Thor Biocrude (Thor–NL) and Susteen Technologies (Susteen–D) are taking the next step in the development and roll-out of a novel and low-cost biomass waste-to-fuel technology platform called Thermal Catalytic Reforming (TCR). TCR is a biomass conversion technology that converts low value wet organics bio-waste into high value biocrude (TCR-oil), green hydrogen-rich bio-syngas, and solid bio-char, that can be processed to biofuels and biochemicals. In a preliminary project, the Thermal Catalytic Reforming (TCR) technology has been validated for 3 different municipal waste feedstocks: OWF (organic wet fraction of municipal solid waste), DIG (digestate from OWF) and PSS (primary sewage sludge). The TCR validation tests have shown proof of technology and economy, and all 3 feedstocks have been successfully converted from organic waste into valuable TCR components. Objectives of this Phase 1 proposal are to (1) explore new bio-based value chains, utilizing relevant bio-waste fractions for bio-product generation, and (2) elaborate a detailed business plan, including the assessment of the potential impact of the proposed value chains.

TO-SYN-FUEL will demonstrate the conversion of organic waste biomass (Sewage Sludge) into biofuels. The project implements a new integrated process combining Thermo-Catalytic Reforming (TCR©), with hydrogen separation through pressure swing adsorption (PSA), and hydro deoxygenation (HDO), to produce a fully equivalent gasoline and diesel substitute (compliant with EN228 and EN590 European Standards) and green hydrogen for use in transport . The TO-SYN-FUEL project consortium has undoubtedly bought together the leading researchers, industrial technology providers and renewable energy experts from across Europe, in a combined, committed and dedicated research effort to deliver the overarching ambition. Building and extending from previous framework funding this project is designed to set the benchmark for future sustainable development and growth within Europe and will provide a real example to the rest of the world of how sustainable energy, economic, social and environmental needs can successfully be addressed. This project will be the platform for deployment of a subsequent commercial scale facility. This will be the first of its kind to be built anywhere in the world, processing organic industrial wastes directly into transportation grade biofuels fuels which will be a demonstration showcase for future sustainable investment and economic growth across Europe. This project will mark the first pre-commercial scale deployment of the technology processing up to 2100 tonnes per year of dried sewage sludge into 210,000 litres per year of liquid biofuels and up to 30,000 kg of green hydrogen. The scale up of 100 of such plants installed throughout Europe would be sufficient to convert up to 32 million tonnes per year of organic wastes into sustainable biofuels, contributing towards 35 million tonnes of GHG savings and diversion of organic wastes from landfill. This proposal is responding to the European Innovation Call LCE-19.

FlexJet will build a pre-commercial demonstration plant for the production of advanced aviation biofuel (jet fuel) from waste vegetable oil and organic solid waste biomass (food waste), successfully demonstrating the SABR-TCR technology (traditional transesterification (TRANS) and Thermo-Catalytic Reforming (TCR) combined with hydrogen separation through pressure swing adsorption (PSA), and hydro deoxygenation (HDO) and hydro cracking/ isomerisation (HC)) to produce a fully equivalent jet fuel (compliant with ASTM D7566 Standards). This project will deliver respective environmental and social sustainability mapping and it will validate a comprehensive exploitation business plan, building on already established end user interest with existing offtake agreements already in place with British Airways. The project plant installed at the source of where the waste arises in BIGA Energie at Hohenstein (Germany) will produce 1,200 ton of jet fuel from 3,482 tonnes of dried organic waste and 1,153 tonnes of waste vegetable oil per year. A subsequent scale-up first commercial plant would be constructed immediately after the project end to produce 25,000 tonnes per year of aviation fuel. The FlexJet project consortium has undoubtedly bought together the leading researchers, industrial technology providers including airline off takers and renewable energy experts from across Europe, in a combined, committed and dedicated research effort to deliver the overarching ambition. Building and extending from previous framework funding this project is designed to set the benchmark for future sustainable aviation fuel development and growth within Europe and will provide a real example to the rest of the world of how sustainable aviation biofuels can be produced at both large and decentralised scales economically whilst simultaneously addressing social and environmental needs.