Net Zero Liquid Fuel
UR Fuel’s Mission: To Provide Access to the World’s Energy. This project addresses the reduction of global greenhouse gas emissions with SAF made using hydroxyisovalerate and nutrients from liquid waste, specifically urine, for the fermentative production of biobased isobutanol in LDES apparatus, alongside ethanol offgas from DAC. UR Fuel Inc.'s innovative low energy input technology will initially support the SFO (San Francisco International Airport) efforts to reduce global greenhouse gas emissions by providing drop-in synthesized hydrocarbon fuels from urine waste streams producing ethanol, renewable energy sources, gaseous carbon oxides for SAF (Sustainable Aviation Fuel). The project proposes to create plug and play modular scalable sustainable net zero closed loop energy manufacturing facility modules partnering with local municipal wastewater treatments plants to expand throughout the County through prefabricated State permits and by using renewable energy sources from local power companies, as well as solar panels and urine fueled microbial fuel cells.
Challenge at the Local, National and Global Scope
Local: MOU: Airlines at SFO currently use over 1 billion gallons of jet fuel annually. If sustainable aviation fuel suppliers are able to increase global supply from the current 5 million gallons per year to 500 million gallons per year, the use of SAF could prevent nearly 4.8 million metric tons of greenhouse gas emissions per year – equivalent to taking over one million cars off the roads.
National: MOU: DOE, DOT and DOA: “…government wide commitment to scale up the production of SAF to 35 billion gallons per year by 2050. A near-term goal of 3 billion gallons per year is established as a milestone for 2030.”
Global: Bill Gates: Getting Around, ie. Planes, Trucks, Cargo Ships account for 16% of Global Greenhouse Gas Emissions. Of Transportation Related Emissions, Airplanes account for 10%.
● 51,000,000,000 x .16 = 8,160,000,000 Metric Tons Global Greenhouse Gas Emissions / Getting Around
● 816 Million Metric Tons of Global Greenhouse Gas Emissions are Attributed to Airplanes
UR Fuel project's successful outcome is to prevent nearly 816 Million Metric Tons of global greenhouse gas emissions by producing Net Zero Liquid SAF in a quantifiable and substantial amount towards the 85 Billion Global Gallons SAF needed for Airplanes per year.
III. Size and Capacity of the Project:
Total Addressable Market
Theoretical Total Addressable Market (Global) Considering a daily production of roughly 1.5–2 L of urine per person and a world population of 7.7 billion people, the daily global production of urine is estimated to be in the range of 1.16‐1.54×10^10 L which equates to 4.22–5.62×1012 L a year. (Urine in Bioelectrochemical Systems: An Overall Review).
Total Addressable Market (US Population) = 40 - 52 Billion Gallons / Year
Closed Loop FAA Total Addressable Market (US Passenger Aviation Liquid Waste to Power) = 9.79 Million Gallons / Year (US Market)
UR Fuel’s Serviceable Addressable Market Timeline Capacity to Scale:
2022-2024 Short Term Nameplate Capacity = 1,014,000 Gallons / Year
Closed Loop Local Addressable Market (SFO Passenger Aviation Liquid Waste to Power) = 151,724 Gallons / Year (SFO)
Short Term Nameplate Capacity defines the TRL 6, TRL 7, TRL 8
2023-2025 Midterm Construction and Operations (Phase 1): SFO - SAF Nameplate Capacity = 167,700,000 Gallons / Year
Total County Addressable Market (San Mateo County Urine to Power) = 110-150 Million Neat Gallons / Year (County)
Mid Term Nameplate Capacity defines the TRL 8 and TRL 9
2024-2027 Midterm Construction and Operations (Phase II): Multi Airport - SAF Nameplate Capacity = (7x) 167,700,000 Gallons / Year
Total Bay Area 7 County Addressable Market = 1.1 - 1.5 Billion Neat Gallons / Year (Bay Area - 7 County)
Mid Term Nameplate Capacity defines the TRL 10 and TRL 11
This Trajectory allows UR Fuel to near DOE, DOT and DOA’s government wide commitment to scale up the production of SAF to 35 billion gallons/year by 2050
2026-2030 Long Term: Capacity = (35x) 167,700,000 Gallons / Year US Airport - SAF
US Total Addressable Market (US Population) = 40 - 52 Billion Gallons / Year
Long Term expands the modular scalability model with locations in close proximity to US airports and regional municipal WWTPs.
