Table of Contents
- Executive Summary: Biodajet Fuel Synthesis in 2025
- Market Size, Growth Projections, and Forecasts Through 2030
- Key Players and Corporate Initiatives (e.g., Boeing.com, Gevo.com, Neste.com)
- Core Synthesis Technologies: From Feedstocks to Final Fuel
- Recent Breakthroughs and Emerging Innovations
- Regulatory Drivers, Certifications, and Industry Standards (e.g., IATA.org, ASTM.org)
- Supply Chain Dynamics and Feedstock Sourcing
- Cost Competitiveness and Commercialization Pathways
- Sustainability Metrics and Environmental Impact
- Future Outlook: Roadmap to Mainstream Adoption and Industry Scenarios
- Sources & References
Executive Summary: Biodajet Fuel Synthesis in 2025
In 2025, biodajet fuel synthesis technologies are at the forefront of the global shift toward sustainable aviation, with multiple commercial-scale facilities operational and new projects underway. The leading synthesis approaches include Hydroprocessed Esters and Fatty Acids (HEFA), Alcohol-to-Jet (ATJ), Fischer-Tropsch (FT), and emerging catalytic routes utilizing diverse feedstocks such as waste oils, agricultural residues, and municipal solid waste.
The HEFA pathway remains the most mature and widely adopted for commercial biodajet production. Companies such as Neste and World Energy are scaling up production with facilities in Singapore, the United States, and Europe, with combined annual capacities exceeding one million tonnes. In 2025, Neste continues to expand its Singapore biorefinery, aiming for over 1.3 million tonnes per year of sustainable aviation fuel (SAF) production capacity. Concurrently, World Energy‘s Paramount plant in California is undergoing further expansion to increase output and meet growing demand.
Fischer-Tropsch synthesis, leveraging gasified biomass or municipal waste, is progressing through major demonstration and early commercial deployments. Velocys is advancing its Bayou Fuels project in Mississippi, utilizing waste woody biomass feedstock to produce SAF via FT synthesis. The company is targeting final investment decisions and the commencement of construction in the coming years. Similarly, Shell is collaborating on FT-based SAF projects, including the Altalto Immingham project in the UK, which is poised to convert municipal solid waste into commercial-scale jet fuel.
Alcohol-to-Jet (ATJ) synthesis is gaining traction, with LanzaJet commencing production at its Freedom Pines Fuels plant in Georgia, USA. The facility utilizes ethanol derived from industrial waste gases and agricultural residues, converting it to SAF via proprietary catalytic processes. With a capacity of 10 million gallons per year and plans for rapid scale-up, ATJ technology is expected to diversify feedstock options and enhance the flexibility of SAF supply chains.
Looking ahead, the next few years will see accelerated commercialization and scale-up of these synthesis technologies. The International Air Transport Association (IATA) and airline alliances are setting ambitious SAF adoption targets, stimulating investment and policy support. Companies are increasingly forming cross-sector partnerships to secure feedstocks, optimize synthesis pathways, and expand global SAF production. Continuous innovation in catalytic efficiency, feedstock logistics, and process integration will be vital for reducing costs and meeting decarbonization goals in aviation through 2030 and beyond.
Market Size, Growth Projections, and Forecasts Through 2030
Biodajet fuel synthesis technologies—referring to the suite of processes for converting biomass into sustainable aviation fuel (SAF)—are gaining significant traction as the aviation sector intensifies decarbonization efforts. By 2025, the market for biodajet fuel synthesis is characterized by a rapid expansion of production capacity, rising investments, and a concerted push for commercialization across multiple technology pathways. Key synthesis technologies include Hydroprocessed Esters and Fatty Acids (HEFA), Alcohol-to-Jet (AtJ), Fischer-Tropsch (FT), and emerging thermochemical and biochemical conversion processes.
The global SAF market, underpinned by biodajet fuel synthesis, is expected to grow from a nascent stage to a multi-billion-dollar segment over the next five years. In early 2025, capacity is still limited relative to global jet fuel demand, with Neste—the world’s largest SAF producer—reporting an annual production capability of 1 million tons, aiming for 1.5 million tons by 2024 and further expansion by 2026. World Energy, another major player, operates large-scale HEFA-based SAF facilities in the United States, with ongoing investments to scale output.
