Sustainable Aviation Fuel: Operational Challenges, Techno-economics, and Life Cycle Analysis

Achieving net-zero emissions in aviation requires using 100% sustainable aviation fuels (SAFs), which demands a 57% annual increase in production between 2022 and 2030 followed by a 13% yearly growth rate from 2030 onward. Although third-generation feedstocks demonstrate significant potential for high emissions reduction (∼8.0 gCO₂e/MJ) with low cost and high sustainability, the variation in feedstocks currently utilized in SAF production has achieved only a 1.47% reduction in CO₂ emissions. A techno-economic analysis has demonstrated that a hybrid pathway is the most effective method for producing SAF. For cost-effective SAF production, a hybrid approach leveraging hydroprocessed esters and fatty acids (HEFA) for short-term scalability and catalytic decarboxylation and gasification/Fischer–Tropsch/pyrolysis ($0.40/L) for long-term sustainability is considered. The life cycle assessment (LCA) of SAFs indicates a potential reduction in greenhouse gas emissions by 26–93% compared to fossil-based jet fuel, excluding land use change effects (LUC). However, including direct and indirect LUC in LCA is crucial for a comprehensive assessment. Infrastructure requirements for SAF deployment at airports must adopt a forward-thinking approach, exploring innovative solutions and policies to promote SAF usage. Further investment in feedstock availability, process optimization, and infrastructure could lower prices, enabling greater market penetration.