Financing Sustainable Aviation Fuels 2025
Page 11 of 44 · WEF_Financing_Sustainable_Aviation_Fuels_2025.pdf
The primary infrastructure needed for a greenfield
HEFA facility includes:
1. Feedstock pre-treatment to reduce the risk
that feedstock impurities poison catalysts and
reduce process efficiency. The complexity of
these facilities depends on the variety and
quality of feedstocks used. Facilities with
more homogeneous feedstock may have
lower CapEx for pre-treatment compared to
plants that can handle a wider range of oils
or fats.
2. Hydro-processing units that convert
lipid-based feedstocks into jet fuel through
hydrogenation and isomerization. While
commercially proven, these steps still represent
a significant portion of the capital expenditure,
given the high pressures and temperatures
required for the reaction.
3. Hydrogen production as a critical input for the
hydro-processing reaction. Hydrogen is subject
to market availability if supplied from external
facilities or can be produced on site, but that will
significantly increase the CapEx needs.
Alcohol-to-Jet
While the capital investment for an Alcohol-to-Jet
facility is generally higher than for HEFA, due to the
complexity of the conversion process, the pathway
remains attractive, especially in regions with
abundant ethanol production and infrastructure.
Factors that influence the CapEx requirements for
an Alcohol-to-Jet SAF refinery are:
1. Ethanol production: While many Alcohol-to-Jet
facilities rely on external suppliers for ethanol,
there may be a strategic or logistical need
to integrate ethanol production facilities into
the overall SAF project, especially in regions
where a stable ethanol supply chain is not yet
fully developed. On-site ethanol production
significantly increases CapEx requirements,
driven by the need for biomass handling,
fermentation and distillation.
2. Alcohol dehydration and oligomerization:
These units are needed to convert alcohols
into hydrocarbons and represent a significant
portion of the capital expenditure, as they must
operate at high temperatures and pressures;
they also involve catalysts that need to be
replaced periodically.
3. Feedstock handling: Given that ethanol
is a liquid feedstock, handling and storage
infrastructure is less complex than for the lipid-
based feedstocks used for HEFA. However,
because ethanol is more volatile and flammable,
the facility must invest in specialized storage
and transport, particularly in case ethanol supply chains are not well developed. Being
able to deal with different types of alcohol,
such as butanol, would also add to the
CapEx requirements.
Gasification-Fischer Tropsch
The Gasification-Fischer Tropsch (G-FT) pathway
currently represents a high-CapEx option for
SAF production, primarily due to the complexity
and scale of the process equipment required.
The technology involves the gasification of solid
feedstock into syngas (a mixture of hydrogen
and carbon monoxide), which is then converted
into hydrocarbons through the Fischer-
Tropsch process.
The key steps in the Gasification-Fischer Tropsch
production that drive CapEx are:
1. Feedstock pre-treatment and handling:
Different feedstocks require specific pre-
treatment steps. Biomass is typically more
heterogeneous and challenging to process.
In addition, biomass is bulky, has lower energy
density and degrades over time, requiring
complex supply chain and storage capabilities.
In contrast, municipal solid waste or industrial
waste streams are generally cheaper to
procure, despite having their own challenges,
such as regulatory requirements, sorting
and cleaning.
2. Gasification: This process converts
carbon-rich feedstocks into syngas at high
temperatures. The infrastructure needed
for this represents a large portion of the
investment due to the high temperatures
and pressures involved. This method
also requires complex emission control
systems to manage the release of gases
and particulate matter, which increases the
overall capital investment.
3. Syngas cleaning and conditioning: Syngas
produced from gasification contains impurities
such as sulphur, tar and particulates that
must be removed. The syngas cleaning and
conditioning stage involves various filtration,
scrubbing and chemical processes, each
requiring specialized equipment. This phase
is critical for ensuring the longevity and
efficiency of the Fischer-Tropsch catalysts,
but it significantly increases CapEx due to the
complexity and precision required.
4. Fischer-Tropsch reaction: After syngas is
produced it is converted into hydrocarbons
through the Fischer-Tropsch process.
Fischer-Tropsch reactors require high-
capacity infrastructure designed to operate
continuously under elevated pressures and
temperatures, which also drives significant
energy consumption. While capital
investment for
an AtJ facility is
generally higher
than for HEFA,
the pathway
remains attractive,
especially in
regions with
abundant ethanol
production and
infrastructure.
Financing Sustainable Aviation Fuels 11
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