Techno-economic and environmental impacts assessments of sustainable aviation fuel production from forest residues†

The aviation sector contributes approximately 2.5% to global GHG emissions, driving a growing interest in mitigating its environmental impacts through use of sustainable aviation fuel (SAF). A critical component in SAF development lies in securing sustainable feedstock supplies to ensure competitive pricing and minimal environmental impact. This novel study compares the techno-economic and life-cycle environmental impacts from cradle-to-gate of SAF production from forest residues as a lignocellulosic biomass feedstock. The fuel production pathway considered in this study includes conversion of lignocellulosic biomass (forest residues) to renewable jet fuel through gasification, producing synthesis gas and subsequently SAF (FT-SPK-SAF) through Fischer–Tropsch synthesis in the presence of a catalyst. Techno-economic models of feedstock (forest residues) supply, pretreatment, and conversion processes for SAF production at 90 Mg per day capacity were developed and evaluated. Considering the value of co-products, the minimum selling price (MSP) of FT-SPK-SAF was $1.87 per kg or $1.44 L ($5.45 per gallon). The global warming impact of forest residue-based SAF was estimated to be 24.6 g_{CO2 eq.} per MJ of SAF, which was lower than that of SAF from other lignocellulosic feedstock types. Additionally, this study evaluated the changes in carbon removal efficiency of SAF when accounting for soil carbon change. The outcomes of this study are useful for developing strategies to achieve economic feasibility and greenhouse gas reduction goals of SAF production from biobased sources, while also outlining performance targets for enhancing its environmental sustainability at a commercial scale.