The technology mix is evolving. HEFA remains dominant due to commercial maturity and feedstock availability, but FT and AtJ routes are gaining momentum. Shell and partners have announced plans to deploy both FT and AtJ-based plants within the decade, targeting commercial-scale deployment. LanzaTech is advancing gas fermentation-based AtJ synthesis, with several demonstration and commercial projects underway in North America, Europe, and Asia, expecting to contribute significant new capacity by 2027.
Looking ahead through 2030, market forecasts by industry bodies project exponential growth. The International Air Transport Association (IATA) estimates that SAF production could reach 24 billion liters (approximately 19 million tons) by 2030, representing a substantial leap from under 1 million tons in 2023 (International Air Transport Association). This growth will be driven by aggressive mandates—such as the European Union’s ReFuelEU Aviation initiative—and increasing airline offtake agreements.
In summary, between 2025 and 2030, biodajet fuel synthesis technologies are set for rapid scaling, diversification of technology platforms, and deeper supply chain integration. Innovation in feedstock sourcing, process efficiency, and supportive policy environments will be critical to meeting ambitious SAF adoption targets and ensuring a robust, sustainable aviation fuel market by the end of the decade.
Key Players and Corporate Initiatives (e.g., Boeing.com, Gevo.com, Neste.com)
The landscape of biodajet fuel synthesis technologies in 2025 is shaped by aggressive investment, commercial-scale demonstration, and strategic partnerships from industry leaders aimed at accelerating the adoption of sustainable aviation fuels (SAF). A core focus for these key players is the deployment and optimization of advanced synthesis pathways, notably Hydroprocessed Esters and Fatty Acids (HEFA), Alcohol-to-Jet (ATJ), Fischer-Tropsch (FT), and emerging Power-to-Liquid (PtL) processes.
- Neste stands as a global leader in the commercialization and expansion of HEFA technology, transforming waste fats, oils, and greases into renewable jet fuel. In 2024-2025, Neste is completing major capacity expansions in Rotterdam and Singapore, aiming for an annual production capability exceeding 1.5 million tons of SAF by the end of 2025. The company has established offtake agreements with major airlines and is integrating digital solutions to optimize feedstock supply chains and production efficiency.
- Gevo is advancing the Alcohol-to-Jet (ATJ) pathway using renewable ethanol and isopropanol as feedstocks. Its Net-Zero 1 plant, scheduled for operational launch in 2025, is designed to utilize renewable energy and carbon capture, targeting a carbon-negative fuel profile. Gevo has secured long-term agreements with Delta Air Lines and other carriers to supply millions of gallons of SAF annually, signaling strong commercial traction for ATJ-derived fuel.
- Boeing is driving corporate initiatives to accelerate the certification and adoption of 100% SAF in commercial aviation. Boeing collaborates with fuel producers and regulatory bodies, conducts demonstration flights, and provides technical guidance for new synthesis routes—including Fischer-Tropsch and PtL technologies—supporting industry-wide commitments to net-zero emissions by 2050.
- Sasol, a pioneer in Fischer-Tropsch synthesis, is leveraging its expertise to scale up SAF production from biomass and municipal solid waste. In collaboration with Lufthansa Group and other partners, Sasol is piloting commercial-scale FT-SAF production in South Africa and Europe, targeting market entry by 2026.
The outlook for 2025 and the following years indicates rapid growth in biodajet fuel production, with a strong emphasis on scaling diverse synthesis technologies, securing supply chains, and establishing global certification standards. Corporate initiatives are expected to further de-risk emerging pathways and pave the way for greater SAF adoption across the aviation sector.
Core Synthesis Technologies: From Feedstocks to Final Fuel
The synthesis of bio-based sustainable aviation fuel (SAF), often termed as “biodajet,” is undergoing rapid technological evolution as the aviation sector pursues decarbonization targets for 2025 and beyond. The core synthesis technologies—Hydroprocessed Esters and Fatty Acids (HEFA), Alcohol-to-Jet (ATJ), Fischer-Tropsch (FT), and emerging catalytic approaches—are being deployed at commercial and demonstration scales, using a variety of feedstocks.
