US Innovator Crosses The Bridge From Powdered Milk To SAF

US startup Syzygy Plasmonics is advancing sustainable aviation fuel (SAF) production through a novel biogas-to-fuel system that uses renewable electricity to synthesise kerosene jet fuel. The company’s proprietary “Rigel” photocatalytic reactor operates without combustion, converting biogas from sources such as landfills and dairy farms into synthetic fuels, including SAF, syngas, and hydrogen. This technology represents a significant step forward in the electrofuels sector, offering a scalable, feedstock-flexible alternative to traditional biofuels, which have struggled with economic viability and slow adoption. The recent geopolitical tensions triggered by the Iran War and the subsequent closure of the Strait of Hormuz have intensified global fuel price volatility, prompting renewed interest in domestic, renewable fuel production. Syzygy’s approach addresses concerns over supply chain vulnerabilities by enabling local production of SAF using renewable electricity and biogas, reducing reliance on imported fossil fuels. The company has reported a surge in inquiries from airlines and commodity traders keen to secure more resilient and sustainable fuel sources amid the crisis. Syzygy’s first operational project, NovaSAF-1, is underway in Durazno, Uruguay, where it utilises biogas from a powdered milk facility alongside local renewable electricity to produce synthetic paraffinic kerosene with a lifecycle emissions reduction of approximately 90% compared to conventional jet fuel. The startup has secured a six-year offtake agreement with global commodities trader Trafigura, ensuring the entire output of NovaSAF-1 is committed through to 2028. This deal not only facilitates project financing but also positions Syzygy to potentially expand its market share in the SAF industry, competing favourably against existing feedstocks like waste cooking oil. Looking ahead, Syzygy aims to scale production dramatically, targeting up to one million tonnes of SAF annually by 2035. A key milestone in this expansion is a Memorandum of Understanding with Brazilian biogas producer Geo, which will combine Geo’s expertise in biogas from sugarcane residues with Syzygy’s electrified GHG e-Reforming™ technology. This partnership highlights the potential for global replication of the Rigel system, leveraging diverse biogas sources to meet growing regulatory mandates and market demand for low-carbon aviation fuels.