The Future of Sustainable Aviation Fuel: Exploring Key Production Pathways
As the aviation industry seeks to reduce its carbon footprint, Sustainable Aviation Fuel (SAF) has become a crucial part of the conversation as the most viable option to decarbonise flights for the next decade and beyond. SAF can significantly cut emissions compared to traditional jet fuel, but there are several ways to produce it. Each production pathway offers its own set of advantages and challenges. Here's a look at four of the main pathways and what they might mean for the future of aviation.
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HEFA (Hydroprocessed Esters and Fatty Acids)
HEFA is the most established method for producing SAF today. It uses feedstocks like waste oils, animal fats, and vegetable oils to produce a fuel that can be used in existing aircraft engines without modification.
Why It’s Important: HEFA is popular because it can be scaled relatively quickly due to the maturity of the production technology and the ability to re-purpose existing refinery infrastructure. This means that HEFA facilities can be developed and constructed with significantly less CAPEX compared to advanced 2nd generation routes to SAF.
The cost of production is cheaper than other pathways, such as Gasification + Fischer Tropsch or AtJ. This makes it a strong candidate for meeting immediate demand.
Challenges: The main challenge with HEFA is the limited availability of feedstocks. As more industries compete for these resources, the cost could rise, and supply may become a bottleneck. There are also HEFA caps being implemented on the policy and regulatory side which will limit the scalability.
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Gasification + Fischer-Tropsch
This pathway involves turning solid materials like biomass or municipal waste into gas, which is then converted into liquid wax through the Fischer-Tropsch process. Waxes are then upgraded in conventional refinery hydroprocessing steps to produce SAF and by-product naphtha. SAF produced in this way is called Fischer Tropsch synthetic paraffinic kerosene (FT-SPK). It’s a more complex method than HEFA but has the potential to produce large amounts of SAF.
Why It’s Important: Gasification + Fischer-Tropsch can use a wide range of feedstocks, including materials that would otherwise go to waste. This makes it a promising option for large-scale SAF production, especially in areas with abundant biomass or waste resources.
Challenges: The technology is complex and expensive to scale. Building and operating these plants requires significant investment which can be challenging in a nascent market. Policy and regulatory support is essential to enable this pathway to scale at pace.
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Alcohol-to-Jet
Alcohol-to-Jet (AtJ) converts alcohols, like ethanol, into jet fuel. This method can be particularly appealing in regions with established alcohol production industries.
Why It’s Important: AtJ can leverage existing ethanol production infrastructure, which means it could be easier and cheaper to implement in some geographies. It also offers flexibility in terms of the types of feedstocks that can be used.
Challenges: The technology is still in the early stages, and there are technical hurdles to overcome, such as improving the efficiency of the conversion process to make it commercially viable.
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Power-to-Liquid (eSAF)
Power-to-Liquid, also known as eSAF, is a cutting-edge approach that involves creating fuel from renewable electricity, hydrogen, and captured CO2. This pathway is seen as a long-term solution for truly sustainable fuel.
Why It’s Important: eSAF has the potential to produce jet fuel with a very low carbon footprint. Since it doesn’t rely on biological feedstocks, it avoids many of the sustainability issues associated with other methods.
Challenges: eSAF is still in its infancy. The technology is expensive, and the infrastructure needed to produce it on a large scale isn’t fully developed yet. It will take several years before eSAF can be produced in significant quantities.
The future of scaling SAF lies in utilising a mix of these pathways, especially in the early stages of the energy transition. HEFA is currently leading the way, but as technology and infrastructure develop, other methods like Gasification + Fischer-Tropsch, Alcohol-to-Jet, and Power-to-Liquid will play increasingly important roles. Each pathway has its own strengths and challenges, and the best approach may vary depending on regional resources and technological advancements. As the industry continues to innovate and countries seek to reach their Net Zero targets, SAF will become a critical component in reducing aviation’s environmental impact.
Lighthouse Green Fuels announces statutory consultation on its ambitious sustainable aviation fuel project in Teesside
Thursday 16th of May – A statutory consultation for Lighthouse Green Fuels, a proposed sustainable aviation fuel (SAF) facility located in Stockton-on-Tees, is announced today. The consultation will run until 20 June 2024.
