As global air travel expands, the aviation industry is under increasing pressure to reduce its environmental footprint. Sustainable aviation fuel (SAF) has become a key part of the solution—a renewable alternative to traditional jet fuel that can substantially lower carbon emissions.
Progress in SAF technology is picking up speed, propelled by regulatory requirements, industry pledges, and the growing urgency for cleaner transportation options. This article takes a closer look at the key milestones in SAF development, recent innovations, why it is essential, and where the technology is headed next.
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Historical Developments in Sustainable Aviation Fuel
When was sustainable aviation fuel invented?
Sustainable aviation fuel dates back several decades, with early interest driven by concerns over fossil fuel dependence and environmental impact.
The first significant development came in the 1940s when Fischer-Tropsch synthesis produced liquid fuels from biomass. However, it was not until the late 20th century that research into SAF gained momentum.1
In 2008, a major milestone was achieved when Virgin Atlantic operated a commercial flight using a biofuel blend. This demonstrated that SAF could function effectively in existing jet engines without modifications. The successful flight marked the beginning of a serious industry commitment to developing bio-based aviation fuels.2
By 2011, ASTM International, a global standards organization, approved the first SAF pathway, allowing the commercial use of fuels derived from hydroprocessed esters and fatty acids (HEFA). This opened the door for airlines to incorporate SAF into their fuel mix and spurred further research into alternative feedstocks, such as algae and municipal solid waste.3
Recent Breakthroughs in Sustainable Aviation Fuel
In the past decade, SAF development has accelerated, with significant advances in production technology and adoption by major airlines. One of the most important breakthroughs occurred in 2018 when the first transatlantic flight using 100% SAF took place, proving that sustainable fuels could completely replace fossil-based jet fuel under controlled conditions.2
In 2022, Neste, a prominent biofuel producer, significantly scaled up its SAF production, partnering with airlines and fuel suppliers to expand availability. This progress increased the commercial viability of SAF, reducing costs and making it a more accessible option for airlines.3
According to a recent report published in Renewable and Sustainable Energy Reviews, scientists have developed a process to produce SAF from carbon dioxide captured from the air using hydrogen and a metal catalyst. This innovation, known as direct air capture (DAC) fuel synthesis, offers a promising way to create a closed-loop carbon cycle. The process utilizes electrolysis to split water into hydrogen and oxygen, with the hydrogen then reacting with captured CO2 to form hydrocarbons. This method reduces carbon emissions and enables fuel production independent of traditional biomass sources.
If scaled efficiently, DAC fuel synthesis could revolutionize the aviation industry by providing a near-limitless sustainable fuel supply.4
In another study published in Biomass and Bioenergy, researchers successfully converted agricultural and forestry waste into SAF using a novel catalytic process. This approach has the potential to create a circular economy by utilizing waste products instead of relying on crops that could otherwise be used for food production.5
The Importance of Developing Sustainable Aviation Fuel
The aviation sector accounts for approximately 2-3% of global carbon dioxide emissions, making decarbonization a priority.
Unlike ground transportation, where electrification is increasingly viable, aviation remains dependent on liquid fuels due to energy density requirements. SAF provides the best near-term solution to reducing emissions without requiring new aircraft or infrastructure.3
SAF can also improve energy security by diversifying fuel sources. Traditional jet fuel relies on fossil reserves subject to geopolitical instability, whereas SAF can be produced from local biomass, waste, or synthetic processes, reducing reliance on imported oil.3
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Economic benefits also come into play. As the SAF industry grows, it generates jobs in feedstock cultivation, fuel processing, and distribution. Governments worldwide recognize these advantages, leading to policy support through incentives, mandates, and funding for research and development.3
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Challenges in Scaling Up Sustainable Aviation Fuel Production
Despite its benefits, SAF faces challenges in scaling up production to meet demand.
