4 Amazing Ways to Produce SAF: From Waste Oil to e-Fuel Technology Explained
Hello, I'm from GLEC, a company specializing in measuring carbon emissions in the logistics and transportation industry.
Last month, I had the incredible opportunity to tour a refinery where they were converting used cooking oil into aviation fuel. Watching waste oil transform into clean-burning jet fuel felt like witnessing modern-day alchemy. It got me thinking: how many people actually understand the fascinating science behind SAF production?
With the global SAF market projected to reach 18.34 million tons by 2030, understanding how this revolutionary fuel is made has never been more important. The technology behind SAF isn't just impressive - it's reshaping entire industries and creating new opportunities for sustainable development.
Today, I'll break down the 4 main pathways for SAF production that are changing the aviation industry forever. Whether you're an industry professional, environmental enthusiast, or simply curious about clean technology, this guide will give you everything you need to know.
1. HEFA Technology: The "Fat Path" That's Leading the Way
Hydroprocessed Esters and Fatty Acids (HEFA) currently dominates the SAF landscape, accounting for over 95% of all SAF production worldwide. This isn't just a statistic - it represents proven technology that's already powering hundreds of thousands of flights.
How HEFA Works:
The process involves three main steps:
- Step 1: Hydrotreatment - Vegetable oils, used cooking oil, and animal fats are processed with hydrogen under high temperature and pressure
- Step 2: Deoxygenation - Impurities are removed and straight-chain paraffins are produced
- Step 3: Isomerization - The molecular structure is converted to match aviation fuel specifications
Key Feedstocks:
- Used Cooking Oil (UCO): Makes up 60% of HEFA feedstock
- Animal fats: Byproducts from food processing
- Vegetable oils: Palm oil, soybean oil, canola oil
- Algae oil: Emerging as a next-generation feedstock
Real-World Impact: In South Korea, S-Oil and SK Energy are already producing SAF using HEFA technology and supplying it to Korean Air. This demonstrates that HEFA isn't just theoretical - it's operational and scaling globally.
Pros and Cons:
- Advantages: Mature technology, commercially proven, consistent quality
- Challenges: Limited feedstock supply, competition with biodiesel market
2. Fischer-Tropsch (FT): The "Waste Path" Revolution
The Fischer-Tropsch process represents one of the most exciting developments in SAF production because it can turn almost any organic waste into high-quality aviation fuel.
The FT Production Process:
- Stage 1: Gasification - Biomass is converted to synthesis gas (CO + H₂) at high temperatures
- Stage 2: Purification - Impurities are removed and gas ratios are optimized
- Stage 3: FT Reaction - Catalysts convert syngas into liquid hydrocarbons
- Stage 4: Upgrading - Final refining to meet aviation fuel specifications
Feedstock Flexibility:
- Agricultural residues: Rice straw, corn stalks, sugarcane bagasse
- Forestry waste: Wood chips, sawdust, pruning residues
- Municipal solid waste: Household garbage, paper, wood waste
- Energy crops: Switchgrass, miscanthus
Technical Advantages:
- Superior fuel quality: Virtually sulfur and nitrogen-free
- Production flexibility: Can produce aviation fuel, diesel, or other products
- Scalability: High expansion potential due to feedstock diversity
Industry Example: Hyundai Oilbank became the first in Korea to successfully produce SAF using co-processing methods with existing refinery infrastructure, proving that FT technology can be implemented cost-effectively.
3. Alcohol-to-Jet (ATJ): The "Grain Path" Innovation
ATJ technology leverages the existing ethanol infrastructure, making it particularly attractive for countries with established bioethanol industries.
The ATJ Process:
- Step 1: Fermentation - Biomass is fermented to produce ethanol
- Step 2: Dehydration - Water is removed from ethanol to create ethylene
- Step 3: Oligomerization - Ethylene molecules are linked into longer hydrocarbon chains
- Step 4: Hydrogenation - Final conversion to aviation fuel characteristics
Strategic Advantages:
- Infrastructure leverage: Utilizes existing ethanol production facilities
- High carbon reduction: Up to 85% lifecycle GHG reduction potential
- Cellulosic ethanol: Second-generation bioethanol minimizes food competition
Global Development:
- Gevo: Building large-scale ATJ-SAF production facilities in the US
- Byogy: Advancing proprietary ATJ technology for commercialization
- ENEOS Japan: Investing in next-generation ATJ technology development
The beauty of ATJ is that it can tap into the massive global ethanol industry, which already produces over 100 billion liters annually.
4. Power-to-Liquid (PtL): The "Air Path" Future
Power-to-Liquid technology represents the ultimate frontier in SAF production - creating jet fuel literally from air and water using renewable energy.
