US sustainable aviation fuel production startup DG Fuels has selected Fischer-Tropsch (FT) technology co-developed by Johnson Matthey and energy giant bp for its proposed $4 billion SAF plant near the Mississippi River in Louisiana. Subject to approval being received this year, the St. James Parish facility could be in operation by 2028 and would be the largest announced FT SAF production operation in the world, says DG Fuels, with a planned capacity of 13,000 barrels per day, or around 120-135 million gallons of SAF annually. The FT CANS technology is feedstock agnostic although the facility will use plant waste, primarily sugar cane bagasse. Meanwhile, Southwest Airlines has acquired SAFFiRE Renewables, which is utilising technology developed at the Department of Energy’s National Renewable Energy Laboratory to convert corn stover, a widely available agricultural residue feedstock in the US, into renewable ethanol. SAFFiRE is now expected to proceed with developing a pilot plant in Kansas to produce ethanol for conversion into SAF by LanzaJet.

Commenting on its collaboration with Johnson Matthey and bp, DG Fuels’ CEO Michael Darcy said: “Using their co-developed FT CANS technology allows DG Fuels to scale SAF at high volume production and competitive prices for the first time ever. This innovation will take our SAF from the sugar cane fields of Louisiana to cleaner skies all across the world.”

DG Fuels has already secured offtake purchase deals with Delta Air Lines and Air France-KLM, and has a strategic partnership with Airbus to scale up the use of SAF globally. Last November, Air France announced it was investing $4.7 million in the company and the Air France-KLM group acquired an option to purchase up to 25 million gallons (75,000 tons) of SAF annually over a multi-year period beginning in 2029 from the Louisiana plant and a second facility planned in Maine. This is on top of a 2022 offtake agreement by the group for 600,000 tons of SAF from DG Fuels, to be delivered over ten years.

For its first project, the company has earmarked a 3,000-acre (1,200ha) site on the West Bank of St. James Parish for potential development of the near $4bn facility. It says the project is anticipated to create 650 direct permanent jobs, with preference given to local residents and promises to address local needs while protecting the environment and promoting economic prosperity in the area.

To help secure local support for the project, DG Fuels says it has engaged with community members and local government officials to draft a legally binding Community Benefits Agreement that would provide $26 million in funding towards a community centre, a health clinic, paid internships and other benefits. The CBA received support from the St. James Parish Council in February.

The company expects to purchase $120 million of sugar cane waste from local farmers, with nearly one third of this directly benefiting farmers in St. James Parish. This provides an environmentally-friendly and financially attractive alternative to practices where farmers burn the sugar cane trash after harvesting, it adds.

“Our clean facility will have fewer air emissions than a standard US hospital, will have no impact on the Mississippi River and will help to heal our planet,” says the company. “Our fuel made from sugar cane and plant waste is clean, sustainable and created with renewable energy.”

The FT CANS technology converts synthesis gas created in the DG Fuels’ proprietary production process to synthetic crude for further processing into SAF. FT CANS is being used by Fulcrum BioEnergy to convert municipal solid waste into SAF at its Sierra plant.

“Our FT CANS technology solution brings together decades of science and engineering expertise from bp and Johnson Matthey, and this project shows its competitiveness across a range of production scales and feedstock sources the industry needs,” said Noemie Turner, VP Technology Development & Commercialisation at bp. “We’re excited to see the relationship with DG Fuels grow, and we look forward to seeing this project come to fruition.”

Added Christopher Chaput, President of DG Fuels: “With this technology, we will create a product that is responsibly made and can be immediately substituted for conventional aviation fuel with no engine adaptations. This partnership is a significant boost to help the aviation industry reach its climate goals.”

SAFFiRE acquisition

Southwest Airlines first invested in SAFFiRE Renewables during the first phase of the ethanol producer’s pilot project in 2022 and through its newly-launched Southwest Airlines Renewable Ventures (SARV) subsidiary, the airline has now moved to acquire the company. As a result, SAFFiRE is expected to proceed with phase two by developing a pilot plant hosted at Conestoga’s Arkalon Energy ethanol facility in Liberal, Kansas.

“This acquisition marks Southwest’s transition from investor to sole owner of SAFFiRE, expressing our confidence in their technology and its potential to advance our sustainability goals, as well as the goals of the broader industry,” commented the airline’s CEO, Bob Jordan.

