A feasibility study jointly conducted by Air New Zealand and US-based waste-to-fuel developer LanzaJet has concluded that up to 25% of New Zealand’s domestic aviation fuel needs could be met using sustainable aviation fuel produced locally using woody waste residue as a feedstock. The SAF would be produced through a two-stage process, initially converting the wood to ethanol using the CirculAir carbon recycling technology developed by LanzaJet and its sibling, LanzaTech, then using LanzaJet’s alcohol-to-jet (AtJ) pathway to transform the ethanol to SAF. The airline’s Chief Sustainability and Corporate Affairs Officer, Kiri Hannifin, said the findings were “very positive for a country that is heavily reliant on long-haul aviation and trade and currently imports 100% of its jet fuel.” The NZ study result closely followed the announcement of a carbon-to-SAF partnership between LanzaTech and emerging Australian SAF producer Wagner Sustainable Fuels, and another in Japan between LanzaTech and the SEKISUI Chemical Company to convert municipal and industrial waste to ethanol then SAF.

The New Zealand study was co-funded by the airline and its majority shareholder, the New Zealand government, supported by Scion, a Crown research institute focused on forestry and wood products; fuel and infrastructure company Z Energy; and Wood Beca, a project engineering business specialising in oil, gas and wood, to explore opportunities for local production of non-fossil fuels for aviation.

Announcement of the report’s preliminary conclusions followed a contentious decision by the airline to scrap its 2030 carbon emissions reduction targets and withdraw from the Science Based Targets initiative (SBTi), citing challenges to the availability of new, lower-emission aircraft types and alternative fuels, and support from governments and regulators for decarbonisation initiatives.

“Alternative jet fuel such as SAF is currently the only real tool available to address carbon emissions from long-haul aviation, so it’s crucial for connecting New Zealanders, tourists and exporters with the rest of the world,” said Hannifin.

“There is already significant international momentum and, in our view, New Zealand shouldn’t get left too far behind, or we risk seeing the flow of capital go elsewhere, or our valuable raw materials being swooped up by other markets for their own SAF.

“The right settings and regulatory environment will be important as New Zealand considers homegrown SAF because it’s the only way to secure the necessary global investment.”

LanzaJet CEO Jimmy Samartzis welcomed initial results from the feasibility study and said a second phase was now underway to investigate the potential for household and commercial waste to also be used as fuel feedstock.

“Building a new industry requires developing a broad ecosystem for SAF in New Zealand, anchored in technology and supported by policy, capital and demand to help attract funding and make it at a price airlines can afford,” said Samartzis.

CirculAir, the SAF production approach assessed in the study, combines the technologies of LanzaTech and LanzaJet to convert waste carbon into SAF.

“The process starts with LanzaTech’s carbon recycling technology which, in this case, converts gasified forestry residues into ethanol. LanzaJet then converts that into SAF using its proprietary and industry-leading alcohol-to-jet (AtJ) technology,” explained Samartzis.

“Turning woody biomass into SAF is technically possible in New Zealand and with the right settings, is an industry that can get started fairly quickly. We look forward to completing additional analysis into what other feedstocks, such as municipal household and commercial waste, could be used to make domestic SAF production an even more attractive option.”  

Soon before the conclusions were announced from the first phase of the New Zealand study, LanzaTech and LanzaJet signed an agreement to test their CirculAir carbon-to-SAF technology at ‘The Project,’ the Brisbane SAF refinery of Wagner Sustainable Fuels.

The first stage of this process uses LanzaTech’s carbon recycling technology to convert industrial emissions or municipal solid waste into ethanol, which is then transformed into drop-in SAF using LanzaJet’s AtJ technology.

The CirculAir platform is designed to unlock carbon from a multitude of waste-based resources, providing flexibility for feedstock conversion.

“The combination of LanzaJet’s leading SAF solution with the front end of LanzaTech’s proven and commercialised carbon recycling technology makes it possible to create a domestic SAF supply in Australia using local renewable waste sources, further supporting the country’s energy security while also working to protect its natural environment,” said LanzaJet’s Samartzis.

Matt Doyle, CEO of Wagner Sustainable Fuels, said the CirculAir partnership with LanzaTech and LanzaJet would advance his company’s Brisbane refinery and accelerate the development of a SAF industry in Australia, where multiple projects are now being scoped or progressing towards final investment decision.

“Together, these proven technologies can help us realise Australia’s first, fully integrated SAF production facility and provide a path to producing domestic fuel at scale,” he said.

The Wagner Project has also secured backing from both Boeing and the Queensland state government.

Earlier this year, LanzaJet also signed a licensing agreement with Jet Zero Australia, which is developing an AtJ SAF plant in Townsville, North Queensland, and will use agricultural biomass including sugar cane waste as a feedstock for the fuel.

