Sustainable Aviation Fuels: A Review of Current Techno Economic Viability and Life Cycle Impacts

Australia has set a new climate target of reducing emissions by 62–70% below 2005 levels by 2035, with sustainable aviation fuel (SAF) central to achieving this goal. This review critically examines techno-economic analysis (TEA) and life cycle assessment (LCA) of Powerto-Liquid (PtL) electrofuels (e-fuels), which synthesize atmospheric CO2 and renewable hydrogen (H2) via Fischer-Tropsch (FT) synthesis. Present PtL pathways require ~0.8 kg of H2 and 3.1 kg of CO2 per kg SAF, with ~75% kerosene yield. While third-generation feedstocks could cut greenhouse gas emissions by up to 93% (as low as 8 gCO2e/MJ), real world reductions have been limited (~1.5%) due to variability in technology rollout and feedstock variability. Integrated TEA–LCA studies demonstrate up to 20% energy efficiency improvements and 40% cost reductions, but economic viability demands costs below $3/kg. In Australia, abundant solar resources, vast transport networks, and supportive policy frameworks present both opportunities and challenges. This review provides the first comprehensive assessment of PtL-FT SAF for Australian conditions, highlighting that large-scale development will require technological advancement, feedstock development, infrastructure investment, and coordinated policy support.