Lighthouse Green Fuels Ltd would like to hear views on the proposed project and its associated development. Feedback submitted to the consultation will help to shape the project proposals.
At its site in Billingham, the project will convert waste and/or waste biomass into advanced SAF. This SAF will then be distributed to local airports and blended with conventional jet fuel to power flights around the world, saving up to 350,000 tonnes of carbon dioxide per year.
The facility will be the largest of its kind in Europe and convert over 1 million tonnes of waste and/or waste biomass every year into over 175 million litres of SAF. This is the equivalent of fuelling 25,000 short-haul flights to Europe, or 2,500 long-haul flights to destinations such as the Americas or Australia every year.
A series of public information events will be held as part of the statutory consultation. These will give members of the public the opportunity to meet the project team and view the consultation materials.
There are three face-to-face events and three online webinars during this period, including:
| Event location | Date | Time |
| Billingham Forum, Town Centre, The Causeway, Stockton-on-Tees, Billingham TS23 2LJ | 1 June 2024 | 12:00 to 17:00 |
| High Clarence Primary School, Port Clarence Road, Middlesbrough TS2 1SY | 5 June 2024 | 15:00 to 20:00 |
| Billingham Rugby Club, Greenwood Rd, Billingham, Stockton-on-Tees TS23 4BA | 6 June 2024 | 10:00 to 17:00 |
| Online webinar 1 | 28 May 2024 | 18:30 to 20:00 |
| Online webinar 2 | 4 June 2024 | 10:00 to 11:30 |
| Online webinar 3 | 12 June 2024 | 10:00 to 11:30 |
Please register for a webinar by emailing info@lgf.co.uk or calling 0800 157 7346.
Hard copies of the consultation materials are available to view at a local information point in Billingham Library. Electronic copies of the consultation materials are also available on the Lighthouse Green Fuels website, along with further information about the statutory consultation and proposals. More information can be found at www.lighthousegreenfuels.co.uk
Tees Valley Mayor, Ben Houchen, said: “This is a fantastic project that sits at the heart of Teesside’s green industrial growth. Lighthouse Green Fuels will play a key role in decarbonising the aviation industry through the development of Sustainable Aviation Fuel. Critically, the project will create over one thousand high quality jobs for local people across Teesside, Darlington and Hartlepool.
It is important that local people have the opportunity to help shape the project and share their views on the proposals, which is why I encourage everyone to take part in the consultation, by providing your feedback.”
Lighthouse Green Fuels Ltd is owned by Alfanar Group, a global company specialising in project development, manufacturing, and engineering. Alfanar is investing over £1 billion to advance the UK’s domestic SAF production through the development of Lighthouse Green Fuels, with plans to have two additional SAF plants under development by 2028.
Noaman Al Adhami, UK Country Head of Alfanar Projects, said: “Lighthouse Green Fuels will help to address the challenge of Net Zero by delivering an immediate and long-term solution to decarbonising the UK aviation industry.
We are delighted to share our project proposals with you. Your feedback is important to us and we would encourage anyone interested in Lighthouse Green Fuels to learn more about our plans, attend one of our public events and share your views.”
Alfanar welcomes Transport Secretary Mark Harper MP to Teesside as SAF revenue support consultation is launched
Friday 26th April – Yesterday we welcomed Transport Secretary Mark Harper MP to our Teesside site on the day the Government announced measures to give UK aviation and the SAF industry the certainty to create green jobs and cut sector emissions. The Secretary of State toured Lighthouse Green Fuels facility along with Phil Forster, Managing Director at Teesside International Airport. Lighthouse Green Fuels facility is the largest and most advanced SAF project in Europe, and could reach Final Investment Decision in 2025 and be operational in 2028.
The project will take everyday household and commercial waste as well as other forms of non-recyclable waste feedstocks, such as waste biomass, which will be nationally sourced and which there is a plentiful supply of. The “drop-in” fuel will be ready to use in today’s aircrafts with no engine or refuelling infrastructure modifications needed. The facility will produce 175 million litres a year, the equivalent of fuelling 2,500 long-haul flights or 25,000 short-haul flights a year, whilst bringing investment to industrial areas.