Jet Zero, whose investors include Qantas, Airbus and Japanese petroleum group Idemitsu Kosan, plans to produce up to 102 million litres of SAF and 10 million litres of renewable diesel per year. It is targeting production from 2027. 

LanzaTech has also partnered with Japan’s SEKISUI Chemical Company to jointly develop a platform which transforms syngas from municipal and industrial solid waste into ethanol, and then into products including sustainable aviation fuel.

Under a master licence agreement, SEKISUI plans to build multiple facilities across Japan, with the first expected to produce 10 to 12 kilotons of ethanol annually for use not only in SAF but also chemicals and materials including packaging and apparel. The deal extends a decade-long partnership between the two companies to divert garbage away from landfill or incineration for recycling as product feedstock.

Japan is active in recycling and decarbonisation and is one of the leading climate action markets in the Asia-Pacific region. Among its initiatives, it has mandated that by 2030 SAF will make up 10% of all fuel used by its domestic airlines and departing international carriers.

The expanded partnership between LanzaTech and SEKISUI follows the successful operation of a pilot plant established in 2017 in Yorii-machi, Saitama, and the completion in 2022 of a demonstration plant in Kuji City, Iwate, with annual capacity to convert approximately 400 tons of municipal solid waste to ethanol for further processing.

Each year, said the companies in their announcement, Japan generates some 56 million tons of combustible waste, which ordinarily would be sent to landfill facilities, “emitting methane, a greenhouse gas 23 times more potent than carbon dioxide,” or incinerated for power generation, emitting embedded carbon into the atmosphere.

Using the LanzaTech technology, unsorted combustible waste is gasified, then converted into ethanol through the use of a microbial catalyst and gas fermentation technology which requires no chemical catalysts, heat or pressure.

“We are pleased to expand our collaboration with longstanding partner LanzaTech, whose waste-to-ethanol technology is converting municipal solid waste into a valuable resource and providing an innovative solution to ending our reliance on fresh fossil fuels,” said Futoshi Kamiwaki, SEKISUI Representative Director and Senior Managing Executive Officer.

LanzaTech CEO Dr Jennifer Holmgren said the extended agreement also progressed her company’s vision for a circular carbon economy.

“We are grateful to SEKISUI for their commitment to scaling carbon recycling across Japan,” said Holmgren, “and for being at the forefront of developing a global blueprint for other countries and businesses to follow on how to access and utilise the carbon locked in local garbage.

“Our continued collaboration with SEKISUI is setting the groundwork for providing municipalities with a platform that reduces waste, captures carbon, generates valuable feedstocks and, importantly, creates jobs.

Photo: Air New Zealand

Tony Harrington

Correspondent

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North America has seen new sustainable aviation fuel agreements this month announced by Boeing and Canada’s WestJet, as well as Air New Zealand for supply in Los Angeles. Boeing has signed deals with multiple SAF suppliers to source 9.4 million gallons of blended product, its biggest single annual commitment. Of this, 4 million gallons are destined for its Pacific Northwest fuel farms and another 5.4 million gallons for distribution through book-and-claim programmes. In Canada, Calgary-based WestJet has bought the first SAF supplied in the country through Shell Aviation’s Avelia book-and-claim system. And in Los Angeles, Air New Zealand is taking delivery this year of 9 million litres (2.4 million gallons) of neat SAF produced in Singapore by renewable energy group Neste. Additionally, Boeing has just partnered with Australia’s Wagner Sustainable Fuels in developing a SAF blending facility in the state of Queensland.   

Boeing’s latest commitment, 60% greater than its SAF acquisitions in 2023, will be used in the company’s ecoDemonstrator programme, through which technologies and practices designed to increase aircraft efficiency and reduce their emissions are assessed using the company’s fleet of testbed aircraft. The blended supplies, all of which will include 30% SAF developed with waste fats, oils and greases, will also be used on Boeing’s commercial operational flights in the US.

The 4 million gallons of blended SAF destined for Boeing’s fuel farms will be produced by renewable energy group Neste and supplied by two US-based independent suppliers – 2.5 million gallons from EPIC Fuels, which operates major facilities in Oregon and Texas, and 1.5 million gallons from Avfuel, based in Michigan.

The additional 5.4 million gallons of blended SAF will also be provided in two batches, with 3.5 million gallons of Neste-made SAF to be supplied by EPIC Fuels, and 1.9 million gallons produced by World Fuel Services and supplied by World Energy. Through a book-and-claim process, Boeing will purchase the CO2 emissions reductions associated with these deals.

As well as driving up demand for SAF, book-and-claim systems authenticate the environmental attributes and ensure that these are allocated to buyers of the fuel as offset credits towards their net zero carbon emission targets.