SAFFiRE is part of a project supported by the Department of Energy (DOE) to develop and produce scalable renewable ethanol. The Kansas plant will utilise SAFFiRE’s exclusive technology licence from NREL to process 10 tons of corn stover per day into ethanol, with a plan for the ethanol to be converted into SAF by LanzaJet’s alcohol-to-jet (ATJ) technology, which partly owes its development to the DOE’s Pacific Northwest National Lab. LanzaJet was added to the SARV portfolio in February when the airline announced a $30 million investment in the ATJ company.

Another agricultural residue, corn stover is the stalks, leaves and husks of corn plants that is largely left to decompose in the fields after the corn harvest each year. SAFFiRE plans for corn stover to be collected by custom harvesters or by local farmers and processed through a proprietary Deacetylation and Mechanical Refining (DMR) technology developed by NREL, called DMR pretreatment.

“Renewable ethanol is an important feedstock to realising high-volume, affordable SAF, which is a critical part of the journey to net zero emissions,” said Tom Nealon, President of SARV and CEO of SAFFiRE. “We are enthusiastic about the ethanol-to-SAF pathway and SAFFiRE’s potential ability to produce renewable ethanol at a scale that is economically viable.”

Image: Render of the proposed DG Fuels SAF facility on the banks of the Mississippi River in Louisiana

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Southwest Airlines, the world’s fourth-largest carrier, has launched Southwest Airlines Renewable Ventures (SARV), a dedicated platform to invest in sustainable aviation fuel technologies. The Texas-based airline has also announced a $30 million stake in US-based SAF producer LanzaJet, with which it will collaborate to develop a new SAF production plant, largely to support Southwest’s needs. The two companies will work with SAFFiRE Renewables (Sustainable Aviation Fuel from Renewable Ethanol), a technology company in which Southwest has already invested, that converts corn stover to ethanol. LanzaJet has patented an alcohol-to-jet process, through which such feedstocks are converted to ethanol, then SAF, and recently opened the world’s first commercial-scale refinery for this process, Freedom Pine Fuels, in Soperton, Georgia. The proposed new facility with Southwest will also use LanzaJet’s technology to convert SAFFiRE’s cellulosic ethanol into SAF for the airline. 

Like many carriers, Southwest has committed that by 2030, 10% of the jet fuel it uses will be SAF. But the scale of the airline’s fuel requirement is far bigger than most, with a fleet of almost 850 Boeing 737s serving 121 destinations in the US and 10 other countries, and almost 500 new B737 MAX family jets on order to replace older aircraft and further expand operations. In its February 2024 global assessment of airline performance, aviation data group OAG ranked Southwest – the largest low-cost carrier – the fourth busiest operator by flight frequencies, behind American, Delta and United.

“Our launch of SARV and our investment in LanzaJet demonstrate that we are not sitting on the sidelines,” said Southwest CEO Bob Jordan. “Rather, we’re in the game by taking proactive, disciplined steps toward securing affordable SAF for Southwest as we continue to march toward our goal of net zero 2050. 

“We look forward to working with LanzaJet, which is developing potentially important technology that could create more opportunities for Southwest to obtain scalable SAF, a critical component in the success of our environmental sustainability goal to replace 10% of our jet fuel consumption with SAF by 2030.”

The LanzaJet and SAFFiRE Renewables stakes will be aligned by Southwest through SARV, which will collectively manage the airline’s SAF investments, while the core airline will continue to work with multiple SAF producers to procure more of the fuels. 

“SARV’s goal is to help scale SAF through strategic investments, better positioning Southwest to have access to high quality, affordable SAF in accordance with the robust standards of Southwest’s SAF policy,” added Tom Nealon, who is both SARV’s President and SAFFiRE’s CEO. “Through SARV’s investment in LanzaJet, we’re also entering the next phase in the commercialisation of SAFFiRE technology, which is designed to support the production of cellulosic ethanol that can be converted to SAF.” 

Jimmy Samartzis, CEO of LanzaJet, said his company’s ethanol-to-SAF technology “represents the next generation of sustainable aviation fuel and will transform aviation’s ability to meet its 2050 net zero targets.

