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NovaSAF 1 – Biogas to SAF

Pioneering the first electrified biogas-to-SAF plant

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.

Project: NovaSAF 1 electrified biogas to SAF

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

Estancias del Lago dairy in Uruguay where Velocys with support the NovaSAF 1 biogas-to-SAF project for Syzygy Plasmonics

A breakthrough in biogas-to-SAF conversion

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’ role: High-yield FT synthesis

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:

  • High conversion rates and single-pass efficiency
  • More fuel with less feedstock at a lower cost to support project economics
  • Compact, modular reactor footprint
  • Easy integration into electrified systems
  • Proven readiness with >6,000 commercial operating hours

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.

Full biogas-to-SAF technology stack

Syzygy Plasmonics: e-Reforming of dairy biogas into syngas

Velocys: FT conversion of syngas to synthetic crude with upgrading TBD

Aerial photo of dairy where Velocys is supporting Syzgy  with Fischer-Tropsch synthesis for its NovaSAF 1 biogas-toSAF project.

NovaSAF 1 project highlights

Enough SAF produced every year to carry over 8,000 passengers halfway around the world.

Annul nameplate output500,000 gallons of SAF
(1.8 million liters / 1,500 tonnes)
FeedstocksDigested dairy waste (methane + CO2) and renewable electricity
Power source100% renewable electricity
Certifications targetedCORSIA, EU RFNBO, LCFS, U.S. RFS
Start of operationsQ1 2027

A replicable model for biogas-rich regions

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.

TLDR—NovaSAF 1 selects Velocys’ microFTL technology

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.

Why the NovaSAF 1 biogas-to-SAF plant matters

  • First: World’s first commercial biogas-to-SAF project powered entirely by electricity
  • Proven: Relies on Velocys’ field-validated FT technology
  • Replicable: Adaptable for deployment across global biogas sites
  • Compliant: Targets all major SAF certification pathways
Holstein dairy cow in a field next to the Estancias del Lago dairy in Durazno, Uruguay where the Syzygy NovaSAF 1 biogas-to-SAF plant will be built. There is an airplane in the background.

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.