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• Novel conceptual methods for tuning microalgae to aviation biofuel were presented. • Conversion methods that directly act on wet algae biomass are highly desired. • Chemical methods are able to obtain a maximum lipid yield of 98% • Microalgae bio-jet fuel parameters are compiled with ASTM standards. • Zeolite catalytic pyrolysis increased the bio-oil yield from Microalgae to 80 %. Concerns have been raised about the effects of fossil fuel combustion on global warming and climate change. Fuel consumer behavior is also heavily influenced by factors such as fluctuating fuel prices and the need for a consistent and reliable fuel supply. Microalgae fuel is gaining popularity in the aviation industry as a potential source of energy diversification. Microalgae can grow in saltwater or wastewater, capture CO 2 from the atmosphere and produce lipids without requiring a large amount of land. As a result, the production of oil from microalgae poses no threat to food availability. The low carbon footprint of microalgae-derived fuels has the potential to mitigate the impact of traditional aviation fuels derived from petroleum on climate change and global warming. Therefore, aviation fuels derived from microalgae have the potential to be a more environmentally friendly and sustainable alternative to conventional fuels. Gathering microalgal species with a high lipid content, drying them, and turning them into aviation fuel is an expensive process. The use of biofuels derived from microalgae in the aviation industry is still in its infancy, but there is room for growth. This study analyses the potential routes already researched, their drawbacks in implementation, and the many different conceptual approaches that can be used to produce sustainable aviation fuel from microalgal lipids. Microalgae species with fast-growing rates require less space and generate lipids that can be converted into biofuel without imperiling food security. The key challenges in algal-based aviation biofuel include decreased lipid content, harvesting expenses, and drying procedure that should be enhanced and optimized to increase process viability. [ABSTRACT FROM AUTHOR]

[Display omitted] • Biorefinery concept for sustainable processing of microalgae biomass has been discussed. • Reactor technologies for cultivating microalgae has been reviewed. • Factors affecting the microalgae culture system has been reviewed. • Different technologies to convert microalgae into biofuel and value-added products have been presented. • The utilisation of a biorefinery concept can make the valorisation of microalgae economically viable. Microalgal biomass has been proved to be a sustainable source for biofuels including bio-oil, biodiesel, bioethanol, biomethane, etc. One of the collateral benefits of integrating the use of microalgal technologies in the industry is microalgae's ability to capture carbon dioxide during the application and biomass production process and consequently reducing carbon dioxide emissions. Although microalgae are a feasible source of biofuel, industrial microalgae applications face energy and cost challenges. To overcome these challenges, researchers have been interested in applying the bio-refinery approach to extract the important components encapsulated in microalgae. This review discusses the key steps of microalgae-based biorefinery including cultivation and harvesting, cell disruption, biofuel and value-added compound extraction along with the detailed technologies associated with each step of biorefinery. This review found that suitable microalgae species are selected based on their carbohydrate, lipid and protein contents and selecting the suitable species are crucial for high-quality biofuel and value-added products production. Microalgae species contain carbohydrates, proteins and lipids in the range of 8% to 69.7%, 5% to 74% and 7% to 65% respectively which proved their ability to be used as a source of value-added commodities in multiple industries including agriculture, animal husbandry, medicine, culinary, and cosmetics. This review suggests that lipid and value-added products from microalgae can be made more economically viable by integrating upstream and downstream processes. Therefore, a systematically integrated genome sequencing and process-scale engineering approach for improving the extraction of lipids and co-products is critical in the development of future microalgal biorefineries. [ABSTRACT FROM AUTHOR]