Metafuels: Revolutionizing Sustainable Aviation Fuel Production with E-Methanol
The aviation industry is under immense pressure to reduce its carbon footprint, and sustainable aviation fuels (SAFs) have emerged as a crucial element in achieving this goal. However, the high cost and limited availability of SAFs pose significant challenges for airlines striving to meet their ambitious carbon neutrality targets. A Swiss startup, Metafuels, believes it has the solution: a groundbreaking technology that utilizes e-methanol to produce e-SAFs, offering a more efficient and cost-effective alternative to conventional methods.
Metafuels is currently operating a pilot project and demonstration plant at the Paul Scherrer Institute (PSI), Switzerland’s largest research hub for natural and engineering sciences. The company’s innovative approach centers around e-methanol, a methanol produced using renewable energy. This distinction is critical, as the use of renewable energy significantly reduces the carbon footprint of the resulting SAF. The potential market for e-SAFs is enormous, projected to reach 80-120 billion gallons by 2050, according to the International Energy Agency and the International Air Transport Association.
While many companies are exploring e-SAF production, Metafuels distinguishes itself through its unique production process. Traditional methods typically rely on the Fischer-Tropsch process, a complex series of chemical reactions that convert synthetic gas into liquid hydrocarbons. Metafuels, however, has opted for methanol synthesis, a different synthetic fuel pathway. This involves producing methanol from carbon monoxide and hydrogen using renewable energy or utilizing an existing sustainable methanol feedstock. The methanol is then converted into longer-chain hydrocarbons suitable for jet fuel.
Metafuels’ process involves additional steps and utilizes a proprietary catalyst to drive the desired chemical reactions. According to CEO Saurabh Kapoor, this innovative approach provides Metafuels with a significant competitive advantage. "It’s all about how you convert methanol to SAF selectively and efficiently, where we believe we have a lead on competitors," he explains. The company’s pilot project at PSI has demonstrated the efficacy of its technology, and the results, soon to be published and verified, are expected to garner significant attention within the industry.
Metafuels claims its methanol-to-SAF process is significantly more efficient and cost-effective than the traditional Fischer-Tropsch method. Kapoor asserts that, under identical conditions, their e-SAF production costs could be 50% lower and yield 80% higher than Fischer-Tropsch. This represents a substantial improvement in both economic and environmental terms. The company’s team of international specialists, coupled with collaboration with PSI and the use of advanced technologies like AspenTech’s digital twin, further strengthens their position. The company’s e-SAF product, branded as Aerobrew, is currently being produced at a rate of one liter per day at the pilot plant, with the demonstration plant capable of producing 50 liters per day.
Metafuels’ ambitions extend beyond laboratory-scale production. Chairman Leigh Hackett emphasizes the scalability of their process, envisioning single production trains capable of producing up to 2,000 tons of Aerobrew per day. He also points out that Metafuels is currently the only known startup globally focusing on methanol-to-SAF technology, while other companies exploring this pathway are primarily large established corporations. This positioning allows Metafuels to capitalize on the growing demand for sustainable aviation fuel with a unique and potentially disruptive technology.
The company’s success in developing a viable e-SAF production process has attracted significant investment. Metafuels secured $9 million in a funding round in December 2024, following an $8 million raise in 2023 and a $5 million grant from the Swiss Federal Office of Energy, bringing their total secured funding to $22 million. This investment allows Metafuels to scale up their operations and expand their reach. The company has already signed agreements to establish e-SAF facilities in Denmark and The Netherlands, with the Danish plant projected to commence operations in 2028, and has begun discussions with potential buyers, including airlines, fuel suppliers, airports, and corporate travelers.
Beyond developing and operating its own e-SAF production facilities, Metafuels plans to license its technology to other interested parties. This two-pronged commercial strategy allows the company to maximize the impact of its innovation. While initial project development will focus on local and pan-European markets due to the availability of renewable electricity, the company’s long-term vision is global. Metafuels recognizes the importance of considering the entire value chain, including methanol synthesis, when determining the location of e-SAF production sites, taking into account factors like decarbonization, competitiveness, and efficient utilization of resources like CO2 and renewable energy.
Metafuels is not content with simply being a participant in the e-SAF market. Their ultimate goal is to become the lowest-cost e-SAF provider, enabling widespread adoption of sustainable aviation fuel and significantly contributing to the decarbonization of the aviation industry. With their innovative technology, ambitious plans, and commitment to affordable decarbonization, Metafuels is poised to play a leading role in shaping the future of sustainable aviation. Their success could pave the way for a greener, more sustainable future for air travel, allowing the industry to reduce its environmental impact and meet its ambitious carbon reduction goals.