“We’re proud to be working with Southwest Airlines to build out this industry as well as working with SAFFiRE Renewables to use ethanol made right here in the US,” he added. “Southwest’s equity investment in LanzaJet will help us continue to grow and scale to meet the demands of the aviation industry, while unlocking the significant potential of the US biofuels industry to benefit local communities and support the agriculture industry.”

Development of the new SAF plant in the US will be led by LanzaJet, which will also support Southwest’s aims to commercialise the SAFFiRE corn-to-ethanol technology. The airline will be “the anchor SAF offtaker”.

“The US is an incredibly important market for us,” said Samartzis. “It’s our home, where our technology is originated and scaled, the site of our and the world’s first commercial ethanol-to-SAF plant, and an important opportunity to support the existing US biofuels and ethanol industries with our leading ethanol-to-SAF technology.

“The alignment of Southwest and LanzaJet is a powerful combination that has the potential to integrate the SAF value chain and to double down on the US ethanol, aviation and biofuel industries. Our work together will lead us closer to meeting aviation’s decarbonisation goals by continuing to scale SAF production in the United States, while also tapping into the US ethanol industry’s potential to catalyse the next generation of SAF production.”

SAFFiRE has been collaborating with the US Department of Energy’s National Renewable Energy Laboratory and holds both a licensing agreement and some exclusivity rights to technology to produce cellulosic ethanol from corn stover. Southwest Airlines has matched a grant from the Department to create SAF via the alcohol-to-jet process, through which sugars in the feedstock are fermented to ethanol, which is then deoxygenated to create low carbon fuel. SAFFiRE has previously said it can produce 7.5 billion gallons (27 billion litres) of SAF per year by 2040.

Southwest’s stake in LanzaJet closely follows the energy company’s activation of the Freedom Pines Fuels plant, which is targeting production of renewable fuels including up to 1 billion gallons of SAF by 2030. LanzaJet is also progressing other developments including plans for an alcohol-to-jet plant in Australia with partners including JetZero, Qantas, Airbus and the Queensland state government.

In addition to Southwest, LanzaJet’s investors include British Airways and Japan’s All Nippon Airways, LanzaTech, Shell, Mitsui & Co, Suncor Energy, plus sustainability investors Breakthrough Energy and Microsoft’s Climate Innovation Fund.

Photo (Ashlee D. Smith): Southwest Airlines Boeing 737 MAX-8

Tony Harrington

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The board of directors of Oxford, UK-based Velocys has given its backing to an offer from a consortium of US, UK and Singapore climate-focused investment houses to acquire the company. Without an immediate injection of funds, Velocys is in danger of running out of cash next month and going into insolvency, warned the company. A spin-out from the University of Oxford, Velocys has been developing technology to enable production of drop-in sustainable aviation fuels from a variety of waste materials and is involved in two projects in the UK and US to build commercial-scale SAF production plants. Listed on the London Stock Exchange, Velocys shares have fallen from a high of £5.80 a share during the past year to 0.23 pence, valuing the company at just under £4 million. The consortium, which is offering 0.25 pence per share in cash and, if the bid is successful, a secured bridging loan of £3.5 million and growth capital of up to $40 million (£31.5m), said Velocys was well-positioned to capitalise on “a compelling market opportunity” for the production of SAF.

The consortium, which has set up a company, Madison Bidco, for the purposes of the acquisition, is made up of London-headquartered global private equity firm Lightrock; New-York based global growth investment firm Carbon Direct Capital; GenZero, an investment platform founded last year by Temasek, the global investment company owned by the Singapore government; and Kibo Investments, a Singapore-based private investment office focused on climate technology. Carbon Direct Capital had previously been expected to make a $15 million investment in Velocys but withdrew when the latter failed to secure further investment from other backers by the end of October.

In a market announcement, Philip Holland, the Chair of Velocys, commented: “The Velocys Board and management have spent a great deal of time and effort trying to secure significant long-term funding to grow the business and accelerate the delivery of its technology to clients. However, reflecting Velocys’ material funding requirements, business model and limited revenue together with the continued challenging public market environment, it has not been possible to raise sufficient funds. This has put the business in an extremely challenging position, with a very real prospect of not being able to continue as a going concern when we reach the end of our cash runway in early January.