HEFA remains the dominant commercial pathway in 2025, producing SAF from lipid-based feedstocks such as used cooking oil, tallow, and vegetable oils. Companies like Neste and World Energy operate large-scale HEFA facilities in Europe, Asia, and North America. Neste’s Singapore refinery, after its 2023 expansion, can now deliver up to 1 million tons of SAF annually, illustrating the scalability of HEFA technology. Neste continues to invest in feedstock flexibility to improve lifecycle emissions and sustainability.
ATJ pathways, using ethanol or isobutanol as intermediates, have progressed to commercial demonstration, notably through partnerships like LanzaJet’s Freedom Pines Fuels facility in Georgia, USA. This plant, scaling up in 2025, converts ethanol—sourced from waste industrial gases and biomass—into SAF via catalytic dehydration, oligomerization, and hydrogenation. The process enables broader feedstock utilization, including cellulosic residues and municipal solid waste, supporting circular economy principles (LanzaJet).
The FT synthesis route, relying on gasification of solid feedstocks (e.g., agricultural waste, forestry residues, or municipal waste) followed by catalytic conversion to liquid hydrocarbons, is gaining momentum. Velocys, through projects like Altalto Immingham, is advancing modular FT technology for SAF production from waste-derived syngas, targeting commercial output post-2025 (Velocys).
Emerging routes, including Catalytic Hydrothermolysis (CH) and Power-to-Liquids (PtL) using renewable hydrogen and captured CO2, are in pilot or early demonstration stages. Gevo is scaling integrated ATJ and renewable hydrogen systems to further reduce SAF carbon intensity, aiming for major scale-up by 2026.
Looking ahead, the outlook for biodajet fuel synthesis technologies is defined by ongoing scale-up, diversification of feedstocks, and integration with carbon capture and green hydrogen. Commercial viability depends on optimizing process efficiency, reducing costs, and securing long-term feedstock supply. Industry collaborations and policy incentives are expected to accelerate deployment and innovation through the late 2020s.
Recent Breakthroughs and Emerging Innovations
The landscape of biodajet fuel synthesis technologies is undergoing rapid transformation as the aviation sector intensifies its decarbonization efforts. Recent breakthroughs in 2025 emphasize both process innovation and feedstock flexibility, with several demonstration plants and commercial ventures accelerating progress toward scalable, cost-effective solutions.
A key trend is the diversification of synthesis pathways beyond traditional hydroprocessed esters and fatty acids (HEFA). In early 2025, Neste announced successful pilot operations for its next-generation process that integrates waste lipids and lignocellulosic feedstocks—enabling greater raw material flexibility and higher greenhouse gas (GHG) reduction. Similarly, TotalEnergies has advanced its Biojet synthesis platform, commissioning a new demonstration unit that applies advanced hydroprocessing catalysts to optimize yield and energy efficiency from a range of renewable feedstocks.
Gasification and Fischer-Tropsch (FT) synthesis are also gaining traction. In 2025, Sasol reported initial positive results from its pilot facility, which converts agricultural residues into synthetic jet fuel using its proprietary FT process. The company is working on refining catalyst performance to lower production costs and improve carbon conversion efficiency, with plans for scaling up by 2027. Meanwhile, Shell has collaborated with technology partners to demonstrate a modular gasification-to-jet system designed for decentralized production, targeting remote regions and smaller airports.
Alcohol-to-jet (ATJ) is another area of significant progress. LanzaTech and Virent, Inc. have both made advances in converting ethanol and isobutanol into drop-in jet fuel. LanzaTech’s process leverages industrial off-gases as carbon sources, with its 2025 demonstration plant achieving milestones in continuous operation and fuel quality certification. Virent, meanwhile, has demonstrated commercial-scale production of synthetic aromatic compounds crucial for jet fuel blendstock, providing performance parity with fossil-derived alternatives.
