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Startup Sora Fuel secures $6M to produce sustainable aviation fuel using direct air capture to fuels process

Sora Fuel, a startup producing sustainable aviation fuel (SAF) using only water, air and renewable energy, raised an oversubscribed $6 million seed round. The Engine Ventures led the round, with Wireframe Ventures and others participating. The funding will be used to expand Sora Fuel’s Boston-based team, develop commercialization partnerships and further advance the company’s novel technology.

Aviation emissions have quadrupled since the 1960s, with aircraft currently accounting for 2.5% of global CO2 emissions and approximately 4% of global warming. As demand for air travel continues to surge, SAF will play a crucial role in decarbonizing this hard-to-abate sector. However, existing SAF production processes are fundamentally constrained, requiring vast amounts of energy, feedstocks and investment to make a meaningful impact, Sora says.

For example, today’s only commercially viable SAF—Hydroprocessed Esters and Fatty Acids (HEFA)—relies on limited waste oil feedstock that alone can cost $3.50 per gallon, while the alcohol-to-jet process competes with agriculture and leads to soil degradation. Waste gasification and point-source power-to-liquid processes are less reliant on valuable resources, however both provide limited greenhouse gas reduction potential, as the underlying feedstocks of both processes contain / rely on non-biogenic sources of carbon.

Sora Fuel offers a new path for producing SAF by capturing and using atmospheric CO2 at costs that are an order of magnitude lower than existing processes. The company’s novel technology includes a liquid bicarbonate electrolyzer that delivers direct air capture (DAC) CO2 at $20 per ton, operating in a fully closed-loop system that uses only water and renewable electricity to produce syngas.

Sora

Compared to incumbent DAC solutions, Sora Fuel’s DAC-to-fuels approach dramatically reduces overall energy inputs, eliminates the need for feedstocks (other than air and water), and provides a scalable process for efficiently and cost effectively producing SAF and any other downstream products of syngas.

Sora Fuel’s technology eliminates 90% of the energy currently required in standard DAC processes, opening up an entirely new and more sustainable path for producing carbon negative fuels. Our patented, closed-loop system enables the direct generation of an economical product and overcomes widespread feedstock constraints, allowing us to produce SAF at prices comparable to current Jet A fuel.

—Gareth Ross, co-founder and CEO of Sora Fuel

Sora Fuel was conceived within The Engine Ventures based on technology from Curtis Berlinguette’s lab at the University of British Columbia. The company’s Chief Science Officer, Patrick Sarver, earned a PhD in Chemistry from Princeton University, completed his postdoctoral research at MIT and worked as a Venture Associate at The Engine Ventures prior to co-founding Sora Fuel. Ross was previously an Executive in Residence at The Engine Ventures, supporting portfolio companies across the clean energy landscape and spent 15 years as an executive at MassMutual, where he most recently oversaw technology and operations.

Comments

Gorr

Way better then the battery and hydrogen solutions. I guess that they can also make gasoline and diesel.

Davemart

' However, existing SAF production processes are fundamentally constrained, requiring vast amounts of energy, feedstocks and investment to make a meaningful impact, '

True.

' Sora Fuel offers a new path for producing SAF by capturing and using atmospheric CO2 at costs that are an order of magnitude lower than existing processes.'

Existing processes are hoping to reduce costs from the present stratospheric levels, with generous assumptions for technical progress, to levels which are simply outrageously expensive and impractical.

' Sora Fuel offers a new path for producing SAF by capturing and using atmospheric CO2 at costs that are an order of magnitude lower than existing processes. The company’s novel technology includes a liquid bicarbonate electrolyzer that delivers direct air capture (DAC) CO2 at $20 per ton, operating in a fully closed-loop system that uses only water and renewable electricity to produce syngas. '

Lovely, if true.

Davemart

Gorr said;

' Way better then the battery and hydrogen solutions'

Not really. You still need to add hydrogen to make the fuel work, and then you end up with a fuel which still turns out pollutants, which hydrogen especially in fuel cells doesn't, and which higher potential weight and hence cost than hydrogen.

Note 'potential' there, as there is one heck of a way to go to develop hydrogen technology to that level.

