TotalEnergies, one of Europe's leading integrated energy companies headquartered in France, is addressing this challenge by transforming its existing refining assets into renewable fuel production hubs. Instead of constructing entirely new facilities, the company is modernizing conventional refineries to produce SAF alongside renewable diesel and other low-carbon fuels. This strategy enables faster commercialization, lower capital costs, and more efficient use of existing infrastructure while supporting Europe's ambitious climate targets.

This article explores how TotalEnergies is leveraging existing refineries to expand Sustainable Aviation Fuel production, the technologies involved, the role of refinery transformation, strategic partnerships, regulatory drivers, and the broader implications for the global Sustainable Aviation Fuel market.

The Growing Need for Sustainable Aviation Fuel

The aviation sector faces unique decarbonization challenges. Unlike road transportation, where electric vehicles are rapidly gaining market share, commercial aviation requires high-energy-density fuels capable of powering long-haul flights. While hydrogen-powered and electric aircraft are under development, they are not expected to replace conventional jet fuel at scale for many years.

Sustainable Aviation Fuel bridges this gap by offering a renewable alternative that can significantly reduce lifecycle greenhouse gas emissions—often by up to 80% depending on the feedstock and production pathway. Because SAF is compatible with existing aircraft and airport infrastructure, airlines can reduce emissions without replacing their fleets.

The growing adoption of SAF is being driven by:

• National and regional emissions reduction targets
• The European Union's ReFuelEU Aviation initiative
• Corporate sustainability commitments
• Rising investor focus on Environmental, Social, and Governance (ESG) performance
• Passenger demand for more sustainable travel options

As a result, demand for SAF is increasing much faster than current production capacity, creating opportunities for energy companies capable of scaling output efficiently.

Why Refinery Transformation Matters

Building new biorefineries from the ground up requires significant capital investment, lengthy permitting processes, and years of construction. TotalEnergies has instead adopted a strategy centered on converting and upgrading existing refineries to process renewable feedstocks alongside traditional refining operations.

This approach offers several advantages:

• Faster deployment of SAF production
• Lower capital expenditure compared with greenfield projects
• Efficient use of existing logistics and storage infrastructure
• Reduced environmental impact through asset reuse
• Greater flexibility to adapt production based on market demand

By leveraging decades of refining expertise and existing industrial assets, TotalEnergies can accelerate SAF commercialization while minimizing operational disruptions.

Transforming the Grandpuits Refinery into a Biorefinery

A cornerstone of TotalEnergies' strategy is the transformation of its Grandpuits refinery in France into a zero-crude biorefinery platform. Rather than continuing conventional oil refining, the site is being redeveloped to manufacture renewable fuels, including Sustainable Aviation Fuel, renewable diesel, and bioplastics.

The Grandpuits project demonstrates how legacy refining infrastructure can be repurposed to support the energy transition. Existing storage tanks, logistics systems, rail connections, and utilities are being integrated into the new renewable fuel production process, reducing the need for entirely new infrastructure.

Once fully operational, Grandpuits is expected to become one of France's flagship renewable fuel production facilities, supplying SAF to airlines operating across Europe while contributing to the country's decarbonization objectives.

Upgrading Existing Refining Assets Across France

In addition to Grandpuits, TotalEnergies is modernizing several of its refining assets, including facilities at La Mède and Normandy, to support renewable fuel production.

These refinery upgrades include:

• Installation of renewable feedstock processing units
• Advanced hydrogen treatment systems
• Improved feedstock pretreatment technologies
• Enhanced logistics for waste-based raw materials
• Integration of SAF blending capabilities

This network of upgraded facilities enables TotalEnergies to increase renewable fuel output while maintaining operational efficiency across its refining portfolio.

Renewable Feedstocks at the Core of Production

One of the defining features of TotalEnergies' SAF strategy is its focus on renewable waste and residue feedstocks. Instead of relying on food-based crops, the company prioritizes materials that support circular economy principles and reduce lifecycle emissions.

Common feedstocks include:

• Used cooking oil
• Animal fats
• Vegetable oil processing residues
• Waste oils and greases
• Agricultural by-products

By utilizing waste-derived resources, TotalEnergies minimizes competition with food production while improving the environmental performance of its fuels.

The company is also investing in research to diversify feedstock sources further, ensuring long-term supply security as SAF demand continues to rise.

HEFA Technology: The Foundation of Commercial SAF

Currently, the primary production pathway used by TotalEnergies is the Hydroprocessed Esters and Fatty Acids (HEFA) process. HEFA converts renewable oils and fats into drop-in aviation fuel that meets stringent international aviation fuel standards.

The advantages of HEFA include:

• Commercial maturity
• Proven scalability
• Compatibility with existing aircraft engines
• High lifecycle emissions reductions
• Integration into existing refinery infrastructure

Although HEFA remains the dominant SAF production pathway today, TotalEnergies recognizes that additional technologies will be necessary to satisfy future demand.

Preparing for Advanced and Synthetic Aviation Fuels

To support long-term aviation decarbonization, TotalEnergies is investing in next-generation SAF technologies beyond HEFA.

