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EUBCE 2025 - Marzouk BENALI - Hybrid Sustainable Aviation Fuel Production: Integrating E-SAF And Bio-SAF Pathways to Maximize Carbon Efficiency

Hybrid Sustainable Aviation Fuel Production: Integrating E-SAF And Bio-SAF Pathways to Maximize Carbon Efficiency

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Recent trends on developing intermediate bioenergy carriers and sustainable biofuels

Hybrid Sustainable Aviation Fuel Production: Integrating E-SAF And Bio-SAF Pathways to Maximize Carbon Efficiency

Short Introductive summary

The innovative hybrid SAF pathway considered in this study combines bio-SAF production through biomass gasification followed by Fischer-Tropsch synthesis, with the valorisation of CO2 from the bio-SAF process emissions into e-SAF using reverse water-gas shift. Such a hybrid solution could enable the scalable production of SAF, and it addresses two key challenges in industry: limited biomass resources and the need for carbon-efficient fuel production. This innovative approach, integrating bio- and e-fuel technologies, aligns with the goals of carbon-neutral growth in aviation and offers a pathway to large-scale SAF production. The SAF production case assessed considered an industrial context for which 490 oven-dry tonnes [odmt]per year of forest harvest residues were available (i.e. about 1,460 odmt per day). The first pathway considering biomass gasification and Fischer-Tropsch synthesis resulted in the production of 2,176 barrels of SAF per day, along with 913 barrels per day of renewable naphtha and 40 MW of extra-electricity. Flue gas resulting from such bio-SAF production route contained about 1,136 tonnes of biogenic CO2 per day.

Presenter

Moderator portrait

Marzouk BENALI

Natural Resources Canada, CanmetENERGY, CANADA

Presenter's biography

Chemical Engineering in training, Dr. Marzouk Benali is a Senior Research Scientist and Research Manager at CanmetENERGY, Natural Resources Canada. With extensive national and international experience in process design, intensification, and sustainability assessment, he leads R&D on bioeconomy, clean fuels, hydrogen integration, and biorefinery technologies. His work supports the scale-up of low-carbon solutions, from lab to demonstration, including intellectual property transfer, standards development, and decision-support tools. Dr. Benali's leadership bridges science, technology, and policy to advance decarbonization in hard-to-abate sectors through integrated, regionally tailored strategies. He is the Canadian delegate to IEA-IETS TCP.

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Co-authors:

G. Bele, Natural Resources Canada, Varennes, CANADA
C. Diffo Teguia, Natural Resources Canada, Varennes, CANADA
M. Benali, Natural Resources Canada, Varennes, CANADA
M. Shokrollahi, Natural Resources Canada, Varennes, CANADA
N. Teymouri, Natural Resources Canada, Varennes, CANADA
N. Navarri, Natural Resources Canada, Varennes, CANADA

Session reference: BP.2.1