The US Department of Energy’s Argonne National Laboratory has developed an innovative technology aimed at increasing the production of cost-competitive sustainable aviation fuel (SAF). This process, funded by the DOE’s Office of Energy Efficiency and Renewable Energy, brings together a team of experts and partners, including Texas A&M University, which transforms organic waste—such as wastewater from breweries and dairy farms—into fuel, holds the potential to cut aviation-related greenhouse gas (GHG) emissions by up to 70%, contributing significantly to the industry’s decarbonisation.
Currently, SAF represents less than 1% of the aviation fuel used globally, while aviation is responsible for approximately 3% of worldwide GHG emissions. Widespread adoption of SAF has been limited by high production costs and complex processes. However, Argonne’s methane-arrested anaerobic digestion (MAAD) technology could address these challenges. Rather than using conventional feedstocks like fats and oils, Argonne scientists are harnessing carbon-rich wastewater, which is both cost-effective and sustainable.
“Both wastewater streams are rich in organics, and it is carbon-intensive to treat them using traditional wastewater treatment methods. By using our technology, we are not only treating these waste streams but making low-carbon sustainable fuel for the aviation industry,” said study author Taemin Kim, an Argonne energy systems analyst.
This process converts the wastewater into volatile fatty acids—essential components for SAF production—using a membrane-assisted bioreactor to increase efficiency and reduce costs. “Volatile fatty acids from waste streams can make biofuel production more sustainable. Our technology uses a special reactor to boost production of these acids, which are essential for creating sustainable aviation fuel,” said Haoran Wu, a postdoctoral researcher at Argonne.
The technology has shown promise in significantly reducing carbon emissions compared to fossil-based jet fuel. Using advanced modelling tools, Argonne scientists analysed both the environmental and economic impacts of their SAF production process, confirming that the waste-to-fuel pathway is a sustainable alternative that effectively lowers carbon emissions.
The project aligns with the DOE’s Sustainable Aviation Fuel Grand Challenge, which aims to boost SAF production to three billion gallons by 2030 and meet 100% of the commercial jet fuel demand with SAF by 2050. In addition, the MAAD technology overcomes a key barrier in SAF production by minimising lactic acid formation, which can inhibit the conversion process. Argonne’s method prioritises volatile fatty acid production, enhancing overall efficiency.
As the team works to commercialise the patent-pending technology, they anticipate scaling it for widespread use, positioning it as a critical solution for reducing aviation’s carbon footprint and supporting the global transition to sustainable energy.