“Bidco is offering the business a secure platform for future growth, alongside an injection of up to $40 million of growth capital, which is expected to ensure that Velocys has the capital resources needed to deliver against its medium-term strategic plans, including to scale up and grow and work towards its long-stated goal of supporting the decarbonisation of the global aviation sector. Whilst it is very disappointing for the business to need to leave the public markets, Bidco’s offer will enable Velocys to continue operating as a going concern.”

The consortium’s confidence in SAF production is based on what the market announcement describes as a “confluence of regulatory support, demand pull by airlines and increased technology readiness,“ adding “Velocys is well positioned to capitalise on these sector tailwinds, given its patented integrated Fischer-Tropsch reactor and catalysis solution and its pipeline of commercial licensing opportunities.”

Velocys said it has a number of third-party clients to whom it supplies its technology, along with its two biorefinery reference projects, the Bayou Fuels Project in Mississippi that would utilise woody waste to produce sustainable fuels and the Altalto Project in Immingham, north-east England, that would process municipal and commercial solid waste into sustainable fuels.

According to the Velocys website, Bayou Fuels is expected to produce 36 million gallons per year of negative-emission transportation fuels using a combination of biogenic feedstock, biomass power and carbon capture and sequestration. Long-term SAF offtake agreements have been signed with Southwest Airlines (15 years) and IAG/British Airways (10 years). In October 2022, the company announced that when the project entered production, then forecast for 2026, the facility would use renewable energy derived from sustainable biomass power instead of solar power that would double the carbon savings for its aviation customers and the enhanced negative carbon intensity would also increase the credits generated under the US Inflation Reduction Act and the California Low Carbon Fuel Standard, improving the revenue and economic profile of the project.

A year ago, the Altalto project, a collaboration with British Airways to produce 20 million gallons of sustainable fuels annually with net negative carbon emissions, was awarded up to £27 million ($34m) in grant funding, with an initial tranche of £7 million from the UK Department for Transport, along with matched private funding, towards completing the Front-End Engineering Design stage. “Following completion of FEED and a successful final investment decision, construction will commence in 2025 with full commercial operation expected in 2028,” the company announced in May. The UK government has set a target of five SAF production facilities to be under construction in the UK by 2025.

Image (Velocys): Visualisation of the proposed Altalto MSW-to-SAF facility in north-east England

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Southwest Airlines has agreed to purchase over 400,000 carbon credits from SMBC Aviation Capital, the world’s second largest aircraft leasing company, to support the airline’s employee business and charitable travel, or to meet CORSIA requirements. As the first aircraft lessor to develop a carbon credit programme, SMBC Aviation Capital announced in September 2022 an initial investment of $53.3 million in projects that align with up to 10 of the 17 UN Sustainable Development Goals (SDGs), including good health and well-being, gender equality and climate action. Part of the investment will also support local community initiatives such as irrigation schemes and micro finance opportunities for women. Carbon credits can be obtained from the Ireland-based lessor by airlines either as part of an aircraft lease contract or independently. It has placed 12 Boeing 737-8 MAX aircraft with Southwest and is also collaborating with partners on scaling up sustainable aviation fuel production.

“Southwest continues to make sustainability a priority and we are delighted to partner with them as the first customer of our newly-established carbon credit programme,” commented David Swan, Chief Operations & Sustainability Officer at SMBC Aviation Capital. “This announcement supports our objective of working with our airline customers to accelerate their path to environmental sustainability. We believe that by taking tangible actions and working together we can make a positive change, especially in a hard-to-abate sector like aviation.”

Through Belgium-based CO2 Logic, SMBC Aviation Capital has invested in a project in Burkina Faso, West Africa, that will provide energy-efficient cookstoves to 28,000 families who have previously relied on traditional cooking methods that are harmful to health and the environment. According to the Clean Cooking Alliance, the use of open fires and solid fuels for cooking causes nearly 4 million premature deaths each year and, according to the US Environmental Protection Agency, the average open fire produces nearly as much CO2 as the average motor vehicle.

Separately, the lessor is working with US carbon project developer C-Quest Capital to forward purchase carbon credits from a range of cookstove projects across Africa, Asia and Central America, which aim to reach over 3.2 million households and meet a minimum of seven SDGs.

Due diligence across all projects has been independently undertaken by Climate Focus, which is based in the Netherlands.

Under the agreement with Southwest, the airline will be acquiring over a five-year timeframe carbon credits certified by either Gold Standard or Verra from SMBC Aviation Capital’s funded projects in Africa and Central America.