 “About 20% of our fuel usage is a SAF blend,” said Ryan Faucett, Boeing’s VP Environmental Sustainability. “We continue to increase our use of this fuel to encourage growth in the SAF industry. We are also working to make SAF more available and affordable to our commercial airline customers through collaboration, investment, research and policy development.”

In Canada, WestJet said it had acquired the first SAF to be supplied in the country by Shell Aviation via its Avelia book-and-claim platform, though neither the volume nor timeframe of the fuel deal were disclosed in the airline’s announcement. Avelia uses blockchain technology to confirm transparent tracking of the environmental attributes of SAF, from production to delivery into aviation fuelling networks.

“WestJet is committed to enhancing our position as a first mover in sustainability technologies,” said Angela Avery, the airline group’s EVP and Chief People, Corporate and Sustainability Officer. “Just as we pioneered advancements in winglets and drag reduction, WestJet proudly stands as the first airline to acquire SAF by Shell in Canada. This first step sets the stage for future collaboration and innovation to encourage investments in this important lever for decarbonisation.”

The airline also added to the industry’s growing global pressure for support of SAF, saying it continued to work with government and industry partners to establish a sustainable, long-term commercial framework for the fuel which, “with the right regulatory and investment environment”, was one of aviation’s more viable and scalable decarbonisation pathways.

Christine Bassitt, Shell Aviation’s GM Americas, welcomed the WestJet deal, which not only supported decarbonisation of air transport, but simultaneously expanded the SAF supply chain in Canada to enable greater access to the fuel. 

Air New Zealand’s latest SAF deal was signed in Singapore during a New Zealand government-sponsored business delegation to South-East Asia, led by Prime Minister Christopher Luxon, a former CEO of the airline. The fuel will be produced by Neste at its recently expanded Singapore refinery, with the first supplies already being delivered to Los Angeles International Airport, from which the airline flies daily. The total order will be fulfilled by 30 November.

This is the biggest purchase of SAF from Neste by any airline based outside North America and Europe for delivery before the end of 2024, and nine times Air New Zealand’s first SAF acquisition from Neste in 2022. The airline’s total global SAF uptake between April and the end of November is expected to be 850 million litres (225 million gallons), as part of a broader decarbonisation programme that includes the introduction of electric aircraft.

Having committed last year to acquire up to 23 all-electric ALIA aircraft from Beta Technologies, the airline has now announced Wellington-Marlborough as the first route for all-cargo flights, to operate in partnership with NZ Post.  Serving as a commercial demonstrator for zero emission operations, the first aircraft will be based in Wellington, the national capital, at the base of New Zealand’s North Island, while Marlborough Airport in Blenheim, at the top of the South Island, will install charging infrastructure for the plane’s return journey across the Cook Strait.

Kiri Hannifin, Air New Zealand’s Chief Sustainability Officer, said the demonstrator aircraft would be used to gradually prepare the national aviation system for lower emission aircraft ahead of 2030, when the airline plans to phase out its fleet of 23 Q300 turboprops, or potentially convert them to new zero-emission propulsion systems.  

“Decarbonising aviation is of global importance, and in New Zealand maintaining regional connectivity through this transition is of national importance,” said Dean Heiford, CEO of Marlborough Airport. “This is a big step for us on our own sustainability journey that we wouldn’t have been able to achieve without partnership. We’re looking forward to sharing our learnings with other regional airports across New Zealand.”

In neighbouring Australia, Boeing has bolstered its latest commitment to SAF by partnering with Wagner Sustainable Fuels, which has commenced the design and construction of a SAF blending facility in the state of Queensland.

Ther new facility, which is due to open later this year, is located at Wagner’s Wellcamp Airport in the regional city of Toowoomba, west of Brisbane, which accommodates flights ranging from turboprop and narrowbody passenger jets to Boeing 747 freight services by Cathay Pacific, which regularly flies fresh produce from the region to Asia and beyond.

“Wagner’s sustainability goals align with Boeing’s work to advance aviation decarbonisation and energy security through renewable energy including SAF, advanced technologies, operational efficiency and fleet renewal,” said Kim Camrass, sustainability lead for Boeing in Australia, New Zealand and South Pacific.

“We’re proud to contribute to the building blocks of a sovereign SAF production industry with this Australian first facility,” said Matt Doyle, CEO of Wagner Sustainable Fuels, “and anticipate by the end of 2024 this facility will mark the start of the supply of SAF in Australia on a consistent basis.

“In collaboration with Boeing, the Wellcamp blending facility will demonstrate the greenhouse gas emissions reduction benefits of SAF for our customers, provide a focus for federal and state policy makers, and introduce the supply chain to this potential AUD3 billion ($2bn) per year industry.”

Photo: Boeing ecoDemonstrator aircraft refuelled with blended SAF

Tony Harrington

Correspondent

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