Syzygy Plasmonics begins development of world’s 1st electrified biogas-to-SAF plant

Photos: Syzygy Plasmonics

Syzygy Plasmonics announced June 3 the initiation of front-end engineering and design (FEED) with Kent for NovaSAF 1, what Syzygy Plasmonics is calling “the world’s first electrified biogas-to-SAF facility.”

The site will serve as a model for scalable, low-cost sustainable aviation fuel (SAF) production, according to the company.

The milestone advances Syzygy’s mission to seize the global opportunity to profitably convert biogas into SAF using clean electricity.

Located in Durazno, Uruguay, NovaSAF 1 is being scaled to produce over 350,000 gallons of SAF annually.

The project is backed by long-term feedstock and site agreements with Estancias del Lago, one of Uruguay’s largest dairy and agri-energy operations.

Permitting and equipment sourcing is ongoing alongside FEED work led by Kent.

Powered by Syzygy’s proprietary NovaSAF™ platform, the facility combines the benefits of biogas and power-to-liquids (PtL) technologies, leveraging waste as feedstock, eliminating the need for pipelines or costly separation while achieving ultra-low water use and carbon intensity.

Syzygy's electrified pathway can potentially qualify as a renewable fuel of nonbiological origin (RFNBO) to meet EU regulations.

“Unique to NovaSAF™ is the ability to provide these social and carbon benefits at a production cost that is unmatched by traditional SAF alternatives like [hydroprocessed esters and fatty acids (HEFA)], [alcohol-to-jet (ATJ)] or PtL,” the company stated.

“This is more than just a sustainable aviation fuel plant,” said CEO Trevor Best. “It’s a new model for biogas economics. We’re unlocking a global asset class of underutilized biogas sites and turning them into high-value clean fuel hubs without pipelines, costly gas separation or subsidy dependence. We believe NovaSAF™ represents one of the few viable pathways to producing SAF at jet parity and successfully decarbonizing air travel.”

Project highlights

• Feedstocks: Cow manure–derived biomethane and CO2, renewable electricity and steam.

• Fuel output: Drop-in SAF compliant with ASTM D7566.

• Annual capacity: Over 350,000 gallons SAF.

• Estimated carbon intensity: More than 80 percent reduction vs. Jet-A.

• Planned final-investment decision: Fourth quarter 2025.

• Commercial operations: First quarter 2027.

Strategic, environmental impact

• More than 50 percent higher SAF yield than conventional thermal biogas-reforming pathways.

• Utilizes both methane and CO2, naturally found in biogas, as feedstocks.

• No gas pipelines necessary, no water-intensive processes.

• Designed for modular, exportable replication in biogas-rich regions.

• Addresses tens of thousands untapped global biogas sites.

• Will comply with EU, U.S. and CORSIA SAF regulations.

“This project reflects our commitment to sustainability while creating local value and advancing Syzygy’s exciting SAF platform,” said Jose Pedro Sanchez, the chief operating officer at Estancias del Lago. “By combining agricultural waste with Uruguay’s nearly 100 percent renewable grid, we’re making low-cost and abundant SAF a reality.”

Tom Bullard, Kent’s executive vice president of operations for the Americas, said, “We’re proud to support Syzygy in delivering the world’s first profitable biogas-to-SAF plant. This milestone highlights Kent’s strength in our global capability to bring complex, cutting-edge energy projects to life.”