Beyond Approval: How Methanol-to-Jet Is Supporting the Commercial Development of Sustainable Aviation Fuel

As demand for sustainable aviation fuel (SAF) grows globally, many projects are held back by limited raw materials and a limited number of production methods that are ready for commercial use today. Expanding the range of approved pathways is becoming even more important as developers evaluate how to bring additional production capacity online.

For years, SAF producers, project developers and technology providers have worked to expand the number of ASTM International-approved pathways available for producing SAF and electro-sustainable aviation fuel (eSAF). ASTM’s recent approval of the methanol-to-jet (MTJ) pathway provides the technical and regulatory foundation necessary for new pathways to move from development into commercial application.

The impacts of MTJ extend beyond the addition of just another approved production route – it reflects a shift in SAF project development. As the industry looks beyond pathway qualification and toward project execution, developers are even more focused on feedstock availability, infrastructure considerations and long-term project viability.

This approval arrives at a time when the industry is focused on the practical challenges associated with bringing new SAF projects into operation.

While the circumstances surrounding each SAF project are different, many developers share a common objective: identifying pathways that can support long-term development while reducing uncertainty during planning and evaluation.

Expanding the Range of Development Options

SAF production today depends largely on feedstocks such as animal fats and vegetable oils, which remain important to the industry. Developers are also evaluating additional pathways that can widen feedstock access and provide greater flexibility when planning future projects.

A key characteristic of the MTJ pathway is the role of methanol as an intermediate feedstock. Methanol can be produced from carbon dioxide and renewable hydrogen, or from biomass-derived syngas, providing developers with access to a range of potential resources.

This can be particularly relevant during project planning. Different regions have access to different resources and supply chains. The ability to produce methanol through multiple routes gives developers another option when evaluating how available resources align with project objectives and site-specific conditions.

For project teams assessing new opportunities, the value of additional pathways is not simply that they produce fuel. They can also expand the range of approaches available for feedstock sourcing, facility design and project development.
As developers evaluate future opportunities, feedstock flexibility is becoming a critical consideration. The ability to align projects with locally available resources may influence not only where facilities are developed, but also how projects are structured from the outset.

Reducing Development Uncertainty

Technical feasibility is only one part of the equation for SAF developers.

Before projects advance through development, project teams must assess whether a pathway is suited to their specific circumstances. Those evaluations often shape both project design and how investment decisions are approached.
ASTM approval of MTJ helps reduce one source of uncertainty by establishing a recognized framework for producing SAF through the pathway. Developers can now evaluate MTJ alongside other approved approaches as part of project planning activities.

In practice, approved pathways can play an important role in how project teams assess development options. The availability of an established route to SAF production may provide additional confidence when evaluating project assumptions and planning activities. Additionally, the flexibility associated with methanol production can provide more options when assessing feedstock strategies and site selection considerations.

Taken together, these factors can support more informed project evaluation and planning. As developers move toward final investment decisions, proven technologies and established process pathways can help reduce execution risk and strengthen confidence throughout project development.

Different Approaches to Project Development

One of the more notable aspects of the early MTJ projects announced to date is the variety of development approaches being pursued.

Rather than following a single model, developers are adapting the pathway to fit different regional conditions, infrastructure assets and project objectives. Technologies like the eFining(tm) process from Honeywell Technologies UOP can create SAF or eSAF from methanol using technology built on a history of methanol processing expertise.

The recent addition of Johnson Matthey Catalyst Technologies’ business to Honeywell Technologies strengthens this end-to-end approach. Together with eFining(tm), these capabilities can help developers move more efficiently from lower-carbon hydrogen and captured carbon to eSAF by simplifying project design and supporting faster implementation.

Verso Energy has announced plans to deploy eFining(tm) technology across seven planned SAF production sites in Europe and the United States using a standardized design approach. The use of a common design across multiple facilities reflects one strategy for supporting project development across different markets.

In China, Jilin Connell plans to use eFining(tm) technology at a facility designed to leverage existing methanol-to-olefins infrastructure while producing sustainable aviation fuel. The project illustrates how existing industrial assets can be incorporated into SAF development plans.

These projects reflect different priorities, but each shows how MTJ can align with business objectives, available assets and practical development strategies.

From Evaluation to Execution

As SAF projects progress through development, stakeholders focus even more on execution considerations alongside technology performance.

Questions around feedstock availability, infrastructure requirements and project design can influence whether projects advance from evaluation into detailed planning and investment review.

ASTM approval of MTJ expands the available SAF pathways. Like other approved routes, MTJ-derived fuel can be blended into existing aviation fuel systems, supporting deployment within current infrastructure. It also gives developers another option to evaluate as they assess feedstock strategies, project design and long-term operations.

The industry’s next phase will depend not only on the number of approved pathways, but also on how effectively those pathways can be integrated into viable projects. MTJ gives developers another approved option to consider as they evaluate future opportunities.

About the author

Dr. Rajesh Gattupalli is President of Honeywell Technologies UOP, part the Process Technology business. Honeywell Technologies UOP is a premier global supplier and technology licensor that designs solutions to drive energy, resource and cost efficiency within the refining, petrochemical and low carbon energy sectors.