U.S. sustainable aviation fuel production surges in 2025
Sustainable aviation fuel (SAF) production in the United States is experiencing rapid growth following a wave of new capacity additions. According to the U.S. Energy Information Administration (EIA), SAF production rose sharply between December 2024 and February 2025, contributing to a significant uptick in the broader “Other Biofuels” category.
SAF, a renewable alternative to petroleum-based jet fuel, is derived from agricultural and waste feedstocks and blended with conventional jet fuel. The recent expansion has been driven by enhanced federal incentives, including tax credits and the U.S. Environmental Protection Agency’s Renewable Fuel Standard (RFS), which have accelerated investments in SAF infrastructure.
By early 2025, U.S. SAF production capacity had reached approximately 25,000 barrels per day (b/d), a marked increase from the 2,000 b/d available at the beginning of 2024. Key facilities contributing to this surge include Phillips 66’s Rodeo, California site, World Energy’s plant in Paramount, California, Montana Renewables’ facility in Great Falls, and New Rise Renewables’ operation in Reno, Nevada. Additional contributions are expected from Par Pacific’s site in Kapolei, Hawaii.
SAF production currently accounts for a growing share of U.S. Other Biofuels, a category which also includes renewable diesel by-products such as naphtha and propane. The EIA estimates that although SAF will remain a small proportion of total jet fuel consumption—just under 2% by 2026—it will dominate the biofuels segment in percentage growth terms.
The broader Other Biofuels production reached a record 33,000 b/d in January and increased further to 44,000 b/d by February 2025, reflecting a 30% month-on-month gain. With SAF capacity projected to more than double between 2024 and 2025, the U.S. aviation sector is poised for a more sustainable fuel transition.