Key Milestones for the Project: Short Term focus for the project is closed-loop sustainable feedstock supply from the local airport in 2022-2024 to define TRL 6, 7 and 8. Midterm moves the project to focus on regional (city and county) municipal liquid waste integration to test the viability for modular scalability in Phase I from 2023-2025 to define TRL 8 (scalable) and TRL 9. Phase II from 2024-2027 complete TRL 10 and 11. The regional integration findings will aid in the national rollout at local and regional airports from 2026-2030. This provides a substantial US case study for net zero liquid SAF from which to grow the global reduction of greenhouse gas emissions attributed to airplanes.
Technical and Commercial Feasibility: ATJ - SPK Practical Application for Modular Scalability Model: This proposal defines the product and manufacturing process, through scientific research and practical application to bring to market the best technologically innovative automated Liquid Waste to Fuel, fermentative to off-gas capture, dehydration, and distribution system to facilitate the renewable zero carbon transformation of liquid waste into jet fuel that can be produced safely and efficiently for any FAA regulated transportation setting. Safety: The project lead developer is also a California licensed architect. The Architect’s oath is to Protect the Public’s Health, Safety and Welfare. Safety is our top priority. Every measure possible will continually be taken to ensure the safety of all involved in this project.
Describe the successful outcomes anticipated by this Project: Successful outcome of this project is to produce Net Zero Liquid SAF needed at a production cost at or below the current retail cost of Jet Fuel 2.22 + LCFS $1.25 Incentive for SAF over conventional fuel totalling UR Fuel Retail SAF = $3.47/gallon, negating the Green Premium. Assumptions:
Retail Cost of Jet Fuel = $2.22/gallon
Current Zero Carbon Option
A. Advanced Biofuel $5.35 Green Premium 141%
LCFS has offered a ~$1.25 incentive for SAF over conventional fuel
B. Electrolysis $8.80 Green Premium 296%
(How to Avoid a Climate Disaster, Gates, Bill. 2021. pdf pp. 34)
Include the amount and type of capital requested from BEC (capital gap explanation and rationale to qualify for BEC funding). We recognize our company may be small potatoes compared to your other applicants. Therefore, we request a grant up to $15 Million to prove out TRL 6, 7 AND 8. If we can prove viability through permitting and engineering, we request additional capital.
2) Project Eligibility (1 page): Projects must meet the following requirements (a) the technology must be proven in conditions to be deployed (TRL 5 or greater) to reduce overall CO2 and is projected to move to a commercial scale project, with substantial development progress toward implementation of said project; (b) schedule to achieve full commercial operations no later than 12/31/2030; and (c) the Project is a fully commercial-scale operation with an established site and all components. The following eligibility also applies by technology.
A. TRL5 Large prototype: components proven in conditions to be deployed to reduce overall CO2 and is projected to move to a commercial scale project, with substantial development progress toward implementation of said project
B. Schedule to achieve full commercial operations by 12/31/2026. Construction is scheduled to start by the end of 2022.
C. The Project is a fully commercial-scale operation with an established site and all components
Technology: B. Sustainable Aviation Fuel
ASTM Qualified Pathway Technology: Alcohol to Jet
Code: ATJ-SPK
Alcohol to Jet (ATJ) ATJ was approved by ASTM for incorporation into ASTM D7566 in April 2016 using isobutanol at blend limit 50%. The ATJ process utilizes dehydration, oligomerization, and hydro processing to convert alcohol feed stocks to a pure hydrocarbon fuel blending component. In April 2018 Ethanol was included as an ATJ feedstock with a blend limit of 50%.
Description: Alcohols (ethanol or isobutanol) from any source converted to jet via dehydration, oligomerization, hydrogenation, and fractionation
Feedstock: Any feedstock (sugars, waste gases, etc.)