Looking ahead, the outlook for biodajet fuel synthesis technologies in the next few years is optimistic. Multiple companies are targeting full commercial deployment before 2030, with incremental scale-ups and further integration of carbon capture and utilization (CCU). Industry bodies such as IATA and CORSIA are supporting harmonized certification frameworks, which is expected to accelerate market acceptance and stimulate additional innovation in feedstock conversion and process intensification.
Regulatory Drivers, Certifications, and Industry Standards (e.g., IATA.org, ASTM.org)
The regulatory landscape for biodajet fuel synthesis technologies is shaped by a confluence of international standards, national mandates, and industry-led initiatives, all intensifying in 2025 and setting the stage for the next several years. The International Air Transport Association (IATA) continues to play a pivotal role in advocating for robust, harmonized regulations to facilitate the global adoption of sustainable aviation fuels (SAFs), including biodajet variants. IATA’s “Fly Net Zero” initiative underscores the aviation sector’s commitment to achieving net-zero carbon emissions by 2050, driving demand for certified SAFs that meet rigorous performance and sustainability criteria.
Central to regulatory approval and market uptake is the certification process governed by the American Society for Testing and Materials (ASTM International). The ASTM D7566 standard defines specifications for aviation turbine fuels containing synthesized hydrocarbons. Recent amendments in 2024 and ongoing reviews into 2025 are expanding the list of approved synthetic fuel pathways, including alcohol-to-jet (ATJ), hydroprocessed esters and fatty acids (HEFA), and emerging catalytic conversion processes. These changes enable fuel producers to commercialize novel biodajet technologies, provided they demonstrate equivalency in safety and performance to conventional jet fuels.
Regulatory agencies in major markets—such as the U.S. Federal Aviation Administration (FAA) and the European Union Aviation Safety Agency (EASA)—are working closely with industry to streamline certification pathways and align sustainability criteria. In 2025, the FAA’s Center of Excellence for Alternative Jet Fuels and Environment is accelerating support for testing and qualification of new biodajet synthesis methods, reflecting a broader policy push for greater SAF uptake under the U.S. SAF Grand Challenge (U.S. Department of Energy).
Industry standards for sustainability, lifecycle carbon accounting, and feedstock traceability are also evolving. Organizations such as the Roundtable on Sustainable Biomaterials (RSB) are integrating stricter sustainability criteria into certification schemes, responding to regulatory expectations for transparency and reduced indirect land-use change impacts. Simultaneously, the International Civil Aviation Organization (ICAO) is refining its CORSIA (Carbon Offsetting and Reduction Scheme for International Aviation) requirements, with updates in 2025 mandating clearer documentation of eligible SAF volumes and associated emissions reductions.
As regulatory and certification frameworks become more robust and globally harmonized, the outlook for biodajet fuel synthesis technologies is increasingly favorable. These mechanisms are not only reducing technical and market barriers but are also fostering collaboration across the value chain, providing clear signals for technology developers and investors to accelerate commercial deployment over the next several years.
Supply Chain Dynamics and Feedstock Sourcing
The supply chain and feedstock sourcing landscape for biodajet fuel synthesis technologies is evolving rapidly as airlines, fuel producers, and governments intensify their efforts to decarbonize aviation. In 2025, the most commercially mature biodajet fuel production pathway remains Hydroprocessed Esters and Fatty Acids (HEFA), leveraging feedstocks such as used cooking oil, animal fats, and non-edible vegetable oils. Key players, including Neste and World Energy, have expanded their global supply networks to secure sustainable feedstocks, with Neste operating extensive pre-treatment facilities and partnerships to process a wide array of waste oils and fats.
The diversification of feedstock sourcing is a strategic imperative. As demand grows, competition for traditional feedstocks tightens, prompting innovation in supply chains. For example, TotalEnergies is piloting the use of low-ILUC (Indirect Land Use Change) crops and agricultural residues in Europe, while EnviTec Biogas is exploring biogenic waste streams for conversion to biojet intermediates. The U.S. Department of Energy’s Bioenergy Technologies Office (BETO) is actively funding supply chain optimization projects to integrate forest residues and municipal solid waste as next-generation feedstocks.
