R.M. Burton, W.T. Smith
ProcessWerx,
United States
Keywords: aviation fuel, wet wastes, feedstocks, precursors, refinery integration
Summary:
Unlocking the bioeconomy at scale requires expanding access to reliable, cost-competitive feedstocks that can integrate with existing refinery infrastructure and conversion pathways including Hydroprocessed Esters and Fatty Acids (HEFA)and Alcohol to Jet (AtJ). A major untapped opportunity lies in the valorization of high-strength waste streams including those rich in fats, oils, and greases (FOG), proteins, and complex carbohydrates routinely landfilled or treated at high cost. ProcessWerx (PWX) has developed a modular technology platform designed to recover and condition these challenging waste streams for integration into synthetic aviation fuel (SAF) and marine fuel production. In partnership with researchers at the National Laboratory of the Rockies, ProcessWerx is integrating real-time, infrared (IR) sensing to rapidly characterize incoming feedstocks for enhanced control process parameters. This closed-loop insight allows operators to adjust extraction and conditioning strategies on the fly, significantly improving system throughput, consistency, and downstream fuel yields. The goal is to demonstrate the technical and economic feasibility of transforming biogenic-rich wastes into a diversified SAF precursor slate. ProcessWerx leads the engineering and system integration, with NLR support on feedstock characterization and data modeling. By converting problematic wastes into consistent, refinery-compatible intermediates, this work represents a critical step toward unlocking the full potential of the distributed resources providing scalable, resilient solutions for enhanced refinery integration.