OIL & GAS

SAF Production: From technological challenge to industrial reality

What is SAF, and why is it technically significant?

Sustainable Aviation Fuel (SAF) is designed to partially or fully replace conventional, fossil-based kerosene in commercial aircraft.

SAF’s main advantage is its ability to be incorporated into the current aviation system without requiring significant changes to engines, aircraft, airport infrastructure, or fuel supply chains. This characteristic, known as “drop-in compatibility,” enables the gradual reduction of emissions by leveraging existing assets and avoiding disruptive transformations in one of the most challenging sectors to decarbonize.

This compatibility is why SAF is currently the most realistic solution for decarbonizing air transport in the short and medium term. Other alternatives, such as direct electrification or certain unconventional propulsion concepts, may be viable in specific niches but do not yet offer a widely applicable solution for medium- and long-haul commercial aviation. SAF, on the other hand, can be gradually integrated into the current fuel supply chain, enabling an immediate reduction in emissions without replacing critical sector assets.

Biogenic SAF is the most mature route

It is produced from renewable feedstocks of biological origin, such as used cooking oil, animal fats, organic waste, and certain streams from the agri-food industry. These feedstocks undergo advanced refining processes to produce fuels that meet the aviation sector’s quality requirements.

Currently, oil- and fat-based routes, particularly HEFA (hydroprocessed esters and fatty acids) technology, represent the primary source of commercial SAF production worldwide. One of its main advantages is the ability to leverage existing infrastructure and expertise within the refining industry, which facilitates relatively rapid implementation and reduces technological risk.

However, the growth of this pathway is constrained by the sustainable availability of feedstocks. As demand for SAF increases, access to suitable feedstocks will be one of the key factors in determining the viability and scalability of new projects.

e-SAF: The fuel of the circular carbon economy

Synthetic SAF, or e-SAF, is produced from low-carbon hydrogen and a carbon source, typically CO₂ captured from industrial processes or directly from the atmosphere. Through various synthesis routes, these molecules are converted into liquid fuels that meet aviation standards.

Unlike biogenic SAF, e-SAF does not depend on the availability of waste or biological raw materials but rather on access to renewable electricity, hydrogen, and carbon sources. For this reason, many analysts believe that e-SAF will be essential in meeting long-term demand for sustainable fuel.

Beyond the fuel itself, this approach represents a paradigm shift in the energy transition. Carbon is no longer viewed exclusively as an emission to be avoided, but rather as a raw material that can be reincorporated into the production cycle. Combined with the deployment of renewable energy and CO₂ capture technologies, this circular carbon economy vision positions e-SAF as one of the solutions with the greatest potential for deeply decarbonizing aviation.

Two complementary paths toward the same goal

Rather than competing with one another, the various SAF pathways are destined to coexist. While biogenic technologies are currently driving market development due to their greater maturity, synthetic pathways offer a long-term growth path with far greater scaling potential. The challenge for the industry is to efficiently combine both solutions, leverage available resources, and develop industrial ecosystems capable of supplying sustainable fuel on a scale that air transport will require in the coming decades.

From alternative fuel to regulatory requirement

For years, the development of sustainable aviation fuel (SAF) was driven primarily by technological initiatives, voluntary sustainability goals, and pilot projects. However, the market has entered a new phase. Today, innovation alone is no longer the main driver of growth; rather, the emergence of regulatory frameworks that set specific decarbonization targets and mandates for the use of sustainable fuels in air transport is the main driver of growth.

In this context, SAF has evolved from an option to a strategic element in the planning of airlines, fuel producers, airport operators, and investors. In Europe, initiatives such as ReFuelEU Aviation are accelerating this transformation by establishing increasing requirements for the use of sustainable fuels and creating clear market signals for developing new production capacities.

However, regulatory compliance goes beyond merely producing fuel. For SAF to generate value in the market, its origin, the sustainability of the raw materials used, and the actual emissions reduction achieved throughout its entire lifecycle must be transparently demonstrated. Consequently, certification, traceability, and chain-of-custody systems have become fundamental to the sector’s development.