“We recognise the important roles that both in-sector and out-of-sector levers play in our sustainability journey,” said Chris Monroe, SVP Finance Treasury & Sustainability, Southwest Airlines. “Expanding our existing partnership with SMBC Aviation Capital supports these projects that are expected to help mitigate carbon while contributing positively to local communities.”

In October 2021, Southwest laid out a 10-year plan to maintain carbon neutrality to 2019 levels, which included the first US-based carbon offset initiative that offered customers loyalty points, and for every dollar contributed towards offsetting Southwest’s carbon emissions, the airline would match the contribution.

The plan also incorporated a target to reduce carbon emissions per available seat mile (including scope 1 and scope 2 emissions) by at least 20% by 2030 through fleet modernisation, route optimisation and other initiatives. The airline also plans to replace 10% of its total jet fuel consumption with sustainable aviation fuel by 2030.

Towards the end of 2021, Southwest signed a 15-year offtake agreement with Velocys Renewables for 219 million gallons of SAF, with deliveries commencing as early as 2026 from the Velocys Bayou Fuels facility in Natchez, Mississippi. The airline estimates the fuel could avoid 6.5 million tonnes of CO2 over the term of the agreement.

In June last year, Southwest announced an investment in SAFFiRE Renewables, a company formed by D3MAX, which in 2021 was awarded a grant by the US Department of Energy towards a pilot-scale facility. The grant is being matched by Southwest and the SAFFiRE project is expected to utilise technology developed by the DOE’s National Renewable Energy Laboratory to convert corn stover, a widely available waste feedstock in the US, into renewable ethanol that then would be upgraded into SAF. The investment and grant supports phase one of the project, which is expected to include technology validation, preliminary design and a business plan for a pilot plant.

“This is a unique opportunity to invest in what we believe could be game-changing technology that could facilitate the replacement of up to approximately 5% of our jet fuel with SAF by2030, with the potential to significantly continue to scale beyond the decade,” commented Southwest CEO Bob Jordan at the time of the announcement. “This first-of-its-kind investment is another step we are taking to address our environmental impact and it also supports our efforts to partner with organisations and government entities to help our industry reach the goal of carbon neutrality by 2050.”

SMBC Aviation Capital has an owned, managed and committed fleet of over 900 aircraft and is working to a target of up to 80% of new technology aircraft in its fleet by the end of 2025. It is working with shareholder Sumitomo Corporation to explore ways to increase the supply of SAF and is also collaborating with Aircraft Leasing Ireland on starting production of SAF in Ireland. It has developed its own framework to achieve net zero in its own operations by 2050 and has offset all of its operational emissions since 2019. Scope 3 emissions are determined by Fexco Group company PACE.

Image (Boeing): Southwest Airlines Boeing 737 MAX

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British Airways could be using sustainable aviation fuel produced in the UK within the next few months following an agreement with one of world’s biggest oil refiners, Phillips 66. It will be produced and blended at Phillips 66’s Humber Refinery in north-east England from waste cooking oils, and supplied to London airports via the existing pipeline infrastructure. The SAF is expected to reduce lifecycle emissions by over 80% compared to the traditional jet fuel it replaces. Phillips 66 has 13 refineries in the United States and Europe, with a global refining capacity of 2.2 million barrels of crude oil per day. It is transitioning to a low-carbon future and last year announced plans to convert its Rodeo refinery in California into the world’s largest renewable fuels plant. The Humber Refinery, which employs over 1,000 workers, started production of renewable diesel in 2018, becoming the first in the UK to convert waste oil into road fuel. In November 2020 it took delivery of a new processing unit to convert used cooking oil (UCO) into low-carbon fuel. The refinery is situated very close to the proposed Velocys facility that will convert municipal solid waste to jet fuel for British Airways.

The airline said the purchase agreement of 36,000 tonnes of SAF with Phillips 66 Limited, a wholly-owned UK subsidiary of Phillips 66, would reduce lifecycle emissions by almost 100,000 tonnes, the equivalent of powering 700 net zero CO2 emissions flights between London and New York on its Boeing 787 aircraft.

The Humber Refinery’s UCO module increased renewable diesel capacity this year to 3,000 barrels per day (BPD) from 1,000 BPD and the company plans to further expand capacity to 5,000 BPD by 2024.

