Thermochemical production of sustainable aviation fuel (SAF) via biogas autothermal reforming assisted by green hydrogen

Sustainable aviation fuel is a key lever for decarbonizing the aviation industry. However, existing production routes face limitations mainly related to feedstock availability and variability, as well as high hydrogen costs. This work presents a novel SAF production process based on biogas autothermal reforming integrated with CO 2 capture and recycling, low-temperature Fischer-Tropsch synthesis, and green hydrogen supplementation via a water electrolyzer. Raw biogas is directly fed to the autothermal reformer, avoiding upgrading to biomethane. The CO 2 produced during reforming, together with that contained in the biogas feed, is separated via amine absorption and recycled back to the reformer, increasing the overall carbon utilization. Green hydrogen is supplemented downstream to achieve the optimal H 2 /CO ratio required for Fischer-Tropsch synthesis. The process is thermally self-sufficient, generating a surplus of medium-temperature heat that can be exported to other units or facilities, and is synergistically integrated with a water electrolyzer, as both the green hydrogen and the oxygen produced are utilized within the plant. Techno-economic and sustainability assessments show high carbon utilization (98%), low hydrogen consumption (0.17 kg H 2 /kg products), and a minimum SAF selling price between 1.15 and 1.95 €/L, close to that of HEFA-derived SAF and primarily driven by hydrogen and biogas costs. When operated with renewable electricity and green hydrogen, the process achieves greenhouse gas emissions of 0.57 kg CO 2 eq per kg of products. While large-scale deployment is constrained by biogas availability, the technology is well-suited for decentralized, small-scale implementation and can complement existing SAF production routes such as HEFA. • Thermally self-sufficient SAF production process powered by renewable electricity. • Conversion of biogas and hydrogen into SAF, diesel, and naphtha at 98% yield. • Biogas fed to ATR with downstream CO 2 capture and recycle via amine absorption. • Green-hydrogen-assisted Fischer-Tropsch and hydrocracking producing drop-in fuels.