fossil fuels and its direct use in existing engines.
After this series of hydrotreatment stages, the final product is liquid fuels Located in the kerosene and diesel range, these biofuels can be used as sustainable aviation fuels (SAFs) and as renewable alternatives for trucks, buses, and other heavy vehicles. Pyrofuel's approach is to ensure these biofuels are compatible with existing infrastructure and engines, reducing implementation costs and accelerating their potential large-scale deployment.
Advanced catalysts: the key to making the process cheaper and viable
Within Pyrofuel, the research group CAT-REN of the ITQ (CSIC-UPV) It leads the design and development of new solid catalysts based on supported metals, specifically designed for the hydrotreatment of liquids derived from forest biomass. These catalysts are materials in which tiny metallic particles are fixed onto a solid support, multiplying their active surface area and their capacity to accelerate specific chemical reactions.
The use of advanced catalysts is crucial for the transformation of pyrolysis oils into final fuels to be successful. more efficient and economically competitiveBy improving the activity and stability of the catalysts, process times are reduced, hydrogen consumption is decreased, and unwanted byproducts are minimized, factors that affect both the cost and the environmental impact of the technology.
The CAT-REN group has accumulated experience in the catalytic treatment of pyrolysis liquids derived from biomassThis experience, gained from previous industrial application projects such as Ceus and Almagreen (cited as references by the researchers themselves), allows them to start with already proven formulations and adapt them to the specific needs of the forestry and pruning waste used in Pyrofuel.
According to the ITQ team, this trajectory has allowed them to achieve enhanced fluids compatible with current transport fuels such as jet fuel and diesel. The challenge now is to further optimize these catalytic formulations, extend their lifespan, and facilitate their industrial scaling without skyrocketing costs—an essential step for sustainable fuels generated from forest waste to compete in the market.
This innovation in the field of catalysis not only responds to a technical need, but is also part of a broader vision of circular bioeconomyIn this approach, waste is seen as a raw material with added value. If the entire chain—from biomass collection in the forest to the use of the fuel in an aircraft—is optimized thanks to these catalysts, the technology can establish itself as a real alternative to fossil fuels in sectors that are difficult to decarbonize.
Environmental impact, fire prevention and circular economy
Beyond the laboratory and pilot plants, Pyrofuel is envisioned as a tool for sustainable land managementFor decades, Spain has been grappling with problems related to the accumulation of forest biomass in mountains and rural areas, which increases the risk of large-scale fires, especially in increasingly hot and dry summers due to climate change.
The initiative takes advantage of these waste accumulated in forests and agricultural holdings to transform them into a renewable energy sourceBy removing them and putting them to productive use, we simultaneously contribute to reducing the fuel load in the countryside and, therefore, the likelihood of catastrophic fires. This dual aspect—energy and risk prevention—is one of the arguments that reinforce public interest in projects like Pyrofuel.
The project also focuses on the design of a Efficient logistics for collection and transport Biomass is an often overlooked but crucial aspect for the economic viability of any large-scale forest management scheme. Organizing fieldwork, coordinating forestry service companies, and finalizing agreements with landowners and government agencies are essential pieces of the puzzle.
From an environmental perspective, fuels produced from forest waste fit within strategies of circular economybecause they transform low-value byproducts—which might otherwise go unmanaged or be burned inefficiently—into energy resources and raw materials for new industrial uses. This approach helps reduce dependence on imported fossil fuels and strengthens the country's energy independence.
Furthermore, since it is biomass of forest and agricultural origin, the carbon released when these fuels are burned is largely considered part of a biogenic cycleThis contrasts with the additional fossil carbon released into the atmosphere when using oil, gas, or coal. If forests are managed properly and land-use changes are avoided, the net carbon footprint can be significantly reduced compared to conventional fuels.
Applications in aviation and heavy transport: sectors that are difficult to electrify
One of the great advantages of converting forest waste into sustainable fuels is that these products can be used to sectors where electrification still presents many barriersThis is the case in aviation, but also in heavy road transport, where the weight of the batteries, range and charging infrastructure still pose considerable challenges.
In the aeronautical field, the sustainable aviation fuels (SAF) They have become a priority for both airlines and European regulators in meeting emissions reduction targets. Pyrofuel aligns with these strategies by proposing a potential supply of SAF produced from local residual biomass, which would help reduce the carbon footprint of flights without requiring radical changes to the aircraft fleet.
In parallel, the project includes applications in the heavy land transportWith particular attention to long-haul trucks and other commercial vehicles for which full electrification is not, in the short term, the simplest solution. In these cases, renewable fuels compatible with current diesel engines can help reduce emissions without the need to replace the entire fleet at once.
The CSIC highlights that this type of biofuel can play a relevant role in the decarbonization of freight transportwhich represents a substantial portion of greenhouse gas emissions. By combining technological improvements in production with policies that promote the use of renewable fuels, the transition to a more sustainable mobility model could be accelerated.
Compatibility with existing distribution infrastructure —from pipelines to service stations and storage systems— adds another point in its favor. Being able to blend or partially replace fossil fuels without completely redesigning these networks facilitates the deployment of solutions like those pursued in Pyrofuel.
Public-private collaboration and industrial scaling horizon
Pyrofuel is also an example of collaboration between public institutions and private companiesThe project is led by the company Meryt Catalysts & Innovation and has the participation of partners from the research and industry fields in Spain, including ITQ (CSIC-UPV), I2con and Neoliquid.
This alliance forms a national network focused on energy innovationWith a distinctly interdisciplinary approach, ranging from materials chemistry and catalysis to process engineering, forestry logistics, and economic feasibility analysis, the combination of diverse profiles allows us to address the challenge of converting forest waste into sustainable fuels from all necessary angles.
With funding from the Ministry of Science, Innovation and Universities, exceeding 1,5 million euros, the aim is not only to advance scientific knowledge, but also laying the foundations for future industrial deployment of the technology. A relevant part of the work focuses on evaluating the technical and economic feasibility of establishing production plants in different parts of Spain.
The ultimate goal is that in the medium term they can emerge facilities capable of supplying part of the demand of fuels for strategic sectors, especially aviation and heavy transport. To this end, the project must demonstrate that the conversion of forest residues into sustainable fuels is stable, safe, competitive, and replicable in different regional contexts.
If the expectations set by the participating teams are met, initiatives of this type could mark a turning point in forest waste management and in the production of renewable energy in Spain, better integrating the rural area into the new value chains of the ecological transition and offering an additional economic outlet to areas that often suffer from depopulation and lack of industrial activity.
All this scientific, technological, and logistical effort paints a picture in which sustainably managed forests They are transitioning from a potential source of fires and emissions to a source of fuels with a lower climate impact, aligned with European decarbonization policies. The evolution of Pyrofuel in the coming years will be key to determining the extent to which this approach can become a stable component of the new energy landscape.