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.

Pathway Energy has announced a major sustainable aviation fuel project in Port Arthur, Texas. Rendering courtesy of Pathway Energy

Houston company's $2B carbon-negative fuel project to rise in Southeast Texas

eyes on SAF

Houston developer of ultra carbon-negative fuels projects Pathway Energy announced a series of commercial-scale sustainable aviation fuel (SAF) facilities with the first being based in Port Arthur, Texas.

The project, estimated to be valued at $2 billion, will be one of the largest decarbonization projects in the world.

Pathway plans to bring commercial SAF to market with its years of experience in waste and biomass conversion processes and technologies that include biomass gasification, Fischer-Tropsch, biomass power generation, and complex biorefinery and industrial processes. Pathway will be working with companies like Sumitomo SHI FW, who will supply the project with gasification process technology packages and power production. Pathway Energy also announced a strategic partnership with Drax Global, which is a biomass feedstock provider.

"We are happy to debut with the best technology and industrial partners in the industry on a market opportunity with global significance," Steve Roberts, CEO of Pathway Energy, says in a news release. "With the ultra negative carbon intensity achieved through our process, Pathway Energy is poised to lead a global market for ultra negative fuels, driving large scale emission reductions across the aviation sector."

In the Port Arthur project, Pathway plans to leverage sustainable biomass feedstock and access to geological storage to sequester carbon and to produce its ultra carbon-negative SAF. The site location already is equipped with industrial scale import and export logistics including established truck, rail, barge, and pipeline access. Pathway will develop a platform of commercial-scale facilities in areas with a high potential for geological storage to utilize BECCS (Biomass Energy Carbon Capture and Storage) and gasification technology to capture and store carbon, according to a news release.

The market for sustainable aviation fuel uses imported, used cooking oil (UCO HEFA). UCO HEFA SAF can’t materially decarbonize aviation since its constrained supply and positive carbon intensity score. Pathway’s ultra carbon-negative fuel is synthetic drop-in jet fuel that achieves a 550% reduction of carbon compared to traditional jet fuel, which is an industry first. Pathway believes this can abate as much as 6,000 flights a year.

Pathway uses an ultra-negative SAF, which carriers require less SAF to achieve emissions reduction as HEFA, which translates to emissions reduction, and lower cost of operations. The aviation industry can potentially achieve up to 8 times more emissions reductions compared to HEFA SAF.

“We saw the opportunity to provide carriers a pathway to completely decarbonize their flights with our net zero blended fuel," Joshua Pearson, Pathway CTO, adds. "This is a new type of SAF production that is 7-9 (times) more carbon negative than the SAF on the market today and represents the most sustainable, cost efficient and de-risked path to decarbonize global aviation.”

Andrew Chang, managing director of United Airlines Ventures, says it's his job to accelerate the airline's mission to decarbonize operations. Photo via LinkedIn

How United Airlines got into the sustainable energy biz

funding SAF

While someone might not immediately make the connection between aviation and the energy transition, United Airlines understands the importance of more sustainable fuel — and has put its money where its mouth is.

According to an International Energy Agency report, the aviation accounted for 2 percent of global energy-related CO2 emissions last year. Earlier this year, United Airlines launched a fund that called for collaboration across the industry.

After only five months, the United Airlines Ventures Sustainable Flight Fund SM increased to nearly $200 million and added new financial partners, airlines, and more. The fund takes on funding from its 13 limited partners and exists separately from United's core business operations.

Andrew Chang, managing director of United Airlines Ventures, says it's his job to accelerate the airline's mission to decarbonize operations. He explains that working together on the fund is the key for advancing sustainable aviation fuel, or SAF.

"We all recognize that we may compete in our core business, but with the importance of sustainable aviation fuel and given that it's an industry that doesn't exist — you can't compete for something that doesn't exist — let's collaborate and work together to explore technologies that can directly or indirectly support the commercialization and production of sustainable aviation fuel," he says on the Houston Innovators Podcast.

United Airlines also recently signed an offtake agreement with Cemvita Factory, a Houston biotech startup that's working on SAF. Chang discusses this partnership on the show, as well as explaining how he works with other startups and what he's looking for.

The offtake agreement and the fund are just two examples of how United is building to a more sustainable future. As Chang explains on the show, the aviation industry hasn't evolved too much over the past three or four decades.

