Sustainable aviation fuels from bio resources: Technological pathways, prospects, and deployment challenges

Abstract

Sustainable Aviation Fuels (SAFs) represent a vital strategy for the decarbonization of the aviation sector, significantly reducing greenhouse gas emissions and improving energy resilience. This paper presents a comprehensive assessment of recent technological advancements and emerging trends in SAF production, focusing on advanced biofuels, power-to-liquid synthetic fuels derived from renewable electricity, and process innovations that enhance lifecycle sustainability and fuel efficacy. This review systematically compares pathways including HEFA, Fischer–Tropsch, alcohol-to-jet, and PtL, based on over 100 peer-reviewed studies, techno-economic assessments, and policy reports published from 2015 to 2025. It evaluates lifecycle GHG reductions (50 % to over 90 %), fuel yields (250–650 L/ton), and production costs (0.85–4.00 USD/L). The analysis identifies ongoing disparities between laboratory-scale innovations and their commercial implementation, especially in high-yield lignocellulosic and PtL pathways, where issues of scalability and cost competitiveness are yet to be addressed. This study identifies key leverage points where innovation can improve scalability, such as feedstock flexibility, catalytic conversion pathways, and modular biorefinery designs. Despite these advancements, the widespread adoption of SAF is constrained by high production costs, insufficient infrastructure, competition for feedstocks, and regulatory inconsistencies across jurisdictions. The document underscores the environmental risks associated with large-scale biomass procurement and the urgent need for a robust SAF supply chain. This paper synthesizes the current status of sustainable aviation fuel (SAF) development alongside policy and market dynamics, providing actionable insights to overcome challenges to a low-carbon aviation future and outlining a pathway for aligning SAF adoption with global climate objectives.