The Critical Role of Process Mass Spectrometry in e-Fuels Production

Climate-friendly energy

The thermometer is rising, all over the world. With 2024 locked in as the hottest year ever recorded and the global average temperature soaring 1.55°C above pre-industrial levels, the race toward net-zero isn’t just a theoretical good idea. It’s urgent. As governments sound the alarm and push for 2050 climate milestones, industries must respond—not tomorrow, but now.

As industries strive to meet 2050 climate goals, electro-fuels (e-fuels) emerge as a crucial element of the solution. These synthetic fuels, produced using renewable electricity, can integrate seamlessly into existing infrastructure, offering a practical bridge between current energy systems and a sustainable future.

E-fuels promise not only sustainability but also continuity in powering diverse sectors such as aviation, freight, and power generation with carbon-neutral confidence. However, the production of e-fuels is complex and requires precision at every stage. To help remedy that problem, process mass spectrometry (MS) can be utilized to help ensure the quality of inputs and outputs, identify inefficiencies, authenticate the origins of materials, and facilitate innovation.

Process mass spectrometry is a real-time analytical technique that measures the composition of gases and liquids in industrial processes with exceptional speed and precision. In e-fuels production, it plays a critical role in monitoring every stage — from green hydrogen generation and Fischer-Tropsch synthesis to direct air capture — helping to ensure purity, efficiency, and regulatory compliance.

The power of process mass spectrometry

Process mass spectrometry can be used for real-time continuous monitoring and analysis of chemical processes. The analytical process involves ionizing sample molecules, separating the resulting ions by their mass-to-charge ratio, and quantifying them to determine the composition of gases or liquids in industrial processes.

Process mass spectrometry is particularly critical in monitoring the Fischer-Tropsch (FT) process, where syngas is converted into liquid hydrocarbons. This high-temperature, high-pressure process requires precise control of various components, including methane, ethane, propane, carbon monoxide, carbon dioxide, and light hydrocarbons. MS provides real-time analysis, helping to ensure that any deviations are quickly identified and corrected, thereby maintaining the integrity of the production process.

Green hydrogen, produced by electrolysis of water using renewable electricity, is a key component of e-fuels. Monitoring the performance of electrolyzers that generate hydrogen and oxygen is essential for optimizing this stage of the overall process. MS technology, as demonstrated in partnerships with clean power companies, helps in identifying inefficiencies and helping to ensure high-purity outputs, which are crucial for the downstream synthesis of e-fuels.

Direct air capture: Real-time analysis in action

The role of process mass spectrometers extends to Direct Air Capture (DAC) systems, which remove CO₂ from the atmosphere. Given the low ambient concentration of CO₂, real-time analysis by MS is vital for maintaining the efficiency and integrity of DAC processes. It has been found that MS outperforms traditional gas chromatography by providing faster and more comprehensive analysis. Notably, the MS monitors water vapour with ease while this is a challenging application for a gas chromatograph (GC). Water is of particular interest as its presence in captured CO₂ risks formation of acids, such as sulfuric and nitric acids, which are a threat to the integrity of pipelines transporting CO₂ to storage or utilization.

Green hydrogen and electrolyzer development

One of the most effective ways to verify hydrogen’s origin is by analyzing the ratio of H₂ to hydrogen deuteride (HD).

Fossil-derived hydrogen carries a higher HD signature due to its isotopic profile. Using dual-resolution magnetic sector technology the MS can detect HD at 150 ppm with 5 ppm precision, offering an unambiguous measure of origin.

Mass spectrometry in the Fischer-Tropsch process

At the heart of e-fuel synthesis lies the Fischer-Tropsch (FT) process, where syngas transforms into liquid hydrocarbons. Catalyzed by iron or cobalt, and running at high temperatures and pressures, this stage demands relentless precision.

MS monitors not only the syngas feedstock but also a cocktail of molecules, including these chemicals:

Methane, ethane, propane
CO, CO₂, N₂
Light hydrocarbons (C₂ -C₆)

Typical FT Stream:

Component	Concentration (%mol)	Precision (abs %mol)
Hydrogen	Balance	0.05
Methane	5.5	0.01
Carbon Monoxide	15	0.05
Nitrogen	2	0.02
Carbon Dioxide	10	0.01
Light Hydrocarbons (C₂-C₆)	<1.5 total	0.002 each

This complex analysis can be completed in under 20 seconds, which means there is insight fast enough to drive real-time process control.

The path forward: Integration, innovation, and scale

The beauty of e-fuel production lies in its interconnectedness. What begins with carbon capture and green hydrogen doesn’t end there—it evolves, transforms, and depends on precision at every turn. One slight inefficiency in hydrogen production can impact the quality of syngas. A subtle shift in syngas composition affects the entire Fischer-Tropsch output. This isn’t just a supply chain; it’s a system of systems, where success is only possible through visibility, responsiveness, and control.

Process mass spectrometry creates feedback loops in places where blind spots used to live so you no longer need to wait to find out what went wrong—you know what’s happening as it unfolds and can make decisions more quickly, optimizing operations.

Overall, the integration of process mass spectrometry into the production of e-fuels and related technologies is not just beneficial but essential. It provides the necessary precision and real-time feedback required to navigate the complexities of modern energy production, helping to ensure that the transition to sustainable energy sources is both effective and reliable.

Additional resources

Online information: Real-time Hydrogen Measurement for Diverse Production Methods
Online information: Process Mass Spectrometers for Real-Time Gas Analysis
Webinar: Thermo Fisher Scientific and CPH2 team up to give renewable hydrogen production the green light
Application Note: Improving production of green hydrogen with fast, precise gas analysis Mass Spectroscopy
Application Note: e-Fuels: Climate-Friendly Energy That Can Put us in the Driving Seat to a Sustainable Future
Application Note: Improving production of Syngas with fast, precise gas analysis MS
Case Study: Thermo Fisher Scientific and CPH2 team up to give renewable hydrogen production the green light
Real-time hydrogen measurement on the Prima Mass Spectrometer
Technical note: Measuring hydrogen spin isomers with Raman spectroscopy
Case study: Process Raman spectroscopy for carbon capture applications

References

World Meteorological Organization. (2025). WMO confirms 2024 as warmest year on record.
International Energy Agency. (2023). Direct Air Capture overview. https://www.iea.org
Dugstad et al. (2014). Corrosion Testing in Dense Phase CO2. CORROSION 2014.
IEA (2023). CO2 capture by DAC vs Net Zero Scenario 2030. https://www.iea.org
Gibson, Eby, Jaggi. (2024). Natural Isotope Fingerprinting of Hydrogen. Int. J. Hydrogen Energy.
Merriman, D. (2022). Application of MS to Catalyst-Based Processes. Analyzer Technology Conf.
European Parliament. (2023). 70% SAF mandate by 2050.
UNFCCC. (2025). Parties to the Climate Change Convention. https://unfccc.int