Road to Carbon-Neutral Aviation: One-Step Conversion of CO2 to Sustainable Aviation Fuels

Aviation has accounted for approximately 3.5% of global CO₂ emissions since the beginning of industrialization. Achieving carbon neutrality and sustainability in aviation requires replacing fossil-fuel-based kerosene with kerosene derived from renewable and sustainable energy sources. This Review focuses on recent advances and challenges in the development of sustainable aviation fuel (SAF) through the one-step conversion of CO₂, known as the CO2AF process, which offers the advantages of a short route and high efficiency. We provide an overview of the bifunctional catalyst system designed to achieve both high CO₂ conversion efficiency and high aromatic selectivity as well as the application of high-pressure fluidized bed reactors that enhance mass and heat transfer rates. In addition, we discuss the engineering challenges associated with the commercial application of the CO2AF process, specifically the stability and longevity of the bifunctional catalyst in high-pressure fluidized bed reactors. Multilevel engineering principles for scaling up the CO2AF process are highlighted, focusing on the interrelationships between molecular motion, catalyst system design, reactor configuration, and overall process integration. We also compare our approach with recent research efforts across the field, aiming to bridge the gap between fundamental science and industrial-scale SAF production. By providing insights into the multiscale research required for bridging these gaps, we hope to contribute to the accelerated development of SAF technologies.