"It's been a challenging market," he says, blaming the ever-evolving macroeconomic conditions for providing challenges for the airline, taking away its focus from new technologies. "But I think we are at a point where the industry is in a healthier place, the sector has consolidated, we are supported by our consumers, and we are now empowered with the financial and strategic capital to think ahead."

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This article originally ran on InnovationMap.

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Rice University spinout lands $500K NSF grant to boost chip sustainability

cooler computing

HEXAspec, a spinout from Rice University's Liu Idea Lab for Innovation and Entrepreneurship, was recently awarded a $500,000 National Science Foundation Partnership for Innovation grant.

The team says it will use the funding to continue enhancing semiconductor chips’ thermal conductivity to boost computing power. According to a release from Rice, HEXAspec has developed breakthrough inorganic fillers that allow graphic processing units (GPUs) to use less water and electricity and generate less heat.

The technology has major implications for the future of computing with AI sustainably.

“With the huge scale of investment in new computing infrastructure, the problem of managing the heat produced by these GPUs and semiconductors has grown exponentially. We’re excited to use this award to further our material to meet the needs of existing and emerging industry partners and unlock a new era of computing,” HEXAspec co-founder Tianshu Zhai said in the release.

HEXAspec was founded by Zhai and Chen-Yang Lin, who both participated in the Rice Innovation Fellows program. A third co-founder, Jing Zhang, also worked as a postdoctoral researcher and a research scientist at Rice, according to HEXAspec's website.

The HEXASpec team won the Liu Idea Lab for Innovation and Entrepreneurship's H. Albert Napier Rice Launch Challenge in 2024. More recently, it also won this year's Energy Venture Day and Pitch Competition during CERAWeek in the TEX-E student track, taking home $25,000.

"The grant from the NSF is a game-changer, accelerating the path to market for this transformative technology," Kyle Judah, executive director of Lilie, added in the release.

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This article originally ran on InnovationMap.

Rice research team's study keeps CO2-to-fuel devices running 50 times longer

new findings

In a new study published in the journal Science, a team of Rice University researchers shared findings on how acid bubbles can improve the stability of electrochemical devices that convert carbon dioxide into useful fuels and chemicals.

The team led by Rice associate professor Hoatian Wang addressed an issue in the performance and stability of CO2 reduction systems. The gas flow channels in the systems often clog due to salt buildup, reducing efficiency and causing the devices to fail prematurely after about 80 hours of operation.

“Salt precipitation blocks CO2 transport and floods the gas diffusion electrode, which leads to performance failure,” Wang said in a news release. “This typically happens within a few hundred hours, which is far from commercial viability.”

By using an acid-humidified CO2 technique, the team was able to extend the operational life of a CO2 reduction system more than 50-fold, demonstrating more than 4,500 hours of stable operation in a scaled-up reactor.

The Rice team made a simple swap with a significant impact. Instead of using water to humidify the CO2 gas input into the reactor, the team bubbled the gas through an acid solution such as hydrochloric, formic or acetic acid. This process made more soluble salt formations that did not crystallize or block the channels.

The process has major implications for an emerging green technology known as electrochemical CO2 reduction, or CO2RR, that transforms climate-warming CO2 into products like carbon monoxide, ethylene, or alcohols. The products can be further refined into fuels or feedstocks.

“Using the traditional method of water-humidified CO2 could lead to salt formation in the cathode gas flow channels,” Shaoyun Hao, postdoctoral research associate in chemical and biomolecular engineering at Rice and co-first author, explained in the news release. “We hypothesized — and confirmed — that acid vapor could dissolve the salt and convert the low solubility KHCO3 into salt with higher solubility, thus shifting the solubility balance just enough to avoid clogging without affecting catalyst performance.”

The Rice team believes the work can lead to more scalable CO2 electrolyzers, which is vital if the technology is to be deployed at industrial scales as part of carbon capture and utilization strategies. Since the approach itself is relatively simple, it could lead to a more cost-effective and efficient solution. It also worked well with multiple catalyst types, including zinc oxide, copper oxide and bismuth oxide, which are allo used to target different CO2RR products.

“Our method addresses a long-standing obstacle with a low-cost, easily implementable solution,” Ahmad Elgazzar, co-first author and graduate student in chemical and biomolecular engineering at Rice, added in the release. “It’s a step toward making carbon utilization technologies more commercially viable and more sustainable.”

A team led by Wang and in collaboration with researchers from the University of Houston also shared findings on salt precipitation buildup and CO2RR in a recent edition of the journal Nature Energy. Read more here.