隨著航空運輸需求成長與淨零碳排目標推動，永續航空燃料(Sustainable Aviation Fuel, SAF)成為航空業減碳的重要路徑之一。然而，現階段SAF仍面臨原料供應不足、製程成本偏高與生命週期環境效益需進一步評估等問題。微藻具有生長速率快、可利用二氧化碳進行光合作用、不與糧食作物競爭耕地，以及可同時提供脂質與殘渣資源等優點，因此具備作為第三代生質燃料原料之潛力。本研究以小球藻利用為核心，建立整合藻油HEFA與藻渣能源回收之SAF生產製程，並進行製程設計、操作條件分析、技術經濟分析與生命週期評估。
本研究以年處理1,500 tonne乾基小球藻為設計基準，建立三種製程情境。Scenario 1為藻油HEFA-SAF結合脫脂藻渣厭氧消化發電；Scenario 2為藻油HEFA-SAF結合脫脂藻渣氣化–Fischer–Tropsch合成製程；Scenario 3則在Scenario 2基礎上進一步導入輕質氣體能源回收，以提升整體能源利用效率。製程模擬方面，本研究使用Aspen Plus建立藻油酯化、轉酯化、甘油重整、加氫處理、厭氧消化、發電、氣化、合成氣淨化、Fischer–Tropsch合成與輕質氣體回收等單元模型，並搭配python建立Fischer–Tropsch產物分布模型。操作條件分析則使用JMP進行Box–Behnken design與反應曲面法，以評估氣化爐與脫硫吸收塔之主要操作因子。經濟分析以固定資本投資、操作成本、最低燃料售價、投資回收年限、淨現值、內部報酬率與投資報酬率作為評估指標；生命週期評估則使用SimaPro與ReCiPe 2016方法分析不同情境之環境衝擊。
製程模擬結果顯示，藻油組成會影響甘油副產物生成量與氫氣自給能力。當藻油中triolein/oleic acid比例達92/8 wt%時，甘油重整所產生之氫氣可滿足加氫處理區之需求。氣化爐操作分析結果顯示，氣化溫度與水蒸氣/生質物比為影響合成氣品質、H2/CO比與合成氣產率之主要因子，而壓力在本研究低壓操作範圍內影響較不顯著。脫硫吸收塔分析結果則顯示，貧液溫度與進料氣體溫度為控制出口H2S濃度之主要操作變因，降低溫度有助於提升MDEA吸收效果。
SAF產品分析結果顯示，HEFA-SAF年產量為188.3 tonne/yr，BtL-SAF年產量為31.94 tonne/yr。兩種SAF產品之密度、黏度、熱值、閃火點、凝固點、煙點、10 %蒸餾回收溫度與終餾點皆符合ASTM D1655與ASTM D7566航空燃油規範，顯示本研究建立之微藻HEFA與藻渣BtL製程皆具有生產合格SAF產品之技術可行性。熱整合結果顯示，各情境經熱交換網路配置後皆可降低外部加熱與冷卻需求，其中加熱需求節省率為40.3 ~ 48.8 %，冷卻需求節省率為58.5 ~ 89.7 %，顯示熱整合可有效改善製程能源效率。
經濟分析結果顯示，Scenario 1、Scenario 2與Scenario 3之固定資本投資分別為2.08、2.49與2.85 million USD，最低燃料售價分別為2,895.25、3,135.43與3,354.72 USD/ton。投資評估結果顯示，三種情境之投資回收年限分別為7、9與10年，且淨現值皆為正值，表示在本研究設定條件下均具備基本經濟可行性。其中Scenario 1因製程較單純且資本成本較低，具有最佳經濟表現；Scenario 2可藉由藻渣氣化與Fischer–Tropsch合成提高燃料產量，但資本成本亦隨之增加；Scenario 3雖導入能源回收單元，但額外設備投資使其經濟表現低於Scenario 1與Scenario 2。敏感度分析結果顯示，SAF產率與年化資本成本為影響最低燃料售價之主要因素。
生命週期評估結果顯示，Scenario 1、Scenario 2與Scenario 3之全球暖化潛勢分別為 56.7、72.1與54.9 gCO2e/MJ SAF，皆低於傳統石化航空燃油之生命週期碳排基準。其中Scenario 3因導入輕質氣體能源回收，可降低外部能源需求，因此具有最低之全球暖化潛勢；Scenario 2則因BtL製程公用工程與能源需求較高，使其環境負荷相對較高。中點指標分析顯示，human carcinogenic toxicity、freshwater ecotoxicity、marine ecotoxicity與fossil resource scarcity為較突出的環境衝擊類別，顯示除溫室氣體排放外，化學品、能源與觸媒使用所造成之毒性與資源消耗亦為微藻基 SAF製程需關注之議題。
綜合而言，本研究證明微藻全株利用結合藻油HEFA、藻渣厭氧消化、藻渣BtL與能源回收單元，可生產符合航空燃油規範之SAF產品，並具備一定之經濟與環境效益。Scenario 1具有較佳經濟性，Scenario 3則具有較佳減碳潛力。未來若能進一步降低微藻培養與前處理成本、提升藻油脂質含量、改善SAF產率並降低BtL系統設備投資，將有助於提升微藻基永續航空燃料製程之商業化可行性與永續表現。

This study evaluates sustainable aviation fuel production through an integrated microalgae biorefinery using C. vulgaris as the feedstock. A design basis of 1,500 tonne/year dry microalgae was adopted, and three process scenarios were developed. Scenario 1 integrates algal oil HEFA-SAF production with anaerobic digestion of lipid-extracted algal residue for power generation. Scenario 2 combines HEFA-SAF production with residue gasification and Fischer–Tropsch synthesis. Scenario 3 further introduces light gas recovery to improve energy utilization. Aspen Plus was used to construct steady-state process models, while Python was applied for Fischer–Tropsch product distribution calculation. JMP was used for response surface optimization, and SimaPro with ReCiPe 2016 was applied for life cycle assessment. The results show that both HEFA-SAF and BtL-SAF satisfy key ASTM D1655 and ASTM D7566 fuel specifications. HEFA-SAF and BtL-SAF production reached 188.3 and 31.94 tonne/year, respectively. Heat integration reduced external heating demand by 40.3 ~ 48.8% and cooling demand by 58.5 ~ 89.7%. Economic analysis showed that Scenario 1 had the lowest minimum fuel selling price, while life cycle assessment indicated that Scenario 3 achieved the lowest global warming potential of 54.9 g CO2e/MJ SAF.

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