Circularity Fuels announced the successful completion of the world’s first end-to-end pilot converting raw agricultural biogas into sustainable aviation fuel (SAF). Over six months, a California dairy farm’s manure digester supplied biogas. About 65% methane and 35% CO₂ which the pilot system processed into jet fuel meeting ASTM D7566 standards.
Using a modular, low-cost system, Circularity’s dual-reactor approach achieved over 98% methane and 90% CO₂ conversion. The resulting fuel can be blended with conventional jet fuel up to 50%, with a carbon intensity of -350.7 gCO₂e/MJ, making it net carbon-negative. This is because it captures methane that would otherwise be vented, a potent greenhouse gas, thus removing roughly 100 pounds of CO₂e per gallon from the atmosphere.
The technology offers a low-cost path to commercial-scale SAF, with projected capital costs at about one-fifth of European SAF plants. This cost advantage, combined with existing federal and state incentives like the EPA’s Renewable Fuel Standard and California’s LCFS, makes dairy biogas-derived SAF competitive with fossil jet fuel.
“The key was proving continuous, economical conversion from real biogas,” said CEO Dr. Stephen Beaton. “We’ve demonstrated a full-stack process that’s ready for commercial deployment.”
Industry experts note this innovation can transform dairy waste management. Turning a waste product into a revenue stream while reducing emissions. Circularity plans to launch its first commercial facility in 2027, targeting biogas resources across the US, Latin America, and Europe.
This breakthrough could significantly boost domestic SAF supply, reduce reliance on imported feedstocks, and support airlines in meeting sustainability mandates.
