Catalytic CO2 hydrogenation to sustainable aviation fuel: mechanisms and pathways to net-zero

Abstract

Aviation's 2.5% contribution to global CO₂ emissions necessitates scalable, sustainable jet fuel alternatives. This review addresses the gap in comprehensive CO₂-to-Sustainable Aviation Fuel (SAF) analyses by examining Power-to-Liquid (PtL) technologies, focusing on CO₂ hydrogenation via Fischer–Tropsch synthesis, methanol-to-jet (MtJ), and direct hydrogenation pathways. We analyze recent advances in bifunctional catalysts and tandem mechanisms, achieving 21–57% energy efficiencies and jet fuel costs of 2–9 € kg⁻¹. A phased 2050 commercialization roadmap aligns technology readiness levels with policies like EU's ReFuelEU. Case studies (Haru Oni, Synhelion, OXCCU) highlight real-world progress, while life cycle assessments reveal carbon intensities of 10–83 gCO₂e MJ⁻¹. Challenges, including catalyst deactivation and green hydrogen scalability, are evaluated alongside opportunities in AI-driven catalyst design and modular reactors. By integrating catalysis, techno-economics, and policy, this work guides researchers, industry, and policymakers toward net-zero aviation.