An integrated process for sustainable aviation fuel production via direct air capture, carbon dioxide electrolysis, and biomass gasification

Sustainable aviation fuel (SAF) derived from direct air capture (DAC) has garnered attention due to its capacity to extract carbon dioxide (CO₂) directly from the atmosphere and utilize it as a carbon feedstock. However, the low hydrogen (H₂) utilization efficiency caused by the reverse water–gas shift (RWGS) reaction and the high production cost remain significant barriers to commercialization. To overcome these challenges, this study proposes a novel integrated SAF production system that combines DAC, CO₂ electrolysis, and biomass gasification (BG). By employing atmospheric CO₂ as the carbon source and biomass as the H₂ source, the system eliminates the need for the RWGS reaction, thereby enhancing H₂ efficiency and reducing overall production costs. The proposed system achieves an energy efficiency of 54.7 %, with a minimum fuel selling price (MFSP) of $3.38/L. Under more stringent environmental regulations, such as a $200/t carbon tax, the MFSP is reduced to $1.58/L. From a life cycle assessment perspective, the global warming potential was estimated at –339.7 g CO₂-equivalent/MJ SAF, thereby achieving net-negative CO₂ emissions. Uncertainty analysis indicates that as the carbon tax increases from $0/t to $200/t, the probability of the MFSP falling below the projected SAF cost for 2050 increases to 34.3 %. This study presents the first SAF production strategy integrating DAC, CO₂ electrolysis, and BG, and demonstrates the economic and environmental advantages of the proposed system through performance analysis of biomass-to-liquid and power-to-liquid processes. This integrated approach offers a practical path to decarbonize aviation, aiding the industry's transition and supporting global climate goals.