Alternative feedstocks for sustainable aviation fuels: Assessment of sugarcane-derived microbial oil

Pioneer facilities for Sustainable Aviation Fuels (SAF) convert fats, oils, and grease into hydrocarbons using the Hydroprocessed Esters and Fatty Acids (HEFA) technology. However, limited feedstock availability and sustainability concerns may restrict broader adoption. Biotechnology offers an alternative by enabling microbial oil production from sugars, expanding the feedstock portfolio with more productive biomass sources or waste materials. This study assessed the economic and environmental impacts of SAF production through HEFA using microbial oil from sugarcane, combining achievable fermentation performance with mature catalytic conversion. The results demonstrated SAF costs between $1.83 and $3.00 per liter and over 50 % reduction in greenhouse gas emissions compared to fossil fuels. Sensitivity analysis identified fermentation performance as the key factor driving these outcomes. Additionally, this approach yielded higher SAF per hectare than soybean-oil-based HEFA, potentially reducing emissions from land-use change.