Max Blend Percent: 50%
3) Project Description (≤25 pages):
Description of the Project Design and Processes:
UR Fuel’s Mission is to Provide Access to the World’s Energy. We trust that this project will dissolve the assumption that our bodies are here to consume the environment’s energy sources. We propose that humans can be collaborative contributors with the environment to produce all the energy needed within a sustainable and regenerative mindset, framework and scalable model.
Biological production of isobutene has been known since the 1970s. UR Fuel builds on this knowledge in addition to relatively recent metabolic engineering developments. UR Fuel furthers these developments with a unique feedstock solution that enables anaerobic production of ethanol and isobutene at economically viable yields and production rates. Our process considers the conversion of 3-hydroxyisovalerate, which is found in urine, to isobutene, through activation of the enzymatic process mevalonate diphosphate decarboxylase. UR Fuel uses the fermentative production of isobutanol followed by isobutanol recovery and chemo catalytic dehydration. Post dehydration, UR Fuel undergoes an oligomerization process to convert the ethylene to olefins; elongating these molecules. In addition to urine’s amino acids providing expediency to the primary fermentation process, UR Fuel explores the potential of urine as a nitrogen source for lipid production using a proprietary Yarrowia Lipolytica strain. This is in addition to the pathway using fermentable sugars and yeast, Saccharomyces cerevisiae, to create a closed loop net energy to production of SAF. Post oligomerization, iso-olefins are then emulsified through Hydrogenation of these lipids and fractionation is undergone to isolate the paraffins from the isoparaffins. The final product is synthetic paraffinic kerosene (spk).
UR fuel’s unique process includes a “nutrients solution” and sustainable feedstock from urine and agricultural biomass waste. Initial fermentable pathways use glucose from biomass containing sugars (raisins and other local agricultural waste). A proprietary yeast similar to Saccharomyces cerevisiae (ScMDD) initially activates this pathway. Yarrowia Lipolytica will run parallel to be proven out to replace the need for glucose and Saccharomyces cerevisiae or run in conjunction to arrive at a pathway to Net Zero Liquid.
I. Initial Block Flow Diagram:
II. Industrial Design Bioreactor in Abstract Block Flow Diagram:
III. Critical Interfaces Outside the Scope/Boundaries of the Project
a. TRL 6, TRL 7 and TRL 8: SFO and airlines
b. TRL 8 and TRL 9: San Mateo County Wastewater Treatment Plant (WWTP)
c. TRL 10 and TRL 11: Bay Area 7 County Wastewater Pathway and associated airports
d. Expand modular manufacturing to network of airports and regions throughout the US
IV. Project Details Including: Size (Nameplate Capacity (gal(SAF)/hr)), annual capacity, nameplate capacity and estimated (specific and average) energy inputs at plant level (e.g., kWh/kgH2, ton(water)/ton(H2), etc.).
The Project Details defined below describe the Total Addressable Market from a First Principles Premise: that we, as humans, produce urine which can be converted into usable energy. For the purposes of UR Fuel, this project specifically focuses on human liquid waste, as a sustainable regenerative feedstock from which to produce SAF. The Aviation industry’s drive for SAF in the coming years provides a market distribution opportunity for the expansion of alternative net zero fuel and energy sources to permeate the country through its network of airports and their respective city and regional jurisdictions into the US and greater globe. With an appropriately designed small scale bioreactor, this technology can also be employed in more remote and developing locations.
Project Details and Model for Modular Scalability Across the Country:
UR Fuel’s business model is to partner with municipal wastewater treatment plants to provide a plug and play modular fermentation module to scale across the country providing SAF to local and regional airports.
Rationale:
● Starting with liquid waste instead of municipal solid waste for SAF has the added advantage of a lower energy input and therefore hastens the arrival of net zero liquid fuel.
● Many local Municipal Wastewater treatment plants throughout the country are currently undergoing upgrades.
● This Project mutually addresses municipal waste water initiatives. Wastewater treatment and release to natural bodies of water and soils can be costly and has come under environmental scrutiny.
● The dual SAF and wastewater treatment challenge becomes an opportunity and a mutually beneficial relationship.
According to the EPA, 16,000 publicly-owned wastewater treatment plants operate in the United States and its territories. The construction of wastewater treatment facilities blossomed in the 1920s and again after the passage of the CWA in 1972 with the availability of grant funding and new requirements calling for minimum levels of treatment. A majority of these facilities are now in need of renovation and upgrades.
