Chemical and Biological Engineering ETDs

Publication Date

Summer 7-31-2025

Abstract

This study provides a comprehensive systems-level evaluation of an integrated circular biorefinery for sustainable aviation fuel (SAF) production. Employing supply chain optimization, technoeconomic analysis, lifecycle analysis, policy modeling, and multicriteria decision analysis, the research assesses technical feasibility, economic viability, and environmental performance. The circular economy model demonstrates exceptional resource efficiency, achieving a 92.3% overall circularity score with strong material recycling, water reuse, waste minimization, and near-complete energy recovery, resulting in net-negative carbon emissions and net energy export. Scaling the facility to commercial capacity (500 million liters per year) enables significant economic improvements. The minimum fuel selling price (MFSP) decreases from $4.85/L at demonstration scale to $0.55/L at commercial scale, supported by economies of scale and optimized logistics. Monte Carlo simulations show an 86.6% chance of producing SAF below $1.00/L. Transportation optimizations reduce per-liter costs by 90% and cut supply chain greenhouse gas emissions by 44.8%, while dynamic inventory and just-in-time logistics strengthen supply chain resilience. Comprehensive policy stacking – including federal and state incentives such as RFS D3, IRA 45Z, and LCFS credits – contributes over 80% MFSP reduction and enhances life cycle GHG mitigation, achieving up to 57% reductions in sectoral emissions. Strategic hydrogen sourcing, with 34.5% internal production via biomass gasification and electrolysis, plays a critical role in lowering costs and carbon footprint. Multicriteria decision analysis confirms GHG mitigation and policy-adjusted MFSP as key drivers of optimal system performance, with more than 94% scenario viability. By integrating circular economy principles, process intensification, policy frameworks, and hydrogen management, this work establishes scalable framework for deploying economically viable and environmentally sustainable SAF solutions across diverse regional contexts.

Keywords

Sustainable Aviation Fuel (SAF), Circular Biorefinery, Technoeconomic Analysis, Supply Chain Optimization, Policy Incentives, Life Cycle Assessment, Hydrogen Sourcing, Circular Economy, Greenhouse Gas Reduction, Process Simulation

Document Type

Dissertation

Language

English

Degree Name

Chemical Engineering

Level of Degree

Doctoral

Department Name

Chemical and Biological Engineering

First Committee Member (Chair)

Fernando Garzon, PhD

Second Committee Member

Shuya Wei, PhD

Third Committee Member

Julie Allred Coonrod, Ph.D

Third Advisor

Jamie Gomez, Ph.D.

Fourth Committee Member

William L. Kubic, Jr., Ph.D.

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