The ability to verify these aspects is relevant not only from a regulatory standpoint. It also influences the financing of new projects, buyer confidence, and the product’s commercial competitiveness. Therefore, the success of an SAF project depends as much on the robustness of its technological solution as on its ability to meet the sustainability and traceability requirements demanded by an increasingly stringent regulatory environment.

The real challenge is scaling up production

From an industrial standpoint, the major challenge for SAF is no longer proving that it can be produced but rather developing sufficient capacity to meet growing demand. Current production remains far below the volumes required by the aviation sector’s decarbonization goals in the coming decades. This requires progress on several fronts: increasing industrial capacity, optimizing production routes, securing access to raw materials or feedstock molecules, and developing infrastructure to support this growth.

The scaling challenge cannot be addressed as an isolated, single-process issue. Depending on the chosen pathway, an SAF project requires integrating hydrogen, CO₂ capture or conditioning, chemical synthesis, product processing, utilities, storage, traceability, shipping, and, in many cases, connection to existing logistics networks. Therefore, SAF production must be understood as a complete industrial system where the overall performance depends as much on the efficiency of the core process as on the quality of its energy, operational, and logistical integration.

Industrial integration: One of the keys to Up SAF

As the SAF market evolves, the challenge is to develop new production capacities efficiently, competitively, and in a scalable manner. In this context, integrating SAF production units into existing industrial complexes is becoming increasingly important.

Refineries and other energy assets have the necessary infrastructure, utilities, storage, logistics connections, and operational expertise to accelerate the deployment of new production capacities. Process integration often reduces investments, optimizes energy consumption, and capitalizes on operational synergies that improve a project’s overall viability.

This approach is particularly relevant for advanced SAF and e-SAF production routes, where the interaction between hydrogen, CO₂, energy, utilities, and logistics infrastructure directly impacts the facility’s competitiveness. Therefore, a significant portion of the sector’s future growth could come from the gradual transformation of existing industrial assets, not only from entirely new (greenfield) projects.

From this perspective, the development of SAF is part of a broader industrial transition strategy in which converting and adapting energy infrastructure can be just as significant as constructing new plants. This approach allows for risk reduction, asset utilization, and scalability—three key factors for accelerating the decarbonization of air transport.

How IDOM can support its clients

Developing SAF projects requires a comprehensive approach combining process knowledge, industrial integration capabilities, and regulatory understanding. IDOM supports its clients throughout the entire project development cycle by combining process knowledge, industrial integration expertise, and multidisciplinary engineering capabilities. Our goal is to help transform technological opportunities into viable, competitive projects that are ready for implementation.

During the initial phases, we support the evaluation of technological alternatives, the definition of development strategies, and the analysis of the technical, economic, and environmental feasibility of each option. This approach enables us to compare different production configurations, identify key constraints, and minimize uncertainty before making significant investments.

As the project progresses, our early-stage engineering optimizes the integration of the various process units and their interaction with utilities, storage, logistics, and existing infrastructure. This aspect is particularly important in SAF and e-SAF projects, where the competitiveness of the asset largely depends on the efficient integration of energy systems, hydrogen, CO₂, and supply chains.

IDOM’s expertise covers new facilities and integration projects within existing industrial assets.

• Feasibility studies and technology selection for SAF and e-SAF projects
• Conceptual engineering and Front-End Engineering Design (FEED) for new sustainable fuels plants.
• Integration of SAF and HVO production units into existing refineries and energy complexes.
• Projects related to H₂ production and associated energy integration
• Experience in CO₂ capture, conditioning, and utilization
• Energy optimization and process integration in complex industrial environments.

Thanks to this combination of capabilities, IDOM is able to take a holistic approach to SAF projects, integrating strategy, technology, and engineering to accelerate the transition to sustainable aviation fuels.