Added a spokesperson for Phillips 66: “While the UCO module will be an important part of our SAF supply, we will also be producing SAF via other production pathways at the refinery.”

The refinery, which Phillips 66 says is one of the most complex in its portfolio and one of the most sophisticated in Europe, has a crude oil processing capacity of 221,000 BPD. It produces some 14 million litres of fuel per day, some of which is sold at its JET branded petrol stations and also jet fuel to airlines, as well as raw materials that can be transformed into a range of other products, including into essential components for electric vehicle batteries.

“The refinery was the first in the UK to co-process waste oils to produce renewable fuels and now we will be the first to produce SAF at scale, and we are delighted British Airways is our first UK customer,” said Humber Refinery General Manager Darren Cunningham. “We are currently refining almost half a million litres of sustainable waste feedstocks a day, and this agreement demonstrates our ability to supply them.”

The Humber Refinery is one of three investment partners in the Humber Zero project for large-scale decarbonisation in the immediate region and incorporates a cluster of local energy-intensive industries that make up more than 20% of the local economy and one in 10 jobs, and lie 1km from the North Sea coastline on the south bank of the River Humber. By 2030, Humber Zero aims to remove up to 8 MT/CO2 annually by integrating carbon capture and storage, alongside green and blue hydrogen production, into these existing, co-dependent industries. As well as decarbonising local industry, it is expected to provide hydrogen power for over one million local homes.

“This agreement with British Airways aligns with our strategy to create a refinery of the future, where we’re producing fuels from waste, being a critical part of the electric vehicle supply chain, reducing the carbon intensity of our processes through carbon capture and using hydrogen to power the refinery,” said Cunningham. “It secures long-term business in an ever-changing world.”

British Airways and Phillips 66 are members of the UK Department for Transport’s Jet Zero Council Delivery Group, with both supporting government plans for a future SAF blending mandate and a business model for investing in advanced waste-to-jet fuel projects.

“The UK has the resources and capabilities to be a global leader in the development of SAF and scaling up the production of SAF requires a truly collaborative approach between industry and government,” said British Airways Chief Executive Sean Doyle.

“We are excited to develop our relationship with Phillips 66 Limited further with a view to growing production capacity and using a wider range of sustainable waste feedstocks to supply our future flights. The development of SAF is a major focus for us and forms part of our commitment to achieving net zero carbon emissions by 2050 through a series of short, medium and long term initiatives.”

BA’s parent company IAG pledged two years ago to invest a total of $400 million on alternative sustainable fuel development over the following 20 years. Its Altalto Immingham project with Velocys aims to convert over 500,000 tonnes each year of non-recyclable household and commercial solid waste into sustainable aviation fuel, which would be supplied via the same pipeline as for the Phillips 66 fuel. According to an investor statement from Velocys last month, depending on progress of UK government policy and the project going ahead, commissioning and startup would commence in 2027, with full-scale commercial operation to follow that same year.

In February, British Airways announced it was to invest in SAF technology provider and SAF producer LanzaJet’s first commercial-scale Freedom Pines Fuels facility in Georgia, USA. The deal includes purchase of SAF to power a number of BA flights from the US from late 2022 and early-stage planning of a potential commercial-scale biorefinery in the UK. This would be produced using LanzaJet’s alcohol-to-jet process, which can use any source of sustainable ethanol, including, but not limited to, ethanol made from non-edible agricultural residues such as wheat straw and recycled pollution. LanzaJet, which is involved in three UK projects, and British Airways are also partnering with Nova Pangaea Technologies on ‘Project Speedbird’ to develop the first SAF facility in the UK to utilise woody residues from the UK, which aims to produce 100 million litres of SAF per year by 2025.

The purchase agreement with British Airways follows a Phillips 66 memorandum of understanding signing with Southwest Airlines in April this year “to advance the commercialisation of sustainable aviation fuel, focusing on public awareness and research and development.” The MoU also includes both sides exploring a future SAF supply agreement involving Phillips 66’s renewable fuels Rodeo Renewed project in California. The facility is expected to be capable of producing an initial 800 million gallons per year of renewable fuels and, subject to permits and approvals, could be completed in early 2024.

Photo: The Phillips 66 Humberside Refinery

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