Swiss Metafuels Tackles SAF Costs with E-Methanol Innovation

Sustainable aviation fuels (SAFs) have become essential to global decarbonization strategies, but high costs and limited availability remain significant hurdles. Addressing these challenges, Swiss startup Metafuels has developed a cost-effective method to produce SAFs using e-methanol as a core input.

Based at the Paul Scherrer Institute (PSI) in Würenlingen, Switzerland’s largest research hub for natural and engineering sciences, Metafuels is advancing a pilot project and demonstration plant to produce e-SAFs. Unlike the widely used Fischer-Tropsch process, Metafuels employs methanol synthesis, a method its founders claim offers substantial advantages.

The methanol synthesis pathway converts carbon monoxide and hydrogen into methanol at high pressure using zinc oxide and copper catalysts. This methanol is then synthesized into longer-chain hydrocarbons, such as jet fuel. “It is all about converting methanol to SAF selectively and efficiently, where we believe we have a lead on competitors,” said Saurabh Kapoor, CEO, Metafuels, in an interview with Forbes.

“Compared to a Fischer-Tropsch project in the same location and conditions, our e-SAF production costs are anticipated to be 50% lower, with an 80% higher yield. These savings and efficiency gains are substantial,” Kapoor explained.

Metafuels’ laboratory pilot currently produces one liter of its branded e-SAF, Aerobrew, per day, while its demonstration plant has a daily capacity of 50 liters. “It can replace conventional jet fuel for any aircraft type, whether for short or long-haul flights. Our ultimate goal is to scale up to production trains of 2,000t per day,” said Leigh Hackett, chairman, Metafuels.

The startup is transitioning from research to commercialization. In December 2024, Metalfuels raised US$9 million in a funding round led by Celsius Industries, RockCreek, Fortescue Energy Ventures, and Verve Ventures. Combined with US$8 million raised in 2023 and a US$5 million grant from the Swiss Federal Office of Energy, the company has secured US$22 million in total funding.

In addition to producing e-SAFs, Metafuels plans to license its technology. Hackett announced agreements to establish facilities in Denmark and the Netherlands, each with a production capacity of 12,000L per day. The Danish plant is expected to begin operations in 2028.

“Decarbonization and competitiveness depend on the effective use of resources like CO2 and renewable energy,” Kapoor said.