Inherently safer process design for bio-jet fuel production

Abstract

This paper entitled “Inherently safer process design for bio-jet fuel production” provides an overview of the application of inherently safer design (ISD) principles in the production of sustainable aviation fuel (SAF), addressing aspects related to process safety and decarbonization of the aviation sector.

First, the author emphasizes the importance of bio-jet fuel as an alternative capable of reducing life-cycle emissions by up to 80% compared to conventional fuel, as a basis for addressing the challenge of operating with flammable materials and elevated pressure and temperature conditions.

One of the central aspects of the work is the application of the principles of minimization, substitution, moderation and simplification across three production routes —HEFA, SHC and ATJ—, demonstrating that modifications such as reducing hydrogen inventory or substituting acid catalysts significantly improve safety without affecting yield. This enables safer designs from the early stages of the process rather than relying on later corrective measures.

Additionally, examples are presented illustrating the impact of these modifications, such as operating at lower temperatures using alcohol-tolerant microorganisms in the ATJ route.

Finally, the study discusses challenges related to maintaining the economic and environmental performance of the process, and highlights the importance of early integration of inherently safer design to promote commercially viable and environmentally responsible bio-jet fuel plants.