Decentralized Model for Sustainable Aviation Fuel (SAF) Production from Residual Biomass Gasification in Spain

Decarbonizing air transport is a major challenge in the global energy transition since electrification is not yet feasible. Sustainable aviation fuel (SAF) is a promising solution because it can reduce CO2 emissions without major infrastructure changes. This study proposes a decentralized model for producing SAF in Spain through the gasification of residual lignocellulosic biomass followed by a refinement process using Fischer–Tropsch (FT) synthesis. The model uses underexploited agricultural residues such as cereal straw, vine pruning, and olive pruning, converting them into syngas in medium-scale facilities situated near biomass sources. The syngas is then transported to a central upgrading unit to produce SAF compliant with ASTM D7566 standards. The following two configurations were evaluated: one with a single gasification plant and upgrading unit and another with three gasification plants supplying one central FT facility. Energy yields, capital and operational expenditures (CAPEX and OPEX), logistic costs, and the levelized cost of fuel (LCOF) were assessed. Under a conservative scenario using one-third of the available certain types of biomass from three regions of Spain, annual SAF production could reach 517.6 million liters, with unit costs ranging from 1.63 to 1.24 EUR/L and up to 47,060 tonnes of CO2 emissions avoided per year. The findings support the model’s technical and economic viability and its alignment with circular economy principles and climate policy goals. This approach offers a scalable and replicable pathway for decarbonizing the aviation sector using local renewable resources.