Techno-economic analysis of waste-to-SAF pathways with carbon capture and storage and green hydrogen integrations

De-fossilising the aviation sector is essential for global climate goals, with sustainable aviation fuels (SAF) identified as a key low-emission solution. Municipal solid waste (MSW), when converted to refuse-derived fuel (RDF), offers an abundant, largely biogenic feedstock for SAF production while diverting waste from landfills. This research study analyses the production of SAF from RDF gasification via bioenergy with carbon capture and storage (BECCS) and power biomass to liquid (PBtL) concepts with Fischer-Tropsch (FT) and Methanol-to-Jet (MTJ) fuel syntheses as production pathways. The processes are modelled within Aspen Plus and single process units are validated against industrial plant data. In the BECCS route, 95% of carbon dioxide (CO₂) is captured post-syngas conditioning and permanently sequestered, enabling potential negative emissions and carbon credits. The PBtL route integrates green hydrogen from water electrolysis for syngas conditioning, with the electrolytic oxygen supporting gasification and reforming. Results show that integrating green H₂ boosts SAF yield but increases energy demand. The MTJ-H 2 pathway demonstrated the lowest levelized cost of production of £7.7/kg SAF, although this is still higher than conventional jet fuel and thus not competitive within the current market. As such, policy frameworks and economic incentives remain essential to achieve large-scale deployment of SAF.