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)
Project Partners: Syzygy (biogas reforming) | Velocys (FT synthesis) | Honeywell UOP (fuel upgrade) | Kent (EPC) | Trafigura (offtake)
Start of Operations: Expected 2028
Status: Development phase | FID expected 2026
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.
Velocys’ solution includes a compact microchannel Fischer-Tropsch reactor, Oxford-engineered FT catalyst, and years of FT synthesis knowledge… all working together 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
Honeywell UOP: Upgrading of FT crude to synthetic paraffinic kerosene (SPK), aka jet fuel
Kent: Engineering, procurement, and construction (EPC)
Trafigura: Offtake
| 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 | 2028 |
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.
NovaSAF 1 uses raw biogas containing both methane and carbon dioxide as its primary feedstock. Rather than separating and upgrading the gas to renewable natural gas (RNG), the project reforms the raw biogas directly into synthesis gas for Fischer–Tropsch fuel production.
NovaSAF 1 combines Syzygy Plasmonics’ all-electric reforming technology, Velocys’ microFTL™ Fischer–Tropsch technology, and Honeywell UOP upgrading technology to produce sustainable aviation fuel from biogas.
The syngas production step uses an electrically powered reforming process rather than conventional combustion-based heat sources. When paired with renewable electricity, this approach can help reduce the carbon intensity of the fuel production pathway.
Raw biogas contains both methane and carbon dioxide derived from biological sources. Technologies capable of reforming both components directly can reduce processing steps while creating a pathway to convert waste-derived carbon into sustainable aviation fuel.