However, they are looking to do a round the world flight non stop on hydrogen:

https://fuelcellsworks.com/news/ekpo-to-supply-fuel-cell-stacks-for-first-non-stop-h2-flight-around-the-world/

What SAF does is avoid the need for substantial redesign of aircraft, which is why the airline companies are so keen on it.

Boeing comment that they are unsure of the safety of hydrogen aircraft.

I think they underestimate themselves.

They have proven expertise in building unsafe aircraft using regular jet fuel, and don't need the help of hydrogen to do so.

dursun

Direct air capture is a scam, only make money if it's subsidized

Roger Brown

I found an open access paper (https://www.cell.com/cell-reports-physical-science/fulltext/S2666-3864(23)00485-X) on bicarbonate electrolyzers that gives some insight in to how this technology could be used to capture CO2. In this paper they are considering the production of formate for direct formate fuel cells rather than the production of jet fuel, but the CO2 capture principles are the same.

Here are some paragraphs from the introduction:

"Traditionally, CO2 capture and CO2ER have been considered separately.10 CO2 captured from dilute sources should be first converted (typically to solid calcium carbonate, CaCO3), transported, thermally decomposed, and pressurized to become ultra-pure CO2 gas feedstock (Figure S1).11,12 For the prevalent alkaline- or neutral-medium-based aqueous membrane electrode assembly (MEA) electrolyzers, over 50% of the capital cost would come from this solid-state thermal regeneration process4,9 which is highly energy intensive.

To address this critical challenge, rather than relying on the CO2(gas) feedstock, bipolar membrane (BPM) electrolyzers with aqueous bicarbonate HCO3-(FAQ) input were demonstrated (Figure S2b).11,15,20,21 In principle, the energy-intensive CO2 regeneration process could be circumvented."

The process starts from a metal oxide (KO2 in the example given in the paper). The process may be summarized as follows:

KO2 ==> KOH(Aq)+CO2 ==> KHCO3(Aq) ==> KHCO2(Aq) + oxygen

KO2 obtained from mineral sources is dissolved in water where it becomes potassium hydroxide (KOH). KOH absorbs CO2 and become potassium bicarbonate (KHCO3) which is electrolytically upgraded to potassium formate (KHCO2). The potassium formate can be used to power a direct formate fuel cell (DFFC). This method of producing hydrocarbon fuel avoids going all the way down the energy well to carbonate and therefore avoid the high energy cost of pulling the CO2 back out of this well. However several additional comments are in order.

First this method of carbon capture is not circular. The KOH is not regenerated at the end of the process ready to capture more CO2. Instead you have to keep mining and process mineral rock containing metal oxides as the following paragraph from the paper makes clear:

"At scale, our strategy fits well into the global framework of carbon capture, utilization, and sequestration (CCUS). Various alkali basalt mineral rocks, containing CaO, MgO, SiO2, Na2O, and K2O, were found in abundance on Earth and used for enhanced weathering.25 They are efficient for removing CO2 from the atmosphere and would form carbonates and bicarbonates.25,26 The insoluble components could be separated and buried for carbon sequestration, while the soluble components, containing potassium, sodium, and calcium, etc., with our method, could be converted electrochemically into energy-rich metal-formate fuels (Figure 1G) for seasonal energy storage. A direct formate fuel cell (DFFC) possesses a high volumetric energy density (53g H2 per liter) and high specific energy density (2.13 kWh kg-1, more than 5 times that of the state-of-the-art lithium-ion batteries). Currently, a state-of-the-art DFFC demonstrated a peak power density of 302 mW cm-2, which is already quite competitive against the standard H2 PEM (proton-exchange membrane) fuel cell (~700 mW cm-2),27 thus opening the door for seasonal or even multi-year storage of the intermittent wind and solar electricity."

Secondly the claim of 20x lower cost of carbon capture seems questionable. Enhanced rock weathering has been considered as a mean of CCS and the economics are considered to be highly doubtful (https://climate.mit.edu/explainers/enhanced-rock-weathering). I suspect the 20x claim depends on accounting methods. If you count the mining and processing of minerals as a cost of fuel production and only count the cost of the blowers required to pass air over your vats of KOH then maybe you can claim low carbon capture costs. However, I do not think that this method could be used for pure CCS at such low cost.

Davemart

Excellent link, Roger.

