Liberal, Kansas – SAFFiRE Renewables, LLC has begun construction on its pilot plant at Conestoga Energy’s Arkalon Energy facility, marking a pivotal step in the company’s mission to produce sustainable aviation fuel (SAF) from corn stover. The plant, set to be operational by Q4 2025, will process 10 tons of corn stover daily into cellulosic ethanol, which can then be upgraded into SAF with at least 83% lower carbon emissions compared to conventional jet fuel.
The project is supported by Southwest Airlines and the Department of Energy’s Bioenergy Technologies Office (BETO), with proprietary technology developed by the National Renewable Energy Laboratory (NREL). The groundbreaking event included notable figures such as Senators Jerry Moran and Roger Marshall, and Growth Energy CEO Emily Skor, who highlighted the plant’s potential to boost the local economy and the broader biofuels industry.
“SAFFiRE’s technology has the potential to fuel aviation’s sustainable transition and positions U.S. agriculture at the forefront of SAF growth.”
Technical Details of SAFFiRE’s Method:
SAFFiRE’s process centers around converting corn stover—a byproduct of corn harvesting—into SAF using a unique Deacetylation and Mechanical Refining (DMR) pretreatment technology developed by NREL. The steps involved are:
- Processing Corn Stover: The stover, usually left to decompose, is collected and pretreated using DMR technology. This process removes impurities like acetic acid, ash, and lignin, improving the efficiency of the subsequent steps.
- Producing Renewable Ethanol: After pretreatment, the stover undergoes hydrolysis, fermentation, and separation into ethanol. This process operates under mild conditions—low temperatures and atmospheric pressure—minimizing costs and avoiding common issues like equipment corrosion and fermentation inhibitors.
- Upgrading Ethanol to SAF: The final step involves upgrading the ethanol into fully certified SAF using alcohol-to-jet technology, creating a low-carbon fuel suitable for the aviation industry.
The DMR technology sets SAFFiRE apart by preserving valuable lignin, avoiding the need for expensive materials, and ensuring high sugar yields with low enzyme requirements. By operating at low temperatures and under alkaline conditions, the process not only reduces operational challenges but also opens the door to innovative uses of lignin in materials like construction and adhesives.
Analysis: SAFFiRE’s groundbreaking pilot plant represents a major advance in the production of sustainable aviation fuel, utilizing cutting-edge technology to create a viable low-carbon alternative for the aviation industry. The project not only aligns with the Biden-Harris Administration’s SAF Grand Challenge but also places the U.S. agriculture and ethanol industries at the forefront of global SAF development.
Source: Southwest Media release