Emerging synthesis routes, such as Alcohol-to-Jet (ATJ) and Fischer-Tropsch (FT) processes, are gaining momentum, which broadens the potential feedstock base. LanzaTech is scaling up its gas fermentation technology to convert industrial off-gases to ethanol, subsequently processed into jet fuel, thereby opening new circular economy supply chains. Similarly, Velocys is advancing FT-based production using municipal solid waste and woody biomass as feedstock, with commercial facilities slated for commissioning in the coming years.
In 2025 and beyond, supply chain resilience will be tested by increasing mandates for Sustainable Aviation Fuel (SAF) blending, such as those set by the European Union and U.S. initiatives. Traceability and certification systems, such as those managed by the ISCC System, are being strengthened to ensure sustainability compliance across complex, global feedstock supply networks. Looking ahead, the sector’s outlook hinges on further integration of waste-based supply chains, continued innovation in feedstock pre-treatment, and expanded multi-stakeholder collaborations to ensure robust, scalable, and sustainable feedstock sourcing for biodajet synthesis technologies.
Cost Competitiveness and Commercialization Pathways
The cost competitiveness and pathways to commercialization for biodajet (bio-based sustainable aviation) fuel synthesis technologies are entering a pivotal phase in 2025. Several routes—most notably Hydroprocessed Esters and Fatty Acids (HEFA), Alcohol-to-Jet (ATJ), and Fischer-Tropsch (FT) synthesis—are advancing toward commercial scale, driven by policy incentives and increasing airline demand for sustainable aviation fuels (SAF).
HEFA technology is currently the most commercially mature, leveraging existing feedstocks such as used cooking oil and animal fats. Facilities operated by Neste and World Energy are scaling up, with Neste reporting production costs for HEFA-based SAF in the range of $2–$3 per liter—a premium over conventional jet fuel but narrowing as economies of scale are realized. Neste has committed to expanding its global SAF output to 1.5 million tonnes annually by 2024–2025, signaling confidence in ongoing cost reductions.
Meanwhile, ATJ and FT technologies, which utilize cellulosic ethanol or biomass gasification respectively, are at an earlier commercialization stage but are receiving significant investment. LanzaJet, for example, is commissioning its Freedom Pines Fuels plant in Georgia, USA, expected to reach full operational status in 2025. Their ATJ process aims to achieve cost parity with fossil jet fuel by 2027, driven by process improvements and feedstock diversification. On the FT front, Velocys is progressing with its Altalto Immingham project in the UK, targeting commercial operation before 2030 and leveraging municipal solid waste as a feedstock to reduce input costs.
Government mandates and airline offtake agreements are accelerating cost competitiveness. The EU’s ReFuelEU Aviation regulation, effective in 2025, sets SAF blending mandates, creating assured demand and incentivizing scale-up investment (European Union Aviation Safety Agency). In the United States, the Sustainable Aviation Fuel Grand Challenge and tax credits under the Inflation Reduction Act are expected to further improve the economics for producers (U.S. Department of Energy).
Looking ahead, cost parity with conventional jet fuel is likely to hinge on continued scale-up, feedstock innovation, and supportive policy frameworks. As of 2025, the commercialization pathways for biodajet fuel synthesis technologies appear robust, with clear momentum toward broader market adoption and cost competitiveness over the coming years.
Sustainability Metrics and Environmental Impact
Biodajet fuel synthesis technologies are at the forefront of aviation’s decarbonization strategies in 2025, with sustainability metrics and environmental impact central to their ongoing development and deployment. These technologies are primarily evaluated based on lifecycle greenhouse gas (GHG) emissions, feedstock sustainability, energy efficiency, and compatibility with existing infrastructure.
The dominant synthesis routes include Hydroprocessed Esters and Fatty Acids (HEFA), Alcohol-to-Jet (ATJ), Fischer-Tropsch (FT), and emerging pathways such as Power-to-Liquid (PtL). HEFA remains the most commercially mature process, with several large-scale plants achieving over 60% GHG emissions reduction compared to conventional jet fuel, as reported by Neste and World Energy. These reductions are primarily attributed to the use of waste oils and fats as feedstocks, which minimize land-use change and associated emissions.
