CO2 Electrolysis-Assisted CO2 reduction and aromatic supply method for sustainable aviation fuel Production: Cost optimization and Future cost scenarios

• Three PtL-based SAF production cases were designed and optimized to lower the LCOF. • To meet the SAF quality, two aromatic supply methods are considered. • Internal aromatic production increased LCOF by 11.8% due to inefficient syngas use. • CO 2 electrolyzer significantly reduced hydrogen consumption, lowering LCOF by 13.0%. • Future cost scenarios were analyzed based on sensitivity and economic analyses. To achieve carbon neutrality in the aviation sector, sustainable aviation fuel (SAF) is emerging as a promising solution. However, the high levelized cost of SAF (LCOF) remains a key challenge. Additionally, discussions on aromatic supply methods are limited, despite aromatics being essential for SAF’s density requirements. This study evaluates three Fischer-Tropsch-based SAF production processes: Case-1 outsources biomass-based aromatics; Case-2 produces aromatics internally; and Case-3 integrates CO 2 electrolysis (CO2EL) and produces aromatics internally. All cases are optimized to lower the LCOF. In the energy analysis, Case-2 showed 14.2% lower energy efficiency than Case-1 due to inefficient syngas utilization for internal aromatic production. Case-3 exhibited the lowest energy efficiency (38.8%) due to increased electricity consumption from CO2EL. Economically, the LCOF was 3.99 $/kg SAF for Case-1, 4.46 $/kg SAF for Case-2, and 3.88 $/kg SAF for Case-3. Case-2 showed a higher LCOF than Case-1 due to reduced SAF production, whereas Case-3 achieved the lowest LCOF by lowering hydrogen consumption. Future cost scenario analysis indicated that rising carbon taxes on indirect CO 2 emissions from outsourced aromatics will make Case-2 and Case-3 more cost-competitive. Specifically, when the carbon tax reaches 187 $/ton CO2 , the LCOF of Case-1 exceeds that of Case-2. Ultimately, Case-3 remained the most cost-effective option. This study highlights the impact of aromatic supply methods and CO2EL on the LCOF. Internal aromatic production eliminates carbon tax, while CO2EL reduces hydrogen consumption and LCOF. Future cost scenarios suggest that rising carbon taxes will enhance the internal aromatic production, providing insights for cost-effective and sustainable SAF adoption.