Production of High-quality Fatty Acids Feedstock for use in SAF Production

Informations projet

GAFT

N° de convention de subvention: 190104418

DOI

10.3030/190104418

Projet clôturé

Date de signature de la CE 20 Juillet 2023

Date de début 3 Juillet 2023

Date de fin 2 Juillet 2025

Financé au titre de

• The European Innovation Council (EIC)

Coût total

€ 4 025 965,76

Contribution de l’UE

€ 2 499 999,00

Coordonné par

GAFT BV
Netherlands

Periodic Reporting for period 2 - GAFT (Production of High-quality Fatty Acids Feedstock for use in SAF Production)

Période du rapport: 2024-07-03 au 2025-07-02

Résumé du contexte et des objectifs généraux du projet

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.

Travail effectué depuis le début du projet jusqu’à la fin de la période considérée dans le rapport et principaux résultats atteints jusqu’à présent

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.

Progrès au-delà de l’état des connaissances et impact potentiel prévu (y compris l’impact socio-économique et les conséquences sociétales plus larges du projet jusqu’à présent)

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.

Visual description of the electrochemical process (A, B and C) and bioprocess (D, E and F)