Lydian, an electric fuels company, unveiled the successful pilot demonstration of its sustainable aviation fuel (SAF) production technology for both commercial and defense sectors. The pilot plant, located at RTI International in North Carolina, has the capacity to produce up to 25 gallons of fuel per day. This achievement comes just three years after the company’s founding and with a fraction of the capital typically required for SAF demonstrations, marking a significant milestone for both Lydian and the SAF industry.
Lydian’s innovative process uses captured CO2, water, and renewable electricity to create a drop-in alternative to traditional fossil-based jet fuel, achieving up to 95% lower emissions. “In less than three years, we’ve moved from concept to pilot, a crucial step towards our long-term goal of decarbonizing aviation,” said Joe Rodden, CEO and co-founder of Lydian. “This pilot demonstrates the feasibility of our technology to produce SAF and our ability to scale quickly.”
Lydian’s power-to-liquids (PtL) technology is at the forefront of the evolving SAF industry. PtL approaches are gaining traction due to their scalable feedstock, primarily waste CO2 emissions, and minimal land and water usage compared to biofuels. This allows PtL technologies to achieve some of the lowest emissions in SAF production.
Addressing one of the key challenges of PtL technology—the significant electricity required—Lydian’s modular reactors are designed to operate flexibly, optimizing the use of low-cost renewable power. This not only reduces operating costs but also minimizes competition for clean power and lessens strain on the grid, a crucial factor as demand for renewable energy grows in sectors like computing and manufacturing.
“Our system design ensures no compromise on cost or efficiency,” said Dr. Branko Zugic, CTO and co-founder of Lydian. “Advancements in process intensification and conversion efficiency have led to breakthroughs that deliver unmatched cost and logistical advantages for both commercial and defense use.”
Lydian also received a DARPA award through the “Expeditionary Carbon Utilization for Energy Resilience and Stabilization” (ExCURSion) program, which aims to develop portable, closed, rechargeable power systems that store energy as carbon-based fuel. This award will support Lydian’s R&D efforts to create a prototype addressing the logistical challenges of supplying fuel in remote locations.
Fuel transportation is a critical issue for the U.S. Department of Defense (DoD), which consumes over 70 million barrels annually for global operations. Localized fuel production technologies like Lydian’s could significantly reduce the risks and costs associated with transporting fuel to remote areas, while improving energy security.
Looking ahead, Lydian plans to launch its first commercial-scale demonstration plant in 2027, followed by a full-scale commercial facility in 2030 with a production capacity of 20 million gallons per year. The company’s rapid progress is supported by a team of top scientists and engineers from NASA’s Jet Propulsion Lab, Anduril, the National Renewable Energy Laboratory, and leading academic institutions such as Stanford and MIT.
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