NovaSAF 1 is a global first: a commercial-scale sustainable aviation fuel (SAF) facility that will convert dairy biogas (biogenic methane and CO2) and renewable electricity—no green hydrogen, no traditional gasification—into drop-in fuel. Led by Syzygy Plasmonics and supported by Velocys’ Fischer-Tropsch technology, this biogas-to-SAF project represents a next-generation pathway for decarbonized aviation fuel.
Client: Syzygy Plasmonics
Location: Estancias del Lago dairy operation in Durazno, Uruguay
Velocys Role: FT technology licensor (single-core microchannel reactor and FT catalyst)
Start of Operations: Expected Q1 2027
Status: Development phase | FID expected Q4 2025
At the heart of the plant is Syzygy’s GHG e-Reforming™ technology, which produces the ideal 2:1 hydrogen-to-carbon monoxide syngas ratio by splitting methane and CO₂ using light, steam, and renewable electricity. This breakthrough enables fully electrified SAF production without the infrastructure burden of electrolysis or steam methane reforming.
Velocys will license its microFTL™ technology to Syzygy for the project–comprising a compact microchannel Fischer-Tropsch reactor, Oxford-engineered FT catalyst, and years of FT synthesis knowledge–designed to maximize fuel output per molecule of syngas. With a proven track record in both demonstration and commercial environments, Velocys FT technology delivers:
The Velocys FT reactor is key to driving down the total cost of SAF production—enabling profitability at smaller plant scales while maintaining policy compliance across global markets.
Syzygy Plasmonics: e-Reforming of dairy biogas into syngas
Velocys: FT conversion of syngas to synthetic crude with upgrading TBD
Enough SAF produced every year to carry over 8,000 passengers halfway around the world.
Annul nameplate output | 500,000 gallons of SAF (1.8 million liters / 1,500 tonnes) |
Feedstocks | Digested dairy waste (methane + CO2) and renewable electricity |
Power source | 100% renewable electricity |
Certifications targeted | CORSIA, EU RFNBO, LCFS, U.S. RFS |
Start of operations | Q1 2027 |
NovaSAF 1 is designed for global impact. Its modular architecture and electrified design unlock the ability to replicate this model across 50,000+ untapped biogas sites worldwide—from agricultural waste streams to landfill methane hubs. With growing regulatory pressure and rising demand, this all-electric SAF project offers a template for cost-effective, scalable, and policy-aligned SAF deployment.
Velocys is providing the Fischer-Tropsch reactor and Oxford-engineered FT catalyst for NovaSAF 1—the world’s first electrified biogas-to-SAF project. We are helping demonstrate a scalable, profitable, and hydrogen-free SAF pathway using only waste and renewable electricity.
Contact us to learn more about our other SAF projects and our microFTL technology packages.
GHG e-Reforming™ and NovaSAF™ are trademarks of Syzygy Plasmonics.
microFTL™ is a trademark of Velocys Inc.