Lifecycle analyses for FT and ATJ routes, such as those undertaken by Shell and LanzaTech, indicate potential GHG savings in the range of 60-85%, depending on feedstock availability and regional energy mix. FT synthesis, especially when utilizing municipal solid waste or forestry residues, demonstrates substantial reductions in particulate matter and sulfur emissions, further enhancing its environmental profile.
The 2025 outlook sees increasing focus on feedstock sustainability, with certification schemes such as the Roundtable on Sustainable Biomaterials (RSB) integrated into supply chains to ensure traceability and environmental compliance (Roundtable on Sustainable Biomaterials). Energy efficiency metrics are also improving: recent advances in catalyst design and process integration allow some HEFA and FT facilities to operate with energy conversion efficiencies exceeding 70%, according to Neste.
Environmental impact assessments now increasingly account for water use, biodiversity, and local air quality. For example, Neste and LanzaTech both publicly report on water consumption and strive to minimize their operational footprint by employing closed-loop and low-emission processes.
By 2025 and into the next few years, the sector anticipates further reductions in GHG emissions as next-generation technologies—such as PtL using renewable electricity and direct air capture—move from demonstration to commercial scale (Shell). Collectively, these advances underpin the aviation industry’s progress toward its net-zero goals and are expected to solidify biodajet’s role as a cornerstone of sustainable flight.
Future Outlook: Roadmap to Mainstream Adoption and Industry Scenarios
The synthesis technologies underpinning biodajet (bio-derived aviation jet) fuel are rapidly evolving, with 2025 poised to be a pivotal year for both commercial demonstration projects and policy-driven scale-ups. Key pathways—such as Hydroprocessed Esters and Fatty Acids (HEFA), Alcohol-to-Jet (ATJ), Fischer-Tropsch (FT), and emerging Power-to-Liquid (PtL) technologies—are each progressing through critical milestones toward mainstream adoption.
HEFA remains the most mature and widely deployed synthesis route. Major producers like Neste are scaling output at multiple global sites, with new capacity coming online in Singapore and Rotterdam in 2025. Neste alone targets an annual production capacity of 1.5 million tons of sustainable aviation fuel (SAF) by 2025, driven by partnerships with airlines and airports. World Energy has announced expansion of its California facility, aiming to deliver over 300 million gallons per year of SAF, positioning itself as a leading US-based HEFA producer by the mid-2020s.
ATJ technology is advancing through both ethanol- and isobutanol-based approaches. LanzaJet, a leader in ethanol-to-jet synthesis, is commissioning its first commercial-scale Freedom Pines Fuels plant in Georgia, USA, with production ramping up in 2025. The plant is designed for 10 million gallons per year initially, with blueprints for multi-site global deployment. Meanwhile, Gevo is progressing on its Net-Zero 1 project in South Dakota, targeting commercial operations in late 2025 with a focus on isobutanol-derived SAF.
FT synthesis, which can utilize municipal solid waste, forestry residues, and other feedstocks, is being advanced by companies such as Velocys. Their Bayou Fuels project in Mississippi is expected to reach final investment decision in 2025, aiming to produce SAF from waste biomass at commercial scale. Sasol is also collaborating with partners to explore FT-based solutions in South Africa and Europe, integrating renewable hydrogen for greater carbon reduction.
Longer-term, Power-to-Liquid (PtL) approaches—using renewable electricity, captured CO2, and water to synthesize hydrocarbons—are gaining momentum. Sunfire and Audi are piloting PtL plants in Europe, with commercial demonstration projects scheduled for mid-2020s and anticipated scaling by 2030.
Overall, the outlook for biodajet fuel synthesis technologies in 2025 is robust, with multi-pathway investments, supportive policy incentives, and clear roadmaps for capacity expansion. The next few years will likely see HEFA and ATJ dominate early volumes, while FT and PtL gain traction as technology costs decline and regulatory frameworks mature.
Sources & References
- Neste
- World Energy
- Velocys
- Shell
- LanzaJet
- International Air Transport Association
- Gevo
- Boeing
- Sasol
- Gevo
- TotalEnergies
- Virent, Inc.
- ASTM International
- EASA
- ICAO
- EnviTec Biogas
- ISCC System
- Sunfire
- Audi