Sustainable Aviation Fuels: A Review of Current Techno Economic Viability and Life Cycle Impacts

Md Nasir Uddin and Feng Wang ()
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Md Nasir Uddin: School of Science, Computing and Emerging Technologies, Swinburne University of Technology, Hawthorn, Melbourne, VIC 3122, Australia
Feng Wang: School of Science, Computing and Emerging Technologies, Swinburne University of Technology, Hawthorn, Melbourne, VIC 3122, Australia

Energies, 2025, vol. 18, issue 20, 1-46

Abstract: Australia has set a new climate target of reducing emissions by 62–70% below 2005 levels by 2035, with sustainable aviation fuel (SAF) central to achieving this goal. This review critically examines techno-economic analysis (TEA) and life cycle assessment (LCA) of Power-to-Liquid (PtL) electrofuels (e-fuels), which synthesize atmospheric CO 2 and renewable hydrogen (H 2 ) via Fischer-Tropsch (FT) synthesis. Present PtL pathways require ~0.8 kg of H 2 and 3.1 kg of CO 2 per kg SAF, with ~75% kerosene yield. While third-generation feedstocks could cut greenhouse gas emissions by up to 93% (as low as 8 gCO 2 e/MJ), real world reductions have been limited (~1.5%) due to variability in technology rollout and feedstock variability. Integrated TEA–LCA studies demonstrate up to 20% energy efficiency improvements and 40% cost reductions, but economic viability demands costs below $3/kg. In Australia, abundant solar resources, vast transport networks, and supportive policy frameworks present both opportunities and challenges. This review provides the first comprehensive assessment of PtL-FT SAF for Australian conditions, highlighting that large-scale development will require technological advancement, feedstock development, infrastructure investment, and coordinated policy support.

Keywords: sustainable aviation fuels (SAFs); techno-economic assessment (TEA); lifecycle assessment (LCA); carbon emissions reduction; biofuels and synthetic fuels (search for similar items in EconPapers)
JEL-codes: Q Q0 Q4 Q40 Q41 Q42 Q43 Q47 Q48 Q49 (search for similar items in EconPapers)
Date: 2025
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