These include:

Alcohol-to-Jet (ATJ)

Converts sustainable alcohols into aviation fuel.

Biomass-to-Liquid (BtL)

Uses forestry residues and agricultural biomass to produce renewable jet fuel.

Power-to-Liquid (PtL) and e-SAF

Produces synthetic aviation fuels using renewable electricity, green hydrogen, and captured carbon dioxide.

These advanced pathways have the potential to expand feedstock availability while delivering even lower lifecycle greenhouse gas emissions.

Strategic Partnerships Supporting SAF Growth

Scaling SAF production requires collaboration across the aviation value chain. TotalEnergies has established partnerships with airlines, airports, aircraft manufacturers, and fuel distributors to accelerate adoption.

These collaborations support:

• Long-term fuel supply agreements
• SAF certification and testing
• Infrastructure development
• Research and innovation
• Commercial deployment

Partnerships with major aerospace companies and airline groups help ensure that increased production capacity aligns with market demand.

Meeting ReFuelEU Aviation Requirements

The European Union's ReFuelEU Aviation initiative requires fuel suppliers to gradually increase the percentage of Sustainable Aviation Fuel supplied to airports across Europe.

For TotalEnergies, refinery transformation provides a competitive advantage by enabling the company to supply increasing SAF volumes without constructing entirely new production facilities.

This positions the company to play a critical role in helping airlines comply with mandatory SAF blending requirements while supporting Europe's broader climate objectives.

Strengthening the European SAF Supply Chain

Refinery modernization not only increases production but also strengthens regional fuel supply chains.

Existing pipeline networks, storage terminals, port facilities, and transportation systems can continue supporting renewable fuel distribution.

This reduces logistics costs while improving fuel availability across major European aviation hubs.

An integrated supply chain also improves resilience against disruptions and supports reliable long-term fuel delivery.

Economic Benefits of Refinery Conversion

Transforming existing refineries creates significant economic advantages beyond environmental benefits.

These include:

• Preserving skilled industrial jobs
• Extending the operational life of refining assets
• Reducing capital investment requirements
• Supporting regional economic development
• Attracting renewable energy investment

Instead of decommissioning traditional refineries, TotalEnergies is giving these industrial sites a new role within the low-carbon economy.

Challenges in Scaling SAF Production

Despite rapid progress, several challenges remain.

Feedstock Availability

Global supplies of sustainable waste oils remain limited.

Production Costs

SAF remains more expensive than conventional jet fuel.

Infrastructure Expansion

Additional airport storage and blending facilities will be needed as SAF adoption grows.

Regulatory Consistency

Different sustainability certification systems and policy frameworks across regions can complicate international trade.

Addressing these challenges will require continued collaboration among governments, fuel producers, technology developers, and airlines.

Competitive Advantages of TotalEnergies' Refinery Strategy

TotalEnergies' approach offers several strategic advantages over companies building entirely new production facilities.

These include:

• Faster market entry
• Lower investment costs
• Proven industrial expertise
• Existing global logistics infrastructure
• Strong European market presence
• Operational flexibility
• Enhanced supply chain resilience

By maximizing the value of existing refining assets, the company can scale production more efficiently while supporting the broader energy transition.

Future Outlook

The Sustainable Aviation Fuel market is expected to experience robust growth throughout the coming decade as governments implement stricter emissions regulations and airlines pursue net-zero commitments.

Future growth will be supported by:

• Increasing SAF blending mandates
• Expanded refinery conversion projects
• Commercialization of advanced biofuel technologies
• Growth in synthetic aviation fuels
• Improved feedstock collection systems
• Greater investment in renewable hydrogen

Companies capable of rapidly increasing SAF production while maintaining sustainability standards are expected to lead the next phase of aviation decarbonization.

Conclusion

TotalEnergies is demonstrating that the transition to low-carbon aviation does not necessarily require building entirely new fuel production infrastructure. By strategically transforming existing refineries into renewable fuel hubs, the company is accelerating Sustainable Aviation Fuel production while optimizing capital investment, preserving industrial expertise, and strengthening Europe's renewable fuel supply chain.

Its refinery conversion strategy—anchored by projects such as Grandpuits and supported by upgrades at La Mède and Normandy—illustrates how legacy refining assets can be repurposed to meet the growing demand for cleaner aviation fuels. Combined with investments in renewable feedstocks, HEFA technology, advanced SAF pathways, and strategic partnerships across the aviation ecosystem, TotalEnergies is positioning itself as a leading contributor to the industry's decarbonization journey.

As global airline demand for Sustainable Aviation Fuel continues to rise and regulations such as ReFuelEU Aviation accelerate adoption, leveraging existing refinery infrastructure offers a practical and scalable model for expanding production. While challenges such as feedstock availability, production costs, and infrastructure development remain, TotalEnergies' integrated approach provides a strong foundation for long-term growth.

The transformation of conventional refineries into renewable energy hubs represents more than an operational shift—it is a blueprint for how the energy industry can support sustainable aviation while advancing the global transition toward a lower-carbon future.