Periodic Reporting for period 2 - GAFT (Production of High-quality Fatty Acids Feedstock for use in SAF Production)
Reporting period: 2024-07-03 to 2025-07-02
The GAFT project introduces innovations in biofuels and e-fuels, generating long-chain lipid feedstocks for Sustainable Aviation Fuel (SAF). A non-GMO microorganism was developed to ferment various feedstocks (glycerol, organic acids, sugars) into triglycerides, the main input for the HEFA (Hydroprocessed Esters and Fatty Acids) process—the only commercially available SAF pathway. Residual biomass can serve as animal feed, depending on feedstock. GAFT also patented a CO2 electrolyzer that converts renewable electricity into organic acids for efeedstocks. The core innovation is the production of potassium formate (PF) from CO2, water, and renewable power, reaching high concentrations with standard equipment. PF is converted into formic acid (FA), feeding lipid production. This integrated approach increases SAF efficiency by using only the energy required to turn CO2 into hydrocarbons and, through fermentation, fatty acids for HEFA-based SAF.
GAFT optimized a complete bioprocess—including fermentation and lipid extraction—using diverse carbon-rich substrates. Controlled bioreactors and a safe biobased solvent enabled robust lipid extraction. The process was validated at lab and pilot scale (TRL7). Biomass and lipid yields doubled, improving commercial potential. The extraction solvent proved recyclable without loss of performance. A novel transesterification method converted lipids into fatty acid methyl esters (FAME), a key fuel intermediate. Pre-engineering for industrial scale has begun. GAFT also advanced its CO2 electrolyzer, doubling current density and efficiency compared to earlier prototypes, quadrupling output. It was tested at three European pilot sites under intermittent conditions, showing suitability for renewable energy integration. Optimization of materials and design continues. Both bioprocess and electrolyzer reached TRL 7–8, demonstrated under realistic conditions with metrics aligned to commercial feasibility. The technologies are approaching industrial readiness.
GAFT’s system, demonstrated at TRL 7–8, surpasses established technologies like sugars-to-jet and waste-based Fischer–Tropsch. It progressed from pilot to operational validation, proving readiness for industrial deployment. Engineering work with an EPC contractor and a first customer is underway to design a first-of-a-kind (FOAK) commercial plant (TRL 8). Further lab work aims to improve productivity and economics. Crude glycerine was selected as the initial substrate due to its availability as a biodiesel by-product and its low cost as an industrial waste. This supports rapid, cost-effective market entry. GAFT also monitors alternative feedstocks such as second-generation sugars and electro-derived carbon sources, broadening the platform’s sustainability. Strategic partnerships with Argent Energy, Axens, Nextchem, and Saipem support market development and commercialization across multiple sectors.