Reusing Residual Fuel from Retired Aircraft

Reusing Residual Fuel from Retired Aircraft

The aviation industry remains a significant contributor to global carbon emissions, primarily due to its dependence on kerosene-based fuels. Kerosene is favored for its high energy density and relatively low cost, making it difficult to replace with more sustainable alternatives. However, stringent safety regulations and legal constraints result in substantial quantities of unused kerosene from decommissioned aircraft being discarded rather than repurposed.

Challenges in Reusing Residual Fuel

Typically, kerosene is loaded into an aircraft only once, and extracting it from fuel tanks poses considerable risks. The process can introduce contaminants such as water, microbes, or debris, which may cause engine damage or failure—risks that are unacceptable in an industry where safety is paramount. Consequently, the reuse of kerosene in other aircraft remains rare despite its potential environmental and economic advantages.

In an ideal scenario, residual fuel would be removed through a contamination-free process, stored in sterile containers, and transported safely for reuse. However, current practices fall short of this standard. Safety concerns, regulatory barriers, and legal restrictions complicate the process. For instance, kerosene used on international flights is tax-exempt, but removing it from an aircraft and transporting it off-airport can trigger taxes and levies. Furthermore, as a hazardous substance, kerosene must be handled and transported exclusively by licensed companies, adding to the costs and logistical challenges.

Disposal Practices and Industry Responses

Due to these obstacles, companies involved in aircraft dismantling often resort to alternative disposal methods. Residual kerosene may be sold to other industries, such as asphalt production, or blended with motor oil for heating purposes. Alternatively, it is sent to licensed hazardous waste facilities where it is typically incinerated for energy recovery. Both approaches involve regulatory compliance and incur costs, while incineration contributes additional carbon dioxide emissions.

Despite these challenges, some companies are pioneering solutions to safely reuse residual fuel. For example, CH-Aero in the Netherlands has developed advanced defueling and refueling procedures employing specialized pumps and licensed transport services. Michelle Arentz, CH-Aero’s commercial director, highlights the company’s collaboration with firms like Weltens Transport, which has facilitated the safe movement of large quantities of fuel across Europe, demonstrating that technical barriers can be overcome.

Nevertheless, broader adoption of such practices faces persistent regulatory uncertainties, particularly concerning the taxation and classification of reused fuel. The market is also influenced by competition from sustainable aviation fuel (SAF), which is gaining traction as airlines intensify efforts to reduce emissions. Financing remains a critical challenge, as significant investment is required to establish dedicated recycling facilities capable of processing residual aviation fuel safely and efficiently.

Market Dynamics and Future Prospects

As demand for SAF grows, airlines and fuel suppliers are exploring innovative recycling technologies and forming strategic partnerships to improve fuel efficiency and sustainability. Some industry players are investing in their own recycling capabilities, aiming to transform residual fuel from waste into a valuable resource.

While technical solutions for reusing residual aircraft fuel exist, widespread implementation will depend on regulatory clarity, industry investment, and ongoing innovation. As the aviation sector increasingly prioritizes sustainability, effective recycling of residual kerosene could become an important component in reducing emissions and minimizing resource waste.