The PtL Process:
- Stage 1: Direct Air Capture (DAC) - CO₂ is captured directly from the atmosphere
- Stage 2: Electrolysis - Renewable energy splits water to produce hydrogen
- Stage 3: Synthesis - CO₂ and H₂ are combined using Fischer-Tropsch processes
- Stage 4: Refining - Final processing to meet aviation fuel specifications
Revolutionary Characteristics:
- Unlimited feedstock: Only requires water and air
- Maximum carbon reduction: Over 90% reduction when using renewable energy
- Location independence: Can be produced anywhere, regardless of biomass availability
EU ReFuelEU Aviation e-SAF Mandates:
- 2030: 0.7% mandatory e-SAF usage
- 2035: 5%
- 2050: 35%
Current Projects: Atmosfair (Germany) and HIF Global (Chile) are building commercial-scale e-SAF production facilities, proving that this technology is moving from laboratory to reality.
Regional SAF Production Strategies: A Global Perspective
North America: HEFA Technology Leadership
The United States is leading with aggressive SAF targets:
- Phillips 66: Building 800 million gallon annual production capacity
- Marathon Petroleum: Converting existing refineries to SAF-dedicated facilities
- Chevron: Acquired Renewable Energy Group to expand integrated production
Europe: e-Fuel Technology Focus
European strategy emphasizes synthetic fuels:
- Neste (Netherlands): World's largest SAF producer with 1 million tons renewable fuel capacity
- Germany's innovation: BIOJET project for woody biomass-based SAF
- Sweden's breakthrough: Renewable Jet e-fuel commercialization project
Asia-Pacific: Diversified Approach
Asian countries are pursuing multiple pathways:
- Japan: ENEOS developing ATJ technology, ANA investing in algae-based SAF research
- China: Sinopec targeting 1 million tons annual SAF production
- South Korea: Four major refiners planning $1 trillion won joint SAF plant
SAF Feedstock Evolution: The Generation Game
First Generation: FOG (Fats, Oils, Greases)
Current situation:
- Over 80% of current SAF feedstock
- Annual supply potential: ~5 million tons (limited)
- Price pressure from biodiesel competition
Second Generation: Lignocellulosic Biomass
Technological progress:
- Woody biomass: Gasification + FT approaching commercialization
- Agricultural residues: Rice straw, corn stover utilization increasing
- Dedicated energy crops: Switchgrass, poplar cultivation expanding
Third Generation: Algae and Microalgae
Future potential:
- High oil content (50-70%), rapid growth
- Marine cultivation for large-scale production
- Commercial timeline: 2025-2030 for pilot scale, post-2030 for full commercialization
Cost Analysis: The Economics of SAF Production
Current Production Costs (HEFA Technology):
- Feedstock costs: 70-80% of total cost
- Production cost: $2.50-4.00 per gallon
- Premium over conventional jet fuel: 3-5x higher
Cost Reduction Factors:
- Economies of scale: Larger production volumes reduce unit costs
- Technology innovation: Improved catalysts and process optimization
- Government support: Tax credits and subsidies
Regional Cost Variations:
- United States: $3.50-5.00/gallon (strong policy support, up to $1.75/gallon tax credit)
- Europe: $4.00-6.00/gallon (high environmental standards, carbon tax benefits)
- Asia: $3.00-4.50/gallon (relatively lower feedstock and labor costs)
Next-Generation SAF Technologies: What's Coming
Co-processing Technology Expansion
Hyundai Oilbank's success with co-processing demonstrates that existing refineries can produce SAF without massive additional investment. This approach offers:
- No separate facility investment required
- High investment efficiency ratio
- Rapid market penetration potential
Hybrid Production Systems
Combining multiple technologies:
- HEFA + FT technology integration
- Feedstock diversification for supply security
- GS Caltex is building such a system in Indonesia
AI and Digital Technology Integration
Smart production systems:
- AI-based process optimization
- Real-time quality management
- Predictive maintenance for higher efficiency
Blockchain-based Traceability
- Complete supply chain tracking from feedstock to final fuel
- Automated sustainability certification
- Real-time carbon footprint calculation
The Importance of Accurate Carbon Footprint Measurement
At GLEC, we emphasize that precise carbon footprint measurement is crucial throughout the SAF production process. Simply using renewable feedstock doesn't automatically create an environmentally friendly fuel.
Looking Forward: The SAF Production Revolution
The diversification and advancement of SAF production technologies are accelerating the realization of aviation industry carbon neutrality. From first-generation HEFA technology to next-generation e-fuels, understanding and appropriately combining each technology's characteristics is the key to success.
We're witnessing an incredible transformation where waste becomes fuel and air becomes energy. The technology that seemed impossible just a decade ago is now powering commercial flights around the world.
What fascinates you most about SAF production technology? Have you encountered any SAF-related innovations in your industry? I'd love to hear your thoughts in the comments.
In our next post, we'll explore how airlines around the world are adopting SAF and examine their success stories. You'll be amazed by some of the innovative approaches leading airlines are taking!
For consultation and inquiries about carbon emission measurement, please visit the GLEC website.
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