How Sustainable Aviation Fuel Is Made: A Guide to Production Pathways

Sustainable Aviation Fuel (SAF) is produced through several ASTM-certified pathways like HEFA, Fischer-Tropsch, and Alcohol-to-Jet, each with unique feedstocks and processes. Understanding these methods and the critical challenge of feedstock sourcing is key to advancing green aviation.

Ingrid Larsen

October 9, 2026 · 4 min read

Sustainable Aviation Fuel (SAF) represents a cornerstone of the aviation industry's commitment to reducing its carbon footprint. For private jet owners and operators, it is an increasingly vital component of both environmental stewardship and operational strategy. But not all SAF is created through the same process. A variety of distinct, certified technological pathways exist, each transforming different raw materials into a fuel that is fully compatible with existing aircraft. Understanding these production methods—their feedstocks, processes, and scalability—is key to navigating the evolving landscape of green aviation.

Before any SAF can be used, it must be certified as a "drop-in" fuel, meaning it is chemically identical to conventional jet fuel and can be blended with it without requiring any modifications to aircraft or infrastructure. This certification is primarily handled by ASTM International, which approves specific production pathways. These standards ensure that every gallon of SAF meets rigorous safety and performance specifications. The most prominent certified pathways include Hydroprocessed Esters and Fatty Acids (HEFA), Fischer-Tropsch (FT), and Alcohol-to-Jet (ATJ), each offering a different approach to creating a lower-carbon alternative to fossil-based kerosene.

Hydroprocessed Esters and Fatty Acids (HEFA)

The most mature and commercially dominant method for producing SAF today is the HEFA pathway. According to a technical analysis from the University of Sheffield, this process is the foundation of current commercial SAF production. The primary feedstocks for HEFA are lipids, such as used cooking oil, animal fats, and certain vegetable oils. These raw materials are attractive because they are often waste products, avoiding direct competition with food crops.

The conversion process, as described by the technology company Velocys, involves a multi-stage refinement similar to conventional oil refining. First, the oils and fats undergo hydrotreating, a process that uses hydrogen to remove oxygen and other impurities. This is followed by hydrocracking and fractionation, which break down the large hydrocarbon molecules into the precise size required for jet fuel. The result is a high-quality synthetic paraffinic kerosene that can be blended with conventional jet fuel.

Fischer-Tropsch (FT) Synthesis

The Fischer-Tropsch pathway offers a significant advantage over HEFA in its feedstock flexibility. While HEFA is limited to fats and oils, the FT process can convert a much broader range of carbon-containing materials into fuel. According to a report from Capgemini and analysis from Velocys, these feedstocks can include municipal solid waste, agricultural and forestry residues, and even industrial waste gases.

The FT process begins by converting the solid or gaseous feedstock into a mixture of hydrogen and carbon monoxide known as synthesis gas, or syngas. This is typically achieved through a high-temperature process called gasification. The syngas is then cleaned and passed over a catalyst, triggering the Fischer-Tropsch synthesis that converts the gas into liquid hydrocarbons. These liquids are then upgraded and refined into jet fuel. While approved by ASTM since 2009, the Capgemini report notes that this process is still in a commercial pilot phase, with the potential for large-scale production.

Key ASTM-Certified SAF Production Pathways

The primary methods for producing Sustainable Aviation Fuel each have unique characteristics. The most established pathway, HEFA, relies on a specific category of fats and oils, while others like Fischer-Tropsch offer greater flexibility by using a wider variety of waste materials. The following table, based on analysis from Capgemini, Velocys, and the University of Sheffield, compares the core attributes of these certified production technologies.

A comparison of the main production pathways for Sustainable Aviation Fuel, detailing their feedstocks, conversion methods, and key features.
Pathway Name	Feedstock Type	Conversion Process Summary	Key Characteristics
Hydroprocessed Esters and Fatty Acids (HEFA)	Uses lipid-based feedstocks such as used cooking oil, animal fats, and vegetable oils.	A two-stage process involving hydrotreating to remove oxygen, followed by hydrocracking and fractionation to produce paraffinic hydrocarbons.	The most mature and commercially available pathway, currently dominating SAF production. Feedstock availability can be a limiting factor.
Fischer-Tropsch (FT)	Utilizes a wide range of carbon-based materials, including municipal solid waste, agricultural and forestry residues, and industrial waste gases.	Feedstocks are converted into a synthesis gas (syngas), which then undergoes a catalytic process to be synthesized into liquid hydrocarbons.	Offers significant feedstock flexibility, a key advantage for scalability. The technology is approved and in the commercial pilot phase.
Alcohol-to-Jet (ATJ)	Converts alcohols, such as ethanol and butanol, which can be derived from biomass or other renewable sources.	A multi-step chemical process involving dehydration, oligomerization, hydrogenation, and fractionation to create jet-range hydrocarbons.	An approved pathway that diversifies feedstock options beyond lipids and solid waste, leveraging existing alcohol production infrastructure.