Title : Techno-economic and environmental analysis of Sustainable Aviation Fuel (SAF)
Abstract:
Carbon Capture and Utilization (CCU) technologies, especially power-to-liquid (PtL) systems, present a promising pathway for decarbonizing aviation by producing Sustainable Aviation Fuel (SAF), which can reduce lifecycle carbon emissions by up to 80%. This study assesses the technical feasibility of SAF production through two leading PtL pathways—Methanol-to-Jet (MtJ) and Fischer-Tropsch (FT)—comparing their performance, efficiency, and environmental impact. Both processes utilize Direct Air Capture (DAC) for CO? extraction and hydrogen generated via PEM electrolysis.
Using Aspen Plus V14 for process simulation and pinch analysis for heat integration, the results indicate that the MtJ route achieves superior thermal integration with DAC, needing roughly 50% less external heat than the FT pathway. Additionally, MtJ demonstrates marginally higher carbon utilization and SAF yield, along with a 7% improvement in energy efficiency. The overall PtL system efficiency reaches 20.8% for MtJ compared to 18.4% for FT. Moreover, MtJ-based SAF production generates fewer greenhouse gas emissions, particularly when powered by renewable energy like solar or wind, further enhancing its sustainability.
Economically, the Levelized Cost of SAF (LCOP) is estimated at 21.48 AU$/kg by 2025 for an off-grid renewable-powered plant. Under optimistic projections, this cost could drop to 8.86 AU$/kg by 2030—though still nearly six times higher than conventional jet fuel prices. These findings position MtJ as the more technically efficient and environmentally favourable option for large-scale SAF production