In San Mateo County, where the San Francisco International Airport is located, wastewater from homes and businesses is collected by a network of pipes and pump stations. The wastewater is conveyed to the wastewater treatment plant (WWTP), and then treated for discharge to the San Francisco Bay.
The City of San Mateo is currently under a Cease and Desist Order to eliminate sewer overflows. Additionally, their discharge permit requires them to eliminate the blending that occurs under emergency conditions to manage heavy flows, as mandated by the Regional Water Quality Control Board.
The image below shows the current plan to upgrade their facility with completion in 2024. UR Fuel plans to partner with this effort to productively reuse a portion of the wastewater for SAF which has the added benefit of reducing the environmental concerns with its outflow to the San Francisco Bay.
The WWTP treats approximately 11 million gallons per day (mgd) of wastewater. Primary treatment uses gravity to remove solids from the wastewater. Secondary treatment uses biological processes to remove more dissolved waste matter from the wastewater. The WWTP can treat up to 60 mgd per day through primary treatment and 40 mgd through secondary treatment.
Their upgrade and expansion project consists of new liquids treatment process facilities, including a headworks, primary treatment, biological nutrient removal/membrane bioreactor process, biological and chemically enhanced high-rate wet weather treatment, and other plant upgrades, including odor control to serve the new facilities. The high-rate wet weather treatment process consists of a biological contact tank and high-rate clarification to provide secondary treatment of wet weather flows to eliminate blending and meet permit requirements. A new administration building for operations and maintenance staff will house the new main control room and laboratory. These facilities will be designed to provide advanced treatment to 21 mgd and allow the plant to better handle heavy storm events up to 78 mgd.
The Short Term addressable market unique solution for a closed loop SFO - SAF initiative is outlined and discussed below to define TRL 6, 7 and 8. This is precedent to test the scalable modular fermentation model. The Mid Term addressable market municipal wastewater to SAF initiative, will then run concurrently to demonstrate TRL 8 and TRL 9.
1. Servicable Addressable Market
A. 2022-2024 Short Term:
Nameplate Capacity = 1,014,000 Gallons / Year
Calculation: TRL 6, 7, 8
5,324 SQ FT Facility
70 Ft x 70 Ft
30 Tanks (7’ d x 10’ h) 2,600 Gallons / tank
78,000 gallons / harvest (off the shelf tanks)
13 harvests / year
1,014,000 gallons / year Nameplate Capacity
Project Construction and Operations 5,324 SQ FT Facility
Closed-Loop SFO - SAF Initiative
1. Closed Loop Passenger Aviation Neat SAF
Airplane urine is projected to produce 4,937 Gallons / Year (SFO airplane passenger liquid waste)
A. This provides continuous research development and testing as a closed loop stock from the vacuum toilets.
2. UR Fuel’s Closed Loop Local Addressable Market (SFO Airport Liquid Waste to Power) = 151,724 Gallons / Year (SFO)
Assumption is based on the following:
A. SFO Passenger Travel
1. 1,300 Flights / day (SFO)
2. 16,409,625 passengers / year (Total SFO Enplaned and Deplaned Passengers, 2020)
3. Assumption (1) 35mL urination / passenger trip
4. 574,337 Liters / Year
5. Total Theoretical Yield (100%) 151,724 Gallons / year
6. Actual TAM Yield closer to 70% = 106,206 Gallons / Year (SFO)
3. Short Term Nameplate Capacity defines the TRL 6, TRL 7, TRL 8
1. TRL 6: Full prototype at scale: prototype proven at scale in conditions to be deployed
2. TRL 7: Pre-commercial demonstration: solution working in expected conditions
3. TRL 8: First-of-a-kind commercial: commercial demonstration, full-scale deployment in final form
Once TRL 8 is established, The basis for expansion to supply Sustainable feedstock in the form of urine can be expanded to a Mid Term regional wastewater goal.
