Syzygy Plasmonics has begun the front-end engineering and design (FEED) phase for NovaSAF 1, described by the company as the world’s first fully electrified facility converting biogas into sustainable aviation fuel (SAF).
The plant will be built in Durazno, Uruguay, and is expected to produce more than 350,000 gallons of SAF each year. The fuel will meet ASTM D7566 standards and will be created using biomethane derived from cow manure, along with carbon dioxide, renewable electricity and steam.
The project is backed by long-term agreements with Estancias del Lago, a dairy and agri-energy business in Uruguay. It will utilise Syzygy’s proprietary NovaSAF technology platform.
By combining biogas processing with Power-to-Liquids methods, the facility aims to use waste materials as feedstock, reducing water consumption and cutting carbon intensity by more than 80% compared with conventional Jet-A fuel. The design also avoids the need for gas pipelines and expensive gas separation processes.
Syzygy Plasmonics chief executive Trevor Best said the project demonstrates how underused biogas resources can be transformed into valuable clean fuel without relying on subsidies or complex infrastructure. He added that the NovaSAF approach could offer a practical route to producing SAF at cost levels comparable to traditional jet fuel, supporting efforts to decarbonise aviation.
Permitting and equipment sourcing are currently under way alongside the FEED stage, which is being led by engineering and project management firm Kent.
The project is targeting a final investment decision in the fourth quarter of 2025, with commercial operations planned for early 2027. It is expected to achieve a SAF yield around 50% higher than that of conventional thermal biogas reforming methods.
The facility is also being designed to meet SAF standards set by the EU, the United States and the CORSIA international aviation scheme.
Kent’s executive vice-president for operations in the Americas, Tom Bullard, said the company was pleased to support what it describes as the first profitable biogas-to-SAF plant, highlighting its experience in delivering complex energy projects.
Earlier this year, Syzygy reported successful performance testing of what it claims is the world’s largest all-electric greenhouse gas e-reforming demonstration unit in Houston. After more than 3,000 hours of testing in both Houston and Ulsan, South Korea, the company said its Rigel Reactor has shown strong progress in producing lower-cost, high-yield SAF.
Syzygy launches design phase for world-first electrified biogas-to-SAF plant in Uruguay
