Why LanzaJet's SAF Plant is a Game-Changer for Aviation

After 15 years of research and development, US firm LanzaJet has reached a milestone, confirming the first production of sustainable aviation fuel (SAF) from ethanol at its Freedom Pines Fuels plant in Soperton, Georgia.

The facility is the first in the world to commercially produce SAF from ethanol, representing a major step in the decarbonisation of aviation.

LanzaJet has moved its alcohol-to-jet (ATJ) technology from a laboratory setting to a commercial one for the first time. The fuel produced is a 'drop-in' replacement for conventional jet fuel, meaning it is fully compatible with existing aircraft and airport infrastructure without requiring any modifications.

This achievement could go a long way towards shrinking the carbon footprint of the airline industry.

A blueprint for construction and technology integration

LanzaJet calls the Soperton plant a "first-of-its-kind" integrated solution.

The project, which involved an investment of more than US$300m, successfully integrated Technip Energies’ Hummingbird Ethanol-to-Ethylene solution with oligomerisation technology developed jointly by LanzaTech and the US Department of Energy.

The successful construction and integration of these systems now serve as a blueprint for future deployments globally.

Jimmy Samartzis, CEO at LanzaJet, comments: “Today proves what happens when you bring together innovation, resilience, ingenuity and teamwork to think big and develop a new industry, overcome challenges and enable global growth.

"We’re now in a unique position with technology and operational know-how to shape this global industry in the decade ahead.”

Engineering past feedstock challenges

The aviation industry has faced warnings from analysts that SAF produced using Hydroprocessed Esters and Fatty Acids (HEFA) is nearing a limit in terms of available feedstock.

LanzaJet’s proprietary ATJ technology bypasses this potential bottleneck by using widely available ethanol feedstocks such as agricultural residues and municipal solid waste.

This change to ethanol could open new pathways for waste sources and recycled carbon to enter the aviation energy supply chain.

Flyn van Ewijk, Regional Director for APAC at LanzaJet, adds: "Overnight, we shared news that LanzaJet had made history: producing jet fuel from ethanol at the world's first commercial-scale plant.

"This moment is a milestone for the LanzaJet family – the culmination of 15 years of research and development, collaboration, investment and scale-up – but also for our industry as it marks the next wave of SAF technology to reach commercial readiness in nearly a decade."

Global deployment and energy security

LanzaJet is already planning to deliver this technology to multiple regions, including the UK, European Union, Japan and Australia.

The move towards ethanol-based fuel production presents an opportunity for nations to strengthen domestic energy security while simultaneously expanding their agricultural sectors. The fuel itself delivers far fewer lifecycle greenhouse gas emissions than conventional kerosene.

Deploying a novel engineering project of this scale presents major operational difficulties.

"Deploying a first-of-its-kind is not easy, but we've done it," says Flyn.

"I'm proud of our team for what they have achieved and grateful for Jimmy Samartzis's leadership and to Louay Masarweh for his many sleepless nights and unwavering dedication to the mission."