B. 2023-2025 Phase I - Mid Term:
Nameplate Capacity = 167,700,000 Gallons / Year
Calculation: TRL 8 and 9
300’ x 400’ = 120,000 sq ft facility @ $250/sq ft construction = $30,000,000
300 tanks (18.6’ d x 21.3’ h) 43,000 Gallons / tank
12,900,000 gallons / harvest
13 harvests / year
167,700,000 gallons / year Nameplate Capacity
Project Construction and Operations 120,000 SQ FT Facility
Regional San Mateo County - SFO - SAF Initiative
1. Phase I Regional Addressable Market (San Mateo County Urine to Power) = 110-150 Million Neat Gallons annually Assumptions based on the following:
a. San Mateo Population
1. 762,357 x (1.5-2 L / person daily) = 1,143,535 - 1,524,714 L
2. 417,390,458 L - 558,710,610 L annual
3. 110,262,894 G - 147,595,729 G
2. Mid Term Nameplate Capacity defines the TRL 8 and TRL 9
a. TRL 8 (scalable): First-of-a-kind commercial: commercial demonstration, full-scale deployment in final form (scalable)
b. TRL 9: Commercial operation in relevant environment: solution is commercially available, needs evolutionary improvement to stay competitive
C. 2024-2027 Phase II - Mid Term:
Nameplate Capacity = Seven Modules with 167,700,000 Gallons / Year
Project Construction and Operations (7X) 120,000 SQ FT Facility
Regional Bay Area 7 County - Multi-Airport - SAF Initiative
3. Phase II Regional Addressable Market (Bay Area 7 County Urine to Power) = 1.1 - 1.5 Billion Neat Gallons annually
Assumptions based on the following:
4. Population 7.753 Million x (1.5-2 L / person daily) = 11,629,500 L - 15,506,000 L
5. 4,244,767,500 L - 5,659,690,000 L annual
6. 1,121,348,942 G - 1,495,131,923 G
3. Mid Term Nameplate Capacity defines the TRL 10 and TRL 11
A. TRL 10: Integration at scale: solution is commercial but needs further integration efforts
B. TRL 11: Proof of stability: predictable growth
This initiative tests the scalable modular SAF model for Mid Term regional wastewater conversion goal for TRL 10 and TRL 11.
D. 2026-2030 Long Term:
Nameplate Capacity = 35 Modules with 167,700,000 Gallons / Year
Project Construction and Operations (35X) 120,000 SQ FT Facility
US Airport - SAF Initiative
1. US Total Addressable Market (US Population) = 40 - 52 Billion Gallons / Year
2. Long Term Nameplate Capacity is defined from Short and Mid Term Project findings in close proximity to US airports and municipal WWTP.
3. Term Nameplate Capacity defines the US Rollout to define a Global Model.
2. Total Addressable Market
A. Closed Loop Total Addressable Market (US Passenger Aviation Liquid Waste to Power) = 9.79 Million Gallons / Year (US Aviation Closed Loop)
Assumption is based on the following:
US Passenger Travel
1. 2.9 Million Passengers / Day (FAA)
2. 1,058,500,000 Passengers / Year
3. Assumption (1) 35mL urination / passenger trip
4. 37 Million Liters / year
5. Total Theoretical Yield (100%) 9.79 Million Gallons / year
6. Actual TAM Yield closer to 70% = 6.85 Million Gallons / Year (US Market)
B. US Total Addressable Market (US Population) = 40 - 52 Billion Gallons / Year (US Market)
Assumption is based on the following:
1. 329.5 Million (US Population) x (1.5 - 2 L) = 494,250,000L - 659,000,000L / daily
2. 180,401,250,000 L - 240,535,000,000 L / annual
3. 39,682,727,355 G - 52,910,303,140
C. Global Total Addressable Market (World Population) =
Assumption is based on the following:
1. 7.7 Billion People
3. Other Facility Sizes Considered are as follows:
Additional Options:
30 Tanks (15.5’ d x 17.9’ h ) 25,000 Gallons / tank
30 Tanks (18.6’ d x 21.3’ h) 43,000 Gallons / tank = 16,770,000 million gallons / year
200’ x 200’ = 40,000 sq ft facility @ $250/sq ft construction = $10,000,000
100 tanks (18.6’ d x 21.3’ h) 43,000 Gallons / tank
55,900,000 gallons / year
200’ x 400’ = 80,000 sq ft facility @ $250/sq ft construction = $20,000,000
200 tanks (18.6’ d x 21.3’ h) 43,000 Gallons / tank
111,800,000 gallons / year
300’ x 400’ = 120,000 sq ft facility @ $250/sq ft construction = $30,000,000
300 tanks (18.6’ d x 21.3’ h) 43,000 Gallons / tank
12,900,000 gallons / harvest
13 harvests / year
167,700,000 gallons / year Nameplate Capacity
400’ x 700’ = 280,000 sq ft facility @ $250/sq ft construction = $70,000,000
700 tanks (18.6’ d x 21.3’ h) 43,000 Gallons / tank
391 million gallons (391,300,000) / year
b) Technology description of the new or innovative technology solution included in the project (overview and deep dive on critical components/equipment) and a description of how and why the technology is new/unique, improved, and/or innovative to what is already in general use in the commercial marketplace. Please include a brief explanation of which technology options/alternatives have been considered, and a justification of the approach taken by the Project in the proposal.
