Abstract:
Rapid decarbonisation of aviation requires innovative Sustainable Aviation Fuel (SAF) solutions. This work presents a comprehensive multi-pathway approach for SAF production, integrating advanced thermochemical, biochemical, and hybrid processes. At Tomato Sustainables, we optimise lignocellulosic biomass valorisation via pyrolysis and proprietary catalytic upgrading, employing novel process conditions and next-generation bio-catalysts that enable feedstock flexibility and maximise hydrocarbon yield. Detailed composition analysis confirms that our SAF fractions meet or exceed international sustainability and performance standards, with greenhouse gas emissions reductions exceeding 80% (compared to fossil jet), and carbon intensity as low as 32 gCO2e/MJ, verified through rigorous LCA and compliance with CORSIA and REDII criteria.
Our R&D project has produced large volumes of biocrude through pilot-scale runs, supported by robust techno-economic modelling and industry partnerships. Real-world demonstration, including fuel specification testing and successful collaborations with aviation stakeholders, underlines our pathway’s commercial readiness. Strategic alliances are driving scale-up toward annual production targets exceeding 1 million gallons, directly supporting UK and EU policy frameworks for aviation sustainability.
This work highlights the transformative potential of multi-pathway SAF development, which combines technical innovation, advanced analytics, and scalable deployment to accelerate aviation’s transition to climate neutrality. Future research focuses on digital process optimisation and expanding feedstock diversity, ensuring alignment with global net zero objectives and fostering resilient, circular bioeconomy solutions.
Biography:
Dr. Sanjeev Gajjela FRSC is a distinguished scientific and strategic leader with over 20 years of international experience in advancing renewable energy innovation, technology commercialisation, and cross-sector decarbonisation. Holding a PhD in Sustainable Bio Products Catalysis and Biofuels, he has authored or co-authored over 37 patents across the US and UK and has played a key role in securing more than $30 million in grant funding. Notably, one of his patented sustainable aviation fuel (SAF) technologies is currently being commercialised in the United States, valued at over $100 million.
As the Director of Sustainables and co-founder of Tomato Sustainables Ltd, UK, Dr. Gajjela leads the strategic development, commercialisation, and scale-up of innovative sustainable fuel technologies. This includes green hydrogen, renewable dimethyl ether (rDME), bio-LPG, and carbon capture, utilisation, and storage (CCUS) projects. He established the UK’s first dedicated SAF research and development laboratory, managing laboratory setup, health, safety, and environment (HSE) systems, technical governance, and mentoring a high-performing team of scientists.
Dr. Gajjela has managed successful multi-million-pound CAPEX and OPEX portfolios and has commercialised multiple biofuel products, generating over £100 million in revenue. His expertise covers project management (PMP, CSM certified), intellectual property strategy, ESG integration, and sustainability reporting aligned with GRI, CSRD, and SDGs—particularly Climate Action, Clean Energy, and Industry Innovation.
His collaborations include prestigious academic institutions such as the Universities of Sheffield, Surrey, Oxford, Bath, and the Royal Agricultural University, promoting innovation in SAF feedstock, catalyst development, and techno-economic and lifecycle assessments. He serves on the technical advisory board of Senapt Ltd and on editorial boards in chemical engineering and renewable fuels and is a recognised keynote speaker at global bioenergy and sustainability conferences.
Dr. Gajjela’s leadership integrates strategic business planning, grant acquisition, stakeholder engagement, and regulatory compliance. His work makes a significant contribution to the UK Net Zero 2050 agenda and supports the global shift towards sustainable aviation fuels and clean energy.
