Decarbonising Sustainable Aviation Fuel (SAF) Pathways: Emerging Perspectives on Hydrogen Integration

Madhumita Gogoi Saikia (), Marco Baratieri () and Lorenzo Menin ()
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Madhumita Gogoi Saikia: Faculty of Engineering, Free University of Bozen-Bolzano, 39100 Bolzano, Italy
Marco Baratieri: Faculty of Engineering, Free University of Bozen-Bolzano, 39100 Bolzano, Italy
Lorenzo Menin: BiSTEMS srl, 39100 Bolzano, Italy

Energies, 2025, vol. 18, issue 21, 1-19

Abstract: The growing demand for air connectivity, coupled with the forecasted increase in passengers by 2040, implies an exigency in the aviation sector to adopt sustainable approaches for net zero emission by 2050. Sustainable Aviation Fuel (SAF) is currently the most promising short-term solution; however, ensuring its overall sustainability depends on reducing the life cycle carbon footprints. A key challenge prevails in hydrogen usage as a reactant for the approved ASTM routes of SAF. The processing, conversion and refinement of feed entailing hydrodeoxygenation (HDO), decarboxylation, hydrogenation, isomerisation and hydrocracking requires substantial hydrogen input. This hydrogen is sourced either in situ or ex situ, with the supply chain encompassing renewables or non-renewables origins. Addressing this hydrogen usage and recognising the emission implications thereof has therefore become a novel research priority. Aside from the preferred adoption of renewable water electrolysis to generate hydrogen, other promising pathways encompass hydrothermal gasification, biomass gasification (with or without carbon capture) and biomethane with steam methane reforming (with or without carbon capture) owing to the lower greenhouse emissions, the convincing status of the technology readiness level and the lower acidification potential. Equally imperative are measures for reducing hydrogen demand in SAF pathways. Strategies involve identifying the appropriate catalyst (monometallic and bimetallic sulphide catalyst), increasing the catalyst life in the deoxygenation process, deploying low-cost iso-propanol (hydrogen donor), developing the aerobic fermentation of sugar to 1,4 dimethyl cyclooctane with the intermediate formation of isoprene and advancing aqueous phase reforming or single-stage hydro processing. Other supportive alternatives include implementing the catalytic and co-pyrolysis of waste oil with solid feedstocks and selecting highly saturated feedstock. Thus, future progress demands coordinated innovation and research endeavours to bolster the seamless integration of the cutting-edge hydrogen production processes with the SAF infrastructure. Rigorous techno-economic and life cycle assessments, alongside technological breakthroughs and biomass characterisation, are indispensable for ensuring scalability and sustainability.

Keywords: hydrogen; SAF; hydrogenation; isomerisation; hydrodeoxygenation; hydrocracking; gasification (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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