Current Approaches to SAF: Include closed loop from Airport cooking waste and oils, not urine. Current approaches also include municipal solid waste, including wood etc. These feedstocks require greater energy input to convert solid to liquid than starting with a liquid, as this innovation proposes. Current approaches also include fermentable sugars, but these rely on food sources and greater amounts of land that will prove to be an unsustainable pathway.
In an effort to forge a truly net zero sustainable feedstock, UR Fuel explores the potential of urine as a nitrogen source for lipid production using a proprietary Yarrowia Lipolytica strain in addition to the pathway using fermentable sugars and yeast, Saccharomyces cerevisiae, to create a closed loop net energy to production of SAF.
New Unique Improved: Airplanes have pneumatic vacuum toilets which use flush valves to open and pull human waste through the plane’s sewer line into a 200-gallon holding tank. The waste is then vacuumed out by crews on the ground. Pneumatic vacuum toilets are not only efficient, they are undiluted with water and environmentally sensitive to water conservation and extraneous contamination.
The unique opportunity presented by pneumatic vacuum toilets on airplanes provides an undiluted closed loop sustainable feedstock scenario from which to define and deploy pathways TRL 6 and TRL 7 continuing to full scale commercial rollout of this technology.
Airports see a multitude of passengers, visitors and employees. A majority of these people use the bathroom facilities at the airport. Many airports have sustainability goals and the opportunity to capture data to understand and improve upon sustainability goals as it relates to SAF from urine fuel production, size and capacity through project growth.
Current waste water treatment challenge becomes an opportunity for SAF: According to the EPA, Nutrients: Carbon, nitrogen, and phosphorus are essential to living organisms and are the chief nutrients present in natural water. Large amounts of these nutrients are also present in sewage, certain industrial wastes, and drainage from fertilized land. Conventional secondary biological treatment processes do not remove the phosphorus and nitrogen to any substantial extent -- in fact, they may convert the organic forms of these substances into mineral form, making them more usable by plant life. When an excess of these nutrients overstimulates the growth of water plants, the result causes unsightly conditions, interferes with drinking water treatment processes, and causes unpleasant and disagreeable tastes and odors in drinking water. The release of large amounts of nutrients, primarily phosphorus but occasionally nitrogen, causes nutrient enrichment which results in excessive growth of algae. Uncontrolled algae growth blocks out sunlight and chokes aquatic plants and animals by depleting dissolved oxygen in the water at night. The release of nutrients in quantities that exceed the affected waterbody’s ability to assimilate them results in a condition called eutrophication or cultural enrichment.
c) Product Use & Transportation of project output including transportation mechanism (e.g., shipping, pipelines, etc.), distance to end-use from point of production (if applicable), storage (if applicable), end-use (e.g., re-electrification, fuel, etc.), form of end-use product (e.g., ammonia, etc.), etc.
Product Use & Transportation of project output Product use is Sustainable Aviation Fuel (SAF). Transport is initially via Truck and Rail.
SFO has undergone a regional study of the pipelines and SAF transportation options in the short, mid and long term.
UR Fuel’s short term strategic location of the Fermentable Bioreactor Modules at local airports and in close proximity to existing Municipal WasteWater Treatment Plants within the airport region provides a reduction in transportation distance to end-use.
