SAF: A Promising Approach to Meet Growing Jet Fuel Demand

Journal Article · Wed Apr 22 00:00:00 UTC 2026 · Applied Energy

DOI: https://doi.org/10.1016/j.apenergy.2026.127894 · OSTI ID:3363073

Bhatt, Arpit  ^[1]; Tao, Ling  ^[1]; Zhang, Yimin ^[1]; Smolinski, Sharon ^[1]; Tan, Eric  ^[1]; Klein, Bruno ^[1]; Wiatrowski, Matthew ^[1]; Quiroz, David ^[2]

---

1. National Laboratory of the Rockies, Golden, CO (United States)
2. Ohio University

SAF provides a promising approach to aid the rising jet fuel demand from increased travel around the world and reduce the lifecycle emissions from the aviation sector. Although the feasibility of SAF pathways has been demonstrated through economic and environmental metrics quantification, the models used to quantify these variables have a high degree of variability in terms of accuracy and thereby reliability. To understand how to adopt and commercialize SAF, we need to harmonize these process models and assess metrics and technical limitations related to their production technologies. We find the production cost of SAF using hydro processed fatty acids and esters (HEFA), Fischer-Tropsch (FT), and alcohol-to-jet (ATJ) to be $3-$6/gallon gasoline equivalent (gge) and life cycle emissions to be lower than Jet A, except for ATJ using corn grain (<=25%). HEFA utilizing oil feedstocks has the lowest production cost (~$2.9/gge) and highest jet yield (>150 gge/dry ton), while FT has the largest emission reduction (94%) compared to fossil jet. A unique contribution of this study is a comparative analysis of metrics related to SAF processes across technical, economic, and sustainability aspects. A cross-comparison of these metrics shows HEFA using fats, oils, and grease have the most favorable ratings, while HEFA using algae and ATJ using corn stover have more neutral and unfavorable ratings, respectively. These ratings can be improved by implementing the right combination of practical and technological advancements.

• Research Organization: National Laboratory of the Rockies (NLR), Golden, CO (United States)
• Sponsoring Organization: USDOE Office of Critical Minerals and Energy Innovation (CMEI), Office of Energy Technology (E-Tech). Alternative Fuels and Feedstocks Office
• Grant/Contract Number: AC36-08GO28308
• OSTI ID: 3363073
• Report Number(s): NLR/JA-6A20-87948
• Journal Information: Applied Energy, Journal Name: Applied Energy Vol. 415
• Country of Publication: United States
• Language: English