The aviation industry contributes approximately 2% to global greenhouse gas emissions and is recognized as a hard-to-abate sector. It faces increasing pressure to decarbonize because without action, it risks becoming a significant contributor to global greenhouse gas emissions. Sustainable aviation fuel (SAF) is viewed by many countries and the aviation industry itself as one solution to this challenge, offering a viable alternative to conventional jet fuel that can significantly reduce the industry's carbon footprint. But what are the technical challenges and economic projections in scaling SAF production?A Breakthrough for SAF&nbsp; A new process, originally invented by Virent and further developed in collaboration with Johnson Matthey, addresses one of the key limitations of most synthetic SAF blendstocks: their lack of aromatics. The breakthrough is particularly significant, as aromatics influence the physical properties of today’s jet fuel—they lower the freeze point, enhance lubricity and interact with polymer seals within aircraft fuel systems. The BioForming S2A process converts plant-derived sugars into aromatic hydrocarbons to produce SAK (synthesized aromatic kerosene), a biobased aromatic component. SAK enables the creation of 100% SAF blends that can be designed to meet today’s aviation fuel standards without requiring modifications to existing aircraft or fueling infrastructure. This approach was demonstrated with the first commercial trans-Atlantic flight using drop-in 100% SAF, by Virgin Atlantic in November 2023.Moreover, blending SAK can also offer significant environmental benefits compared to fossil jet fuel. Analysis of the fuel used for Virgin Atlantic’s Flight 100 showed that the use of 100% SAF can reduce particulate emissions by 40%, in part due to cleaner-burning biobased aromatics in the SAK. Furthermore, the ability to use a range of feedstocks for SAK production adds to its environmental and operational appeal.Fischer-Tropsch’s Role in SAF&nbsp;&nbsp; Fischer-Tropsch, a process that converts carbon monoxide and hydrogen into synthetic hydrocarbons, has long been recognized for its potential for producing synthetic fuels. One of the major advantages of the FT process is its feedstock flexibility. Unlike traditional jet fuel production, which relies heavily on fossil-derived resources, the FT process uses syngas that can be derived from a diverse range of feedstocks, including biomass, municipal solid waste and even captured carbon dioxide, when combined with hydrogen. This diversity allows the FT process to adapt to different regional resources. By utilizing waste materials and biomass residues for syngas production, the FT process can also support waste management by turning waste into valuable fuel.Feedstock versatility also makes countries deploying the FT process more resilient to supply chain disruptions and feedstock price volatility, as they are not tied to a single raw material. This resilience is particularly important as the world seeks to scale SAF production to meet global demand while minimizing environmental impact.Enhancing FT and Scaling SAF&nbsp; The latest advancements in FT technology have enhanced the process by increasing the efficiency and scalability of SAF production with technology that is more compact and modular, making it suitable for integration into various production environments. The adoption of this flexible FT process is expected to play a pivotal role in the future of SAF production. For instance, DG Fuels has chosen FT CANS—developed by Johnson Matthey in partnership with bp—for its first SAF plant, a $4 billion project in St. James Parish, Louisiana, that plans to utilize locally available sugar cane waste as its primary feedstock. DG Fuels has already announced another SAF project in Nebraska and has plans for many more throughout the U.S. and beyond. These are expected to follow the same blueprint as the Louisiana plant, highlighting the potential for large-scale SAF production.Despite technological advancements, scaling SAF production to meet global aviation demand remains a formidable challenge. Economically, the transition to SAF is driven by both regulatory pressures (to drive demand) and market incentives (to help bridge the cost premium to produce SAF). The International Air Transport Association has set ambitious targets for reducing net aviation emissions, which include the widespread adoption of SAF. However, the cost of SAF is currently higher than that of conventional jet fuel. Moving closer to cost parity with conventional fuels will require investments in technology and infrastructure, as well as supportive policy frameworks that incentivize SAF production and adoption.One major obstacle is ensuring the consistent supply of sustainable feedstock. By using the FT pathway, SAF production can utilize different types of feedstocks, such as agricultural or forestry residues, municipal solid waste or even captured carbon dioxide and clean hydrogen, which vary in abundance by region. This adaptability is crucial for ensuring a resilient supply chain.The path to decarbonizing aviation through SAF is acknowledged by key stakeholders around the world like IATA, but it is not without challenges. The development of production technologies is a critical step toward making SAF a mainstream alternative to fossil-based jet fuels.Author: Paul Ticehurst&nbsp; Managing Director for HyCOgen and FT Liquids&nbsp;&nbsp; Johnson Matthey&nbsp; &nbsp;

2025-09-02 - Scaling SAF: Technological and Economic Perspectives (SAF Magazine)

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The development of production technologies is a critical step toward making SAF a mainstream alternative to fossil-based jet fuels.

Scaling SAF: Technological and Economic Perspectives

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International Fuel Ethanol Workshop & Expo

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Scaling SAF: Technological and Economic Perspectives