USA BioEnergy partners with Johnson Matthey and Honeywell to produce SAF at Bon Wier, Texas, using advanced Fischer-Tropsch technologies.
USA BioEnergy has confirmed that it will deploy advanced process technologies from Johnson Matthey (JM) and Honeywell at its Bon Wier, Texas biorefinery to produce synthetic paraffinic kerosene (SPK), a key component of sustainable aviation fuel (SAF). The collaboration brings together two of the world’s leading technology providers to deliver a fully integrated, large-scale alternative fuels solution.
At the heart of the project, JM’s FT CANS technology, in partnership with bp, and Honeywell UOP’s FT Unicracking process technology will be utilized. Both technologies leverage the Fischer-Tropsch pathway to convert biomass into high-quality SPK that can be blended with conventional jet fuel while adhering to rigorous aviation industry standards.
The Bon Wier facility is expected to process one million tons of sustainably sourced biomass annually, primarily forest thinnings, into approximately 65 million gallons of transportation fuels, including SAF. In addition to the core conversion technologies, Honeywell’s Experion® PKS Distributed Control System (DCS) and integrated safety systems will be implemented to optimize plant performance, reliability, and operational safety.
Tony Wedell, Chief Operating Officer of USA BioEnergy, emphasized the significance of the collaboration, stating, “We are excited to add two of the world’s leading technology providers to our team. Together, we are creating the most comprehensive and integrated solution in the advanced fuels sector.” CEO Nick Andrews further highlighted the project’s environmental and operational impact: “By using responsibly sourced forest thinnings alongside carbon capture and sequestration technologies, our integration with Johnson Matthey and Honeywell enables a fully integrated alternative fuels solution that advances sustainability in aviation.”
Alberto Giovanzana, Managing Director Licensing at Johnson Matthey, noted, “The Bon Wier project is another exemplary deployment of FT CANS at scale, reinforcing decarbonization efforts in air travel while supporting domestic energy and fuel security, as well as job creation.” Rajesh Gattupalli, President of Honeywell UOP, added, “This collaboration demonstrates Honeywell’s commitment to overcoming feedstock limitations in SAF production and scaling technologies that broaden feedstock options, contributing to U.S. energy security.”
This project follows several recent milestones in sustainable aviation fuels. USA BioEnergy has signed a 20-year offtake agreement with Southwest Airlines for up to 680 million gallons of SPK, which, when blended with conventional jet fuel, could yield 2.59 billion gallons of SAF—supporting the International Air Transport Association’s net-zero emissions target for 2050. Meanwhile, JM and Honeywell were also chosen by DG Fuels for a new SAF facility in Minnesota, using the same FT CANS and FT Unicracking technologies. JM’s Catalyst Technologies portfolio has now secured ten to eleven large-scale wins in the 2024/25 financial year, further reinforcing its leadership in sustainable fuel technologies.
It is important to note that Honeywell’s previously announced plan to acquire Johnson Matthey’s Catalyst Technologies business is separate from this collaboration, with discussions related to that acquisition proceeding as part of routine business operations.
