Biogas to SAF
Biogas to SAF is a sustainable aviation fuel pathway that converts raw biogas or renewable natural gas (RNG) into synthesis gas and then into aviation fuel through Fischer-Tropsch synthesis.
NovaSAF 1 is an example of a commercial biogas to SAF project built around this pathway.
This pathway uses raw biogas (containing methane and carbon dioxide) or RNG from waste-derived gas streams to produce synthetic hydrocarbons that can be upgraded into aviation fuel approved for commercial use.
NovaSAF 1 is the first all-electric biogas to SAF project developed around this pathway.
Project at a glance:
- Feedstock: raw biogas (methane and carbon dioxide)
- Pathway: biogas → syngas → FT → SAF
- Product: SAF
- Region: Uruguay
- Offtake: aviation fuel export pathway
What is biogas to SAF?
Biogas to SAF begins by converting methane-rich biogas into synthesis gas, which then enters a fuel synthesis pathway to produce aviation-range hydrocarbons.
The process typically includes:
- Biogas collection and conditioning
- Reforming into synthesis gas
- Fischer-Tropsch synthesis
- Hydrocarbon upgrading into sustainable aviation fuel
This creates a pathway from renewable methane to drop-in aviation fuel.
What feedstocks are used in biogas to SAF?
Biogas used for SAF production comes from organic waste streams that generate methane and carbon dioxide during decomposition.
Common sources include:
- anaerobic digesters
- landfill gas
- agricultural waste systems
- wastewater treatment systems
Depending on the reforming system, raw biogas may be used directly without first separating methane into pipeline-grade renewable natural gas (RNG).
Why is biogas attractive for sustainable aviation fuel production?
Biogas offers an existing renewable carbon source that can be converted into liquid fuels using established chemical pathways.
Advantages include:
- existing methane capture systems
- distributed feedstock availability
- compatibility with syngas-based fuel production
Because methane is already widely captured in waste systems, it can support SAF projects where feedstock logistics are strong.
How does biogas become aviation fuel?
Biogas is first converted into synthesis gas before hydrocarbon synthesis begins.
The process includes:
Reforming
Methane and carbon dioxide are converted into hydrogen and carbon monoxide.
Fischer-Tropsch synthesis
Syngas is converted into synthetic hydrocarbons.
Product upgrading
Hydrocarbons are refined into aviation-range molecules.
The resulting aviation blending component is Fischer-Tropsch Synthetic Paraffinic Kerosene (FT-SPK).
See:
What is NovaSAF 1?
NovaSAF 1 is a commercial biogas-to-SAF project designed to convert raw biogas into sustainable aviation fuel using syngas generation and Fischer-Tropsch synthesis.
The project combines:
- raw biogas feedstock
- syngas production
- Fischer-Tropsch technology
- SAF upgrading for commercial fuel markets
NovaSAF 1 demonstrates how captured biogenic gas streams can be used in advanced fuel production.
Refer to the NovaSAF 1 biogas-to-SAF case study for more detailed information.
How is NovaSAF 1 different from other SAF projects?
NovaSAF 1 uses raw biogas rather than oils, fats, or solid biomass as the primary carbon source.
It also uses an all-electric reformer designed to deliver FT SPK with exceptionally low carbon intensity scores when operating on renewable electricity.
The reforming technology can process methane and carbon dioxide together, removing the requirement to separate raw biogas before reforming.
This creates a distinct pathway compared with:
- HEFA projects using oils
- biomass gasification projects using solids
- waste gasification systems using municipal waste
The project shows how gaseous renewable carbon can enter SAF production.
Velocys’ earlier GTL deployment at Envia demonstrated modular Fischer-Tropsch operation under commercial conditions, providing operating experience that informs later SAF pathways.
Who is involved in NovaSAF 1?
NovaSAF 1 combines syngas generation and Fischer-Tropsch technology through industrial partnership.
The project integrates:
- reforming technology from Syzygy Plasmonics
- Fischer-Tropsch synthesis from Velocys
- downstream fuel upgrading from Honeywell UOP
A binding offtake agreement for the produced fuel is in place with Trafigura.
Why does biogas matter in SAF scaling?
Biogas creates an additional feedstock pathway for SAF production in regions where biogenic gas resources are available, especially where supply is limited for widely distributed.
This matters because SAF scaling depends on feedstock diversity, not a single carbon source.
Biogas expands that flexibility.
Where could biogas to SAF projects grow next?
Biogas-to-SAF projects are especially relevant where raw biogas can be captured, but where full processing to renewable natural gas (RNG) may add unnecessary cost.
Potential regions include:
- distributed agricultural methane supply
- landfill gas locations
- regions with ready access to renewable electricity
Frequently asked questions
Is biogas the same as natural gas?
No. Raw biogas is renewable and contains methane, CO2, and other biogenic gases generated from organic waste streams.
Can biogas really become aviation fuel?
Yes. Biogas can be reformed into synthesis gas and converted into hydrocarbons.
Does biogas-to-SAF use Fischer-Tropsch?
Yes. In syngas-based pathways, Fischer-Tropsch is the hydrocarbon synthesis step.
Is NovaSAF 1 a commercial project?
NovaSAF 1 is designed as a commercial-scale project using renewable biogas feedstock derived from dairy waste.