Just to clarify, what Sora Fuels are claiming is not 20 times cost reduction, but:

' Sora Fuel offers a new path for producing SAF by capturing and using atmospheric CO2 at costs that are an order of magnitude lower than existing processes. '

And:

' direct air capture (DAC) CO2 at $20 per ton,'

I don't see anything in the paper which obviously blows their claims out of the water, including that it the materials are not recycled, if their claims of massive availability of the needed resources is right.

OTOH, I don''t see anything to make me want to bet the farm on it at this stage.

Certainly worth the more detailed research which will certainly follow, as DAC and sequestration would be marvellous if it can be done at any affordable cost.


Davemart

Roger:

Perhaps I should note that I am not disagreeing with your comment, but simply dottiing some i's on it, to make it more bullet proof by using the exact quotes.

I dunno anyone who is currently doing DAC for $200 ton, nor even $400, so what you said is actually accurate, it is just that that is not quite how Sora fuels have laid it out themselves.

Anyhow, they are most certainly claiming a massive reduction in cost, and your link puts some meat on the bone of what they are on about.

Roger Brown

I found another interesting open source paper on bicarbonate electrolysis (https://www.cell.com/joule/pdf/S2542-4351(22)00561-X.pdf). God praise open source publishing. This system of DAC plus fuel production also avoids going down to the bottom of the carbonate energy well but does not require mining minerals containing metal oxides. It does, however, require using water electrolysis in addition to bicarbonate electrolysis. H2 and HCO3- are fed into the bicarbonate electrolyzer and the output is as shown below:

H2 + HCO3- ==> CO + OH- + H2O

Thus the hydroxide (OH-) is regenerated and can be returned to the DAC system. Actually the bicarbonate electrolyzer also produces some amount of H2 so that the output stream is a CO rich syngas mix of CO and H2. If you need a higher proportion of H2 in the syngas then you can either convert CO to H2 via the water gas shift reaction or you can add H2 from electrolysis.

Again as far as I know there is no way of converting this system to a CCS form, so it becomes difficult to compare the carbon capture costs to those of CCS systems. However, the system is not mature, so there is no realistic cost associated with it yet.

SJC

Make the jet fuel at natural gas processing plants They get plenty of CO2 from the wellhead. where they just put it right into the air. Instead you're actually making a fuel out of it, less CO2 omissions

Davemart

Hi SJC

Reduced emissions, maybe.
But the airline industry plans on a vastly increased fleet.

Slightly reduced insanity?

SJC

If you want to do this on the large scale my method will work there are a lot of natural gas processing plants they take the wellhead gas they clean it up they remove the CO2 it's done every day they can make tons of synthetic jet fuel if you use the CO2 twice you've cut the emissions in half it's not slightly.

Davemart

@SJC

I did not intend to diss what you have to say. I am just staggered by the aircraft industry's intention to 'carry on right ahead' when if we keep pumping out GHGs then sea level rises alone with cost much more than the value of the flights etc.

As you say, a reduction by half if achievable is not trivial.

However, I have heard nothing about this tech being introduced, certainly not at scale.

Have you links to any progress for it?

Googling:
' jet fuel from natural gas with sequestration'

Turned up mainly stuff about using biomethane to produce jet fuel.

I did not turn up anything, at least on the first page of results which included sequestration, and the most apposite article was from 2021:

https://www.sciencedirect.com/science/article/abs/pii/B9780323885065502291

'In fact, fuel production in Pearl GTL has prompted Qatar Airways (QA) to become the first commercial airliner to trial jet fuel-GTL. However, mainstream utilisation is challenged due to: (a) lack of availability of jet fuel-GTL for the purpose of re-fuelling at QA’s worldwide destinations. As such, the presence of GTL plants is limited globally due to the availability of natural gas and the high capital costs for GTL plant construction; (b) volatility in jet fuel-GTL prices and the uncertainty in petroleum product markets.'

So it would seem that putting the infrastructure in place, even without worrying about sequestration, would take many years and to be very expensive.

I lost heart to study the sociopathic projections of the aircraft industry for expansion in detail, but they are certainly looking to more than double long range flights by 2050

SJC

In my method you'll be using renewable hydrogen made with renewable electricity and waste heat to make it more efficient it's just where do you get the CO2, you can do direct air capture very expensive or you can get it from power plants, have to separate it from the other gasses or you can get it from well heads its pure CO2

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