Short term distance is 7 minutes (3.6 miles) to SFO trucking. Midterm is 10 minutes (6.5 miles). San Mateo wastewater treatment plant is also on the water, which provides an opportunity to initiate water transport as a viable transportation mode.
Storage
UR Fuel is developing patented mini bioreactor plug and play buildings (120,000 SQ FT) as a product to tie in to airports and wastewater treatment plants throughout the country. We consider this building small for the scale of production. A small footprint is ideal with a continuous production flow to supply the pipeline with SAF for the aviation industry. Storage in this case is minimal. Long duration storage is incorporated into the program of the bioreactor building scalable modules.
End use, form of end-use product (e.g., ammonia, etc.), etc.
Sustainable Aviation Fuel (SAF), Synthetic Paraffinic Kerosene (SPK) 100% Neat
d) Site details including location and justification for specific location, key site components (i.e., availability of water, electricity, gas, heat/steam, other utilities), site access (highways, rail, etc.), rights-of way, easements, other logistical considerations
Short Term Project operations are proposed at 1331 Rollins Road, Burlingame, CA, 3.6 miles from SFO. The Industrial 5,324 SF space can be leased for $10,648 / month. The existing building is part of the existing PG&E power grid. Which allows us to use 100% Renewable Energy. Water, electricity, and all other utilities are existing.
The industrial building consists of 23,000+/- net rentable sq. ft., situated on a 42,000 sq. ft. lot with 250 ft. prominent frontage. Other tenants include an auto repair shop. The building’s flexible layout can cater to a single tenant or multiple tenants.
Minimal Tenant Improvements are required and mainly refer to added safety measures to ensure proper CO2 monitoring of the direct air capture fermentation process and sanitization, as well as Hazardous Materials management plan. Ceiling heights are 18’.
Airport
San Francisco International Airport
7 min drive
3.6 mi
Oakland International Airport
33 min drive
28.6 mi
San Jose International Airport
32 min drive
30.1 mi
Freight Port
Port of Redwood City
Railroad
10.3 mi
Pacific American Services Oakland - CA
14.5 mi
Midterm phase 1 project operations are proposed at/in close proximity to the San Mateo WWTP, which is 10 minutes and 6.5 miles by road to SFO. Water transport is also possible.
Midterm phase II project operations are proposed at/in close proximity to the 7 county municipal wastewater treatment plants. If this project proves to be successful then the supply from these facilities will be greater than the regional SAF needs, and would fall into a different net zero supply chain.
Midterm project operations are also considered in Stockton and Areas with Existing Cold Dark Shell Warehouse Industrial Buildings. Transportation will be an added consideration for this option.
Long-term project operations are located at local airports and their regional Municipal wastewater treatment plants in close proximity to US airports regulated by the FAA.
e) Supply chain and acquisition strategy of all raw material, major feedstock, and consumables (including water and power), and equipment necessary. Include detailed descriptions of critical path agreements such as front-end engineering agreement; technology license and teaming agreements; engineering, procurement, and construction (EPC) contract; long-lead contracts, feedstock agreements, and plant off-take or sales agreements
Supply chain and acquisition strategy of all raw material, major feedstock, and consumables (including water and power)
Raw Materials such as Urine will be sourced from SFO and partner agreements with the waste hauling and municipal waste companies.
Industrial, fermentable sugars and glucose strategy includes partnering with local Salinas and Central Valley agricultural producers to source Agriculture biomass (raisins preferred) and waste
Saccharomyces cerevisiae mevalonate diphosphate decarboxylase enzyme will be sourced locally through local fermentation network at a very small scale. Final yeast will be a proprietary UR Fuel yeast.
Yarrowia Lipolytica will be produced on site using expression kit from Yeastern Biotech Co., Taiwan
Power generation for the initial 5,000 sq.ft. Facility does not require more than the existing 3 Phase, 120/208V 400 Amp service. Fermentation requires little energy input. The industrial building is on PG&E’s power grid. For a premium, the building can run on 100% renewable energy through the PG & E renewable energy program. Power generation strategy for future buildings includes solar and provision to produce UR Fuel microbial fuel cell power.
