USA BioEnergy has selected Johnson Matthey (JM) and Honeywell to provide advanced process technologies for its upcoming sustainable aviation fuel (SAF) biorefinery in Bon Wier, Texas.
The facility, scheduled to be fully operational by 2030, is expected to produce 65 million gallons of biobased fuels annually, including synthetic paraffinic kerosene (SPK) that meets aviation standards.
Fischer–Tropsch technologies at the core
The plant will deploy JM/bp’s FT CANS™ and Honeywell UOP’s FT Unicracking™ technologies, both based on the Fischer–Tropsch pathway. Together, they will convert one million tons of sustainably sourced forest thinnings into renewable transportation fuels, addressing feedstock challenges and supporting the decarbonization of air travel.
Automation, safety, and performance
Beyond the conversion technologies, the facility will also implement Honeywell’s Experion® PKS Distributed Control System and integrated safety solutions to ensure operational reliability and safety.
Long-term SAF supply agreement
A cornerstone of the project is a 20-year offtake agreement with Southwest Airlines for up to 680 million gallons of SPK. Once blended with conventional jet fuel, this supply could generate 2.59 billion gallons of SAF, contributing to the airline’s progress toward net-zero emissions by 2050.
Industry perspectives
Tony Wedell, COO of USA BioEnergy, said that bringing together leading technology providers positions the company at the forefront of advanced fuels. CEO Nick Andrews highlighted the integration of carbon capture and storage in reducing emissions.
Executives from Johnson Matthey and Honeywell emphasized the project’s broader role in decarbonization and energy security in the United States, while also underlining the importance of domestic fuel manufacturing.
A milestone for U.S. renewable fuels
The Bon Wier project builds on other SAF initiatives in the United States that use the same core technologies. USA BioEnergy plans for the Texas facility to be the first in a series of 12 advanced biorefineries, designed to expand sustainable fuel production and carbon capture capacity as part of the national energy transition.
USA BioEnergy is a renewable fuels development and integration group headquartered in Scottsdale, Arizona, with a project pipeline across the southern United States. The company develops sustainable aviation fuel, renewable diesel, and renewable naphtha from forest thinnings, using bioenergy with carbon capture and storage (BECCS) to achieve net-negative emissions. Its Bon Wier, Texas, facility is designed to capture and sequester more than 50 million tons of CO₂ over its lifetime, producing some of the lowest carbon intensity fuels in the industry. USA BioEnergy aims to build a series of 12 advanced biorefineries to accelerate the energy transition.
