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U.S. Plant Produces First Jet Fuel Made from Ethanol

November 28, 2025By ePlane AI
U.S. Plant Produces First Jet Fuel Made from Ethanol
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LanzaJet
Sustainable Aviation Fuel
Alcohol-To-Jet Technology

U.S. Plant Produces First Jet Fuel Made from Ethanol

LanzaJet, a U.S.-based fuel producer, has announced a landmark achievement with the world’s first commercial-scale production of jet fuel derived from ethanol at its Freedom Pines Fuels facility in Soperton, Georgia. This development represents a significant advancement for the aviation industry, introducing the first non-petroleum, renewable jet fuel that is fully compatible with existing aircraft and infrastructure.

The breakthrough is the culmination of 15 years of dedicated research and development, centered on LanzaJet’s proprietary Alcohol-to-Jet (ATJ) technology. This innovative process converts a diverse array of sustainable feedstocks—including agricultural residues, energy crops, municipal solid waste, and captured carbon—into Synthetic Paraffinic Kerosene (SPK), a recognized form of sustainable aviation fuel (SAF).

“This achievement marks the culmination of 15 years of research and development, collaboration, investment, and scale-up, and represents a critical breakthrough for the aviation industry with evidence that ethanol can be transformed into jet fuel at commercial scale,” the company stated.

Addressing Aviation’s Decarbonization Challenge

The aviation sector is under increasing pressure to reduce its carbon footprint, with sustainable aviation fuel currently the only viable near-term solution for lowering emissions from long-haul flights. The predominant SAF production method, Hydroprocessed Esters and Fatty Acids (HEFA), depends on limited feedstocks such as used cooking oil, which restricts its scalability. LanzaJet’s ATJ technology seeks to overcome this limitation by utilizing widely available ethanol, thereby offering the potential to enhance national energy security, strengthen domestic fuel supply chains, and stimulate rural economies.

The ATJ process involves a series of chemical reactions—dehydration, oligomerization, and hydrogenation—that convert ethanol into jet fuel. The resulting SAF, when blended with conventional Jet A-1 fuel, is fully certified and compatible with current aircraft engines. LanzaJet reports that their SAF exhibits a higher energy density than traditional Jet-A fuel, potentially delivering improved performance.

Economic and Industry Impact

The Freedom Pines Fuels facility is a pioneering integrated plant that required an investment exceeding $300 million. It incorporates advanced technologies such as Technip Energies’ Hummingbird (Ethanol-to-Ethylene) process and a joint Department of Energy and LanzaTech oligomerization solution. The plant has created hundreds of construction jobs and now supports over 65 direct and indirect positions in Treutlen County, Georgia, serving as a vital economic engine for the rural community.

LanzaJet is actively expanding its technology on a global scale, with projects underway in the United States, Australia, Japan, India, the United Kingdom, Colombia, and Europe.

Challenges and Market Response

Despite this significant milestone, challenges remain in scaling ethanol-based jet fuel production cost-effectively and navigating complex regulatory environments. The market response has been positive, with growing interest from airlines committed to sustainability, including United Airlines, and increasing investment focus on sustainable aviation fuel producers. At the same time, industry competitors such as Shell and Boeing are expected to accelerate their own SAF initiatives to maintain leadership in the rapidly evolving green aviation sector.

“This is an important milestone for LanzaJet and our investors, and it’s a major win for global aviation—perhaps serving as a beacon of hope for the future,” said Jimmy Samartzis, Chief Executive Officer of LanzaJet.

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Airbus to Update A380 Engine Software by Q1 2026

Airbus to Update A380 Engine Software by Q1 2026

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Outlook for Aviation MRO Surface Treatment Market Through 2030

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American Airlines Software Glitch Disrupts Thanksgiving Travel

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Airbus Limits A320 Operations in Cold Weather for Jets with Pratt & Whitney Engines

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Airbus Issues Repair Directive for 6,000 A320 Family Jets

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Urban Ascent: Coventry takes flight as a drone-ready City

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Chandrasekaran Says Air India Is a Responsibility, Not Just a Business Opportunity for Tata Group

Chandrasekaran Says Air India Is a Responsibility, Not Just a Business Opportunity for Tata Group

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Airbus Issues Emergency Recall of 6,000 A320 Jets Following JetBlue Incident

Airbus Issues Emergency Recall of 6,000 A320 Jets Following JetBlue Incident

Airbus Issues Emergency Recall of 6,000 A320 Jets Following JetBlue Incident Airbus SE has initiated an emergency recall affecting 6,000 A320-family aircraft worldwide after a recent incident involving a JetBlue jet revealed a critical software vulnerability linked to solar radiation. The recall, announced on Friday, mandates immediate repairs and has triggered widespread operational disruptions across major markets including the United States, Europe, Asia, and Latin America. Incident and Recall Details The recall was prompted by an event on October 30, when a JetBlue A320 experienced an unexpected loss of altitude due to a malfunction in its flight-control system. Airbus attributed the failure to intense solar flares that compromised essential data within the aircraft’s flight-control computers. In response, the manufacturer has ordered operators to revert to an earlier software version before the affected jets can resume passenger service. Airbus acknowledged the significant inconvenience caused, stating, “This action will lead to operational disruptions to passengers and customers. We apologize for the inconvenience.” This recall represents one of the largest in Airbus’s 55-year history and comes shortly after the A320 surpassed Boeing’s 737 as the world’s most-delivered jet. Technical Vulnerability and Repair Requirements The software flaw was identified in the Elevator and Aileron Computer (ELAC), which controls the aircraft’s pitch and roll functions. Airbus has warned that over 1,000 jets may also require hardware modifications, potentially prolonging downtime for some operators. The French aerospace supplier Thales Group clarified that the affected software is outside its scope of responsibility. According to an internal Airbus bulletin, all necessary repairs must be completed before the aircraft’s next flight, placing considerable pressure on airlines to expedite maintenance. Impact on Airlines and Travel Disruptions The recall has caused immediate and significant disruptions during a peak travel period. American Airlines, the largest operator of A320 jets globally, reported that 340 of its aircraft require the mandated fix. United Airlines is similarly affected. European carrier Air France has canceled dozens of flights, while Colombia’s Avianca has suspended ticket sales through December 8. Other airlines, including IndiGo, Lufthansa, easyJet, Volaris, and Air New Zealand, have issued warnings of delays and cancellations as they temporarily ground affected aircraft. Although most repairs are expected to take approximately two hours per jet, airlines have expressed concern that labor shortages and existing maintenance backlogs may hinder rapid restoration of service. Airbus Financial Performance Amid Recall Despite the operational challenges posed by the recall, Airbus reported a 7% increase in consolidated revenue, reaching €47.4 billion for the first nine months of 2025. This growth was driven by robust deliveries across its commercial, helicopter, and defense divisions. The company recorded 610 gross aircraft orders and 514 net orders during this period, ending with a backlog of 8,665 jets. Commercial aircraft revenue rose to €33.9 billion, supported by 507 deliveries, while Airbus Helicopters posted a 16% revenue increase to €5.7 billion. The emergency recall highlights the growing complexities and technological risks confronting the global aviation industry as manufacturers and airlines navigate operational pressures.
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