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Syzygy unveils plans for groundbreaking sustainable aviation fuel facility

Syzygy Plasmonics will develop a facility, known as NovaSAF 1, to convert biogas into sustainable aviation fuel in Uruguay. Photo courtesy of Syzygy

Houston-based Syzygy Plasmonics announced plans to develop what it calls the world's first electrified facility to convert biogas into sustainable aviation fuel (SAF).

The facility, known as NovaSAF 1, will be located in Durazno, Uruguay. It is expected to produce over 350,000 gallons of SAF annually, which would be considered “a breakthrough in cost-effective, scalable clean fuel,” according to the company.

"This is more than just a SAF plant; it's a new model for biogas economics," Trevor Best, CEO of Syzygy Plasmonics, said in a news release. "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.”

The project is backed by long-term feedstock and site agreements with one of Uruguay's largest dairy and agri-energy operations, Estancias del Lago, while the permitting and equipment sourcing are ongoing alongside front-end engineering work led by Kent.

Syzygy says the project will result in a 50 percent higher SAF yield than conventional thermal biogas reforming pathways and will utilize both methane and CO2 naturally found in biogas as feedstocks, eliminating the need for expensive CO2 separation technologies and infrastructure. Additionally, the modular facility will be designed for easy replication in biogas-rich regions.

The new facility is expected to begin commercial operations in Q1 2027 and produce SAF with at least an 80 percent reduction in carbon intensity compared to Jet A fuel. The company says that once fully commercialized the facility will produce SAF at Jet-A fuel cost parity.

“We believe NovaSAF represents one of the few viable pathways to producing SAF at jet parity and successfully decarbonizing air travel,” Best added in the release.

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Syzygy Plasmonics has partnered with Volycys on its NovaSAF 1 project, which will convert biogas into sustainable aviation fuel in Uruguay. Photo courtesy of Syzygy

Houston-based Syzygy Plasmonics has announced a partnership with Velocys, another Houston company, on its first-of-its-kind sustainable aviation fuel (SAF) production project in Uruguay.

Velocys was selected to provide Fischer-Tropsch technology for the project. Fischer-Tropsch technology converts synthesis gas into liquid hydrocarbons, which is key for producing synthetic fuels like SAF.

Syzygy estimates that the project, known as NovaSAF 1, will produce over 350,000 gallons of SAF annually. It is backed by Uruguay’s largest dairy and agri-energy operations, Estancias del Lago, with permitting and equipment sourcing ongoing. Syzygy hopes to start operations by 2027.

"This project proves that profitable SAF production doesn't have to wait on future infrastructure," Trevor Best, CEO of Syzygy Plasmonics, said in a news release. "With Velocys, we're bringing in a complete, modular solution that drives down overall production costs and is ready to scale. Uruguay is only the start."

The NovaSAF 1 facility will convert dairy waste and biogas into drop-in jet fuel using renewable electricity and waste gas via its light-driven GHG e-Reforming technology. The facility is expected to produce SAF with at least an 80 percent reduction in carbon intensity compared to Jet A fuel.

Syzygy will use Velocys’ microFTL technology to convert syngas into high-yield jet fuel. Velocys’ microFTL will help maximize fuel output, which will assist in driving down the cost required to produce synthetic fuel.

"We're proud to bring our FT technology into a project that's changing the game," Matthew Viergutz, CEO of Velocys, added in the release. "This is what innovation looks like—fast, flexible, and focused on making SAF production affordable."

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