Advances of Hydrothermal Biomass Liquefaction Using Microalgae: Process Parameters and Biocrude Upgrading Methods

The ReFuelEU Aviation Regulation introduces mandatory targets for sustainable aviation fuels (SAF) from 2025 to 2050. However, hydrotreated esters and fatty acids (HEFA) technology based on waste oils alone is insufficient to meet targets beyond 2030, highlighting the need for alternative biocrude feedstocks to increase SAF production in the EU. Microalgae are promising feedstocks due to their biochemical composition and CO2-utilization potential, although their high moisture content and nitrogen and oxygen levels require energy-efficient conversion technologies. Hydrothermal liquefaction (HTL) is a suitable process for converting wet microalgal biomass into biocrude, with an optimal temperature window of approximately 300–330 °C and typical biocrude yields ranging from 20 to 70 wt%, depending on feedstock composition and operating conditions. However, microalgal HTL remains at TRL 5–7 and faces challenges related to the high heteroatom content of the resulting biocrude. Hydrodeoxygenation (HDO) is a key upgrading step for converting biocrude into drop-in aviation fuels and commonly operates at approximately 250–400 °C and 10–30 MPa H2 pressure. Nevertheless, few studies have addressed the HDO of microalgae-derived biocrude. This review examines microalgal HTL, pilot and demonstration facilities, biocrude yields and quality, and upgrading strategies for producing synthetic drop-in aviation biofuels.