The Role of Biofuels and Sustainable Aviation Fuels in Clean Energy

The Urgency of Energy Transition

Global CO₂ emissions have risen to approximately 37 gigatonnes per year, contributing to a 1°C increase in average global temperatures since pre-industrial times. Greenhouse gases are driving the climate crisis, with CO₂ making up around 75% of global emissions, followed by methane at 20% and nitrous oxide at 5%. Without significant action, current policies are projected to lead to a 3°C rise by 2100—well above the Paris Agreement targets of limiting warming to below 2°C.

This stark outlook places the energy transition at the centre of climate strategy. A mix of technologies will be required to reduce emissions—especially in hard-to-abate sectors like transportation and energy-intensive industries. Renewable fuels such as biofuels and synthetic fuels offer practical, near-term solutions that support decarbonisation while enabling continued operation of existing infrastructure.

The Evolution of Biofuels and Sustainable Aviation Fuel

Biofuels are increasingly recognised as a key transitional solution toward achieving net zero emissions. Several key megatrends are shaping this market:

• Shift in Refining Practices: Traditional refiners, particularly in North America and the European Union, are moving away from conventional refining methods, repurposing existing infrastructure to accommodate biofuels. Meanwhile, refiners in Asia-Pacific and the Middle East are integrating biofuels with petrochemicals, adapting to the declining demand for fossil fuels and diversifying their product offerings.
• Market Growth for Sustainable Aviation Fuel (SAF): SAF is gaining momentum as regulatory frameworks tighten emissions targets in the aviation sector. With increasing investments from both private and public sectors, SAF production capacity is expected to expand significantly, creating new opportunities for sustainable fuel adoption.
• Regulatory Incentives: Governments in North America and the Middle East actively promote biofuel adoption through incentives and grants. These policies provide financial support for producers, encourage research into advanced biofuel technologies and mandate blending requirements to accelerate the shift away from traditional fossil fuels.
• Emerging Industry Players: Technology companies are entering the biofuels industry, bringing innovative approaches to fuel production and refining. Many prefer modular plant designs for greater scalability, rely on single-source suppliers for streamlined operations and require additional support for plant maintenance and optimisation.
• Increased Competition: OEMs, EPC companies and established energy companies are expanding into biofuels, recognising the sector's potential for long-term growth. As more players enter the market, staying competitive requires a proactive strategy focused on efficiency, sustainability and technology-driven solutions.

The Role of Advanced Technologies in Biofuels and SAF

Digitisation is playing an increasingly important role in the energy transition. Real-time monitoring, predictive analytics and data-driven maintenance are becoming essential for improving efficiency, reducing emissions and ensuring reliability in biofuels and SAF operations. As the biofuels and SAF markets evolve, John Crane is leveraging its existing technologies—with a strong focus on digital innovation—to support the transition to lower-carbon fuels and meet the industry's long-term needs.

Key areas of our expertise include:

• John Crane Sense® Digital Technology — Offering real-time condition monitoring and predictive analytics to optimise plant performance and reduce unplanned downtime. By providing actionable insights, this data-driven digital technology enables operators to proactively manage maintenance and improve operational efficiency.
• Wet Seals and Systems — These seals ensure the reliability and efficiency of pumps and agitators in biofuel processing. They are engineered to withstand the unique challenges of biofuels, including variable viscosities and aggressive chemical compositions, while minimising leakage and downtime.
• Dry Gas Seals and Systems — Helping refineries transition to biorefineries with retrofit solutions that improve efficiency and reduce CO₂ emissions. These mechanical seals support gas compression processes and reduce pump seal atmospheric leakages, which makes them essential for biofuel production and enhance operational safety and longevity.
• Dry Gas Seal Retrofits and Upgrades — Enabling the conversion of oil refineries to biorefineries by replacing legacy sealing systems with high-efficiency dry gas seals, reducing CO₂ emissions and improving long-term reliability.
• Filtration Solutions — Removing contaminants such as particulates, water and corrosive elements from biofuels and SAF to improve fuel quality and protect downstream equipment. Advanced filtration extends the lifespan of critical components and ensures compliance with industry standards.
• Couplings — Providing durable, high-performance couplings that transmit torque efficiently in biofuel production environments. Designed for harsh operating conditions, these couplings help reduce vibration, accommodate misalignment and extend equipment service life.

These solutions help improve energy efficiency and contribute to sustainability objectives by enhancing equipment longevity and reducing resource consumption.

Proven Expertise in the Biofuels Sector

John Crane is actively supporting the development of sustainable fuels across a wide range of applications. From refinery conversions to new bioethanol and SAF facilities, our proven solutions are helping reduce emissions and improve reliability in critical operations.

Examples include:

• Refinery Conversions – Supporting major U.S. refineries transitioning to biofuel and SAF production, including facilities converting used cooking oil into sustainable aviation fuel. Our sealing and system solutions are key in enabling lower emissions and improved operational efficiency.
• Biorefinery and Biofuel Facilities – Assisting in the development of next-generation biofuel plants, including bioethanol and SAF production sites in regions such as Canada. John Crane has delivered tailored sealing and system solutions that ensure operational safety, process efficiency and environmental compliance, across several new and innovative fuel technologies.
• Bioethanol Plants – Supplying couplings and sealing solutions to the second-largest advanced bioethanol facility in Europe, ensuring the reliability of key rotating equipment involved in large-scale production.

Looking Ahead: John Crane's Commitment to Innovation

As the biofuels and SAF market expands, John Crane remains committed to investing in new technologies that align with global sustainability goals. Future developments will focus on:

• Enhancing energy efficiency across all product lines.
• Continuing to ignite and nurture expertise and customer-focused capabilities.
• Expanding partnerships with biofuel producers and new market entrants.
• Advancing digital solutions for predictive maintenance and asset management.

By leveraging our expertise and commitment to innovation, John Crane is well-positioned to support the evolving needs of the biofuels sector, ensuring a more sustainable and energy-efficient future.