Cost
One of the primary hurdles is cost. SAF remains significantly more expensive than conventional jet fuel, often costing two to five times as much. However, with increased production and technological improvements, prices are expected to decline over time.4,6
Feedstock availability
While multiple sources, such as used cooking oil, algae, and municipal waste, can be used to produce SAF, ensuring a consistent and scalable supply remains a challenge. Further investment in feedstock development is crucial for the industry's long-term sustainability.6
Regulatory and certification processes
SAF must meet stringent quality and safety standards before being approved for commercial aviation use. While organizations like ASTM International continue to expand the list of approved SAF pathways, the certification process can be lengthy and costly.6
The Future of Sustainable Aviation Fuel
The future of SAF is promising, with increasing commitments from governments, airlines, and fuel producers.
The International Air Transport Association (IATA) has set a goal of achieving net-zero emissions for the aviation industry by 2050, with SAF expected to play a crucial role in meeting this target.3
One of the most exciting future prospects is the development of power-to-liquid (PtL) fuels, which use renewable electricity to synthesize hydrocarbons from water and carbon dioxide. This technology, if scaled successfully, could provide a nearly limitless source of SAF without relying on biomass.3,4
Another emerging trend is the worldwide expansion of SAF production facilities. In 2025, several large-scale SAF plants are expected to come online, increasing global production capacity and helping to reduce costs. Governments are also stepping up policy support, with tax credits, subsidies, and blending mandates becoming more common.3
Research is also ongoing into improving the efficiency of SAF production and exploring novel feedstocks, such as genetically engineered algae and industrial carbon capture.3
Sustainable Aviation Fuel Production is Accelerating—But Can it Scale Fast Enough to Decarbonize Air Travel?
Sustainable aviation fuel has made remarkable progress—from early experimental biofuels to commercially viable options capable of powering flights today.
Breakthroughs in carbon capture, waste-to-fuel processes, and synthetic fuel production underscore how quickly the industry evolves. Still, significant hurdles remain, particularly around scaling up production and bringing down costs.
As governments, airlines, and fuel producers ramp up their investments in SAF, its importance in aviation’s decarbonization efforts will only grow. With continued technological innovation and strong policy support, SAF is positioned to play a critical role in shaping a more sustainable future for air travel.
References and Further Reading
- Sánchez, N. M. et al. (2022). Conversion of waste to sustainable aviation fuel via Fischer–Tropsch synthesis: Front-end design decisions. Energy Science & Engineering, 10(5), 1763-1789. DOI:10.1002/ese3.1072. https://scijournals.onlinelibrary.wiley.com/doi/full/10.1002/ese3.1072
- Virgin Atlantic flies world’s first 100% Sustainable Aviation Fuel flight from London Heathrow to New York JFK. Corporate | Virgin Atlantic. https://corporate.virginatlantic.com/gb/en/media/press-releases/worlds-first-sustainable-aviation-fuel-flight.html
- Undavalli, V. et al. (2022). Recent advancements in sustainable aviation fuels. Progress in Aerospace Sciences, 136, 100876. DOI:10.1016/j.paerosci.2022.100876. https://www.sciencedirect.com/science/article/abs/pii/S0376042122000689
- Gray, N. et al. (2024). The role of direct air carbon capture in decarbonising aviation. Renewable and Sustainable Energy Reviews, 199, 114552. DOI:10.1016/j.rser.2024.114552. https://www.sciencedirect.com/science/article/pii/S1364032124002752
- Pan, H. et al. (2022). Selective production of monocyclic aromatic hydrocarbon from agricultural waste wheat straw for aviation fuel using Ni/ZSM-5 catalyst. Biomass and Bioenergy, 165, 106592. DOI:10.1016/j.biombioe.2022.106592. https://www.sciencedirect.com/science/article/abs/pii/S0961953422002549
- Wang, B. et al. (2024). Sustainable aviation fuels: Key opportunities and challenges in lowering carbon emissions for aviation industry. Carbon Capture Science & Technology, 13, 100263. DOI:10.1016/j.ccst.2024.100263. https://www.sciencedirect.com/science/article/pii/S2772656824000757
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