Production and certification constraints to sustainable aviation fuel adoption: Analysis and synergistic solutions

Sustainable aviation fuels (SAFs) are promising solutions for reducing carbon emissions in the aviation industry and achieving the 2050 net-zero target. Despite their environmental benefits, the adoption and deployment of SAFs remain significantly below expectations. This paper systematically analyzes the key constraints hindering deployment of SAFs, focusing on feedstock availability, technology pathway, safety certification, and sustainability standards. On the production side, the unstable supply of suitable feedstocks, and the lack of mature refining infrastructure result in high production costs. This study presents a comprehensive evaluation of various technology pathways for SAFs. Each pathway demonstrates unique advantages and limitations in terms of yield, feedstock adaptability, environmental impact, and cost-effectiveness. While Hydroprocessed Esters and Fatty Acids (HEFA) is the most mature, its scalability is hindered by feedstock constraints. Fischer–Tropsch (FT) and lignocellulosic-based pathways offer better long-term potential, especially in developing countries. From a certification standpoint, the safety certification process, primarily governed by ASTM D4054, is lengthy, costly, and sample-intensive, thereby raising the entry barrier for new SAF technologies. Additionally, the global sustainability certification standards lack uniformity, and differences among standards such as CORSIA, ISCC, and RSB make market access and recognition more complex. To overcome these barriers, the paper proposes a synergistic strategy that includes localized feedstock development (e.g., cultivation of Arundo donax on marginal land), technological optimization of SAF production pathways, adoption of modelling and simulation for safety certification, and establishment of a globally recognized and equitable sustainability certification system under ICAO’s leadership. These coordinated efforts are essential to accelerate SAF adoption, ensure global participation, and enable the transition of the aviation industry towards a low-carbon future. • Identifies key barriers to SAF adoption in production and certification. • Proposes Arundo donax cultivation on marginal lands to ensure a stable supply of feedstocks. • Compares SAF technology pathways and highlights FT’s potential in developing countries. • Recommends using modelling and simulation to reduce SAF safety certification costs. • Advocates a unified global SAF sustainability certification system under ICAO leadership.