Circularity Fuels Converts Dairy Biogas to Sustainable Aviation Fuel
Circularity Fuels has announced the successful completion of a pioneering pilot project, converting raw agricultural biogas directly into sustainable aviation fuel (SAF). The process involves using biogas sourced from a dairy farm in California, processed over a six-month period to produce a type of jet fuel that meets ASTM D7566 Annex A1 specifications. This innovation is projected to reduce the commercial capital costs for SAF production to one-fifth of those seen in current European plants, positioning the product as a cost-competitive alternative to fossil fuels.
The pilot utilized biogas from a farm housing over 5,000 dairy cattle, where most of the biogas is typically vented into the atmosphere. Circularity Fuels' system captures this methane for conversion, circumventing the need for costly carbon dioxide removal. The technology comprises the electrified Ouro bi-reforming reactor and the compact Aion Fischer-Tropsch synthesis reactor, both of which are modular and skid-mounted, allowing them to operate efficiently at small scales.
Throughout the pilot, the Ouro reactor achieved over 98% methane conversion and more than 90% conversion of CO₂. The resultant jet fuel can be blended up to 50% with conventional Jet-A fuel for current commercial aircraft use. The fuel's life-cycle carbon intensity is reported as -350.7 gCO₂e/MJ, thanks to the conversion of methane, a potent greenhouse gas, into a usable fuel.
Dr. Stephen Beaton, founder and CEO of Circularity Fuels, highlighted the practical success of the project, stating that the initiative proves the economic viability of producing SAF continuously from real biogas. Craig Hartman of Hartman Engineering emphasized the significance of converting raw biogas directly to jet fuel on-site, which opens new opportunities for dairy operators.
The SAF produced through this method qualifies for biofuel incentives under federal and state programs, such as the EPA's Renewable Fuel Standard and California's Low Carbon Fuel Standard (LCFS). These programs have previously supported the scaling of renewable natural gas, ethanol, and biodiesel, and are expected to aid the commercial growth of SAF from biogas.
Following the success of this pilot, Circularity Fuels is planning its first commercial-scale deployment, with construction expected to begin in 2027. The company aims to target agricultural biogas resources across the United States, Latin America, and Europe, further advancing the use of waste streams to produce synthetic fuels.