Transport Secretary the Rt Hon Mark Harper MP said:
"Sustainable aviation fuel protects the future of UK aviation, the thousands of British jobs that depend on it, and the holidays and business travel flights that we all rely on. As part of our plan to grow the economy, the measures announced today will give UK SAF producers like Alfanar, the certainty they need to keep creating skilled British jobs while giving passengers the freedom to continue travelling by air in a way that’s fit for the future.”
Mishal Almutlaq, Alfanar Project’s Chief Investment Officer, said:
“Alfanar welcomes today’s announcement, an important step in the journey towards delivering a thriving SAF market in the UK. We were delighted to welcome Transport Secretary Mark Harper to our Teesside site, which is Europe’s largest and most advanced SAF project.
“The SAF mandate, coupled with a SAF revenue support mechanism, can make the UK a leader in green aviation fuel production. But to deliver the Government’s target of 5 SAF plants under construction by 2025, the SAF revenue support mechanism needs to be introduced at pace.
“Ninety years ago Teesside led the way in producing synthetic fuels which were then used in Spitfires during WW2. With continued Government support Teesside can once again become a crucible for aviation innovation as we tackle the challenge of climate change.”
Aviation Decarbonisation: Navigating the Shift from Fossil to Sustainable Aviation Fuel
In the ever-evolving realm of aviation, sustainability has taken centre stage, prompting a revolutionary shift in the way we approach fuel. At Alfanar Projects we proudly champion this movement towards a greener future, leading the way through transparency and innovative solutions. Let's dive into the pivotal differences between Sustainable Aviation Fuel (SAF) and traditional fossil fuels, exploring their production, composition, and environmental impact.
As aviation fuel undergoes a paradigm shift, understanding the essence of this change begins with production processes. Conventional jet fuels have long been the backbone of the industry, derived from finite fossil resources. However, #SAF offers a departure from this reliance, embracing abundant renewable feedstocks like municipal solid waste, waste oils or forestry residues. This shift not only diversifies our fuel sources but also aligns with the aviation sector's commitment to reducing its environmental footprint.
The composition of aviation fuel plays a crucial role in shaping its impact on the environment. By prioritising sustainable feedstocks and leveraging advanced refining processes, SAF stands out with a cleaner composition and delivers a greener alternative without compromising performance. This nuanced understanding of composition is key for businesses seeking to make sustainable choices in their fuel procurement.
Moving beyond composition, the environmental impact of aviation fuels extends to factors such as particulate matter emissions and overall air quality. SAF excels in this arena, significantly lowering greenhouse gas emissions throughout its lifecycle. The production and use of SAF not only contribute to reduced carbon footprints but also enhance overall air quality, making it a responsible choice for businesses committed to minimising their environmental impact. Replacing fossil fuels with SAF (without the use of carbon capture technologies enhancing this figure even further) offers up to 80% emissions savings compared to the use of conventional jet fuel. This is achieved by reusing carbon that has already been present in the feedstock's lifecycle, instead of generating additional CO2 into the atmosphere.
We stand as pioneers in the production of advanced sustainable fuel at commercial scale, contributing 10% to the UK’s overall Jet Zero strategy 2030 target. Lighthouse Green Fuels is set to become Europe’s largest advanced #waste-to-SAF facility, saving over 750,000 tonnes of #CO2 emissions annually once commercial operation starts. Our commitment to transparency ensures that our clients have access to comprehensive information about the origin, composition, and environmental performance of the aviation fuels we provide. By embracing innovative solutions, we empower businesses to make informed decisions that align with their sustainability goals.
In conclusion, the aviation industry is at a crossroads, and the choice between traditional fossil fuels and SAF is pivotal. With a deep understanding of the nuanced differences in production processes, composition, and environmental impact, businesses can confidently navigate this transition. Join us in charting the course towards an aviation industry that embraces the principles of environmental responsibility and technology innovation – and, as a result, creates a sky that is undeniably greener and more sustainable.