Water No added water is required for production because urine is predominantly water (95%). Water may/will only be used in cleaning the facility.
Equipment UR Fuel’s Industrial designed bioreactors are initially adapted from existing fermentation tanks and distillation equipment with added direct air capture.
Include detailed descriptions of critical path agreements:
Front-end engineering agreement
The project developer is a licensed architect, who has worked in the laboratory, industrial, fermentation, manufacturing, production, warehouse and distribution sectors providing a network of engineers and consultants for this project.
Metabolic, Chemical and Fermentation Engineering consultants as well as mechanical, electrical, plumbing structural, civil, sustainable infrastructure, wastewater and septic engineers are all within the architect’s network for this project.
Initial team will be a small group of experts in their respective field.
Technology license and teaming agreements
Our plan is not to use other technology licenses. We will want a teaming agreement within our own network and organization.
Engineering, procurement, and construction (EPC) Contract
We will hire an EPC Construction Contract Manager / Development Manager to oversee all aspects of the design and construction for Turn Key Operations.
Long-lead contracts, feedstock agreements, and plant off-take or sales agreements
The first effort in this project is to ensure we have an agreement with SFO for the front end Closed-Loop urine feedstock and offtake sales agreement for SAF.
a. Utility requirements including electricity and water. Details should include amount of power and water per unit produced (e.g., kWh/Nm3 of H2); estimated peak power demand in megawatts (MW); source of both power and water including REN power agreements, virtual or locational power purchase agreements, REC purchases, carbon intensity of power source and water source, etc.; and water disposal, if required.
UR Fuel will be a part of PG&E’s 100% Renewable Energy Program. Thus project operations will be Net Zero Energy from the Start.
PG&E 100% Renewable Energy Program
Net Zero Net Energy. The project provides 100 percent of total building energy load measured as kilowatt per square foot through solar panels, wind turbines, or other renewable sources.
Net Zero Water Use. The project provides on-site and/or off-site water usage off-sets to achieve net zero water use. Water usage off-sets may include grey water systems, the retrofit of plumbing fixtures in other buildings, etc.
Electricity: Electrical usage is estimated at 12 to 22 kWh/bbl (1 bbl = 42 gallons)
Gallons / Year
Electrical Use
Cost / month
5,000
2,619 kWh (218 kWh/month)
$560.48
150,000
78,571 kWh (6,548 kWh/month)
$1,681.44
1,000,000
523,809 kWh (43,651 kWh /month)
$9,577.94
150,000,000
78,571,429 kWh (6.5 mil kWh/month)
$1,189,575.42
The above yearly electricity demands table is projected through TRL 8 only.
Water No added water is required for production because urine is predominantly water (95%). Water may/will only be used in cleaning the facility. Water source is SFO, airports, municipal wastewater treatment plants and CalWater - California Water Service.
f) Timeline for construction, permitting, licensing, regulatory approval, and financing, please provide graphically. Indicate financial close/final funding decision, construction, commercial operation date.
USES
PRODUCTION
TRL 6,7,8
FLAGSHIP
TRL 8,9
TRL 10, 11
Schedule
SQ FT
NAME PLATE CAPACITY
June 2022- June 2024
5,324
1 million gallons / year (4,937 Gal/Yr & 151,724 Gal/Yr)
1
2023-2025
120,000
167 million gallons / year
1
2024-2027
120,000
1.3 billion gallons / year
7
2026-2030
120,000
3.3 billion gallons / year
g) Emissions reduction (optional) in metric tons CO2/unit produced. Please show all relevant calculations, source of carbon intensity methodology for calculations, including assumptions and justifications. Detail how this project will avoid/abate emissions now and/or in the future. Please note that this does not have to be full LCA calculation based on ISO standards, but at the minimum should include power/energy input sources and the estimated C-content.
From 2022-2024, UR Fuel can prevent .0096 million metric tons of GHG emissions. (1/500 of 4.8 million metric tons).
From 2023-2025, UR Fuel can prevent 1.44 million metric tons of GHG emissions. (.3 x 4.8 million metric tons.
From 2024-2026, UR Fuel can prevent 12.48 million metric tons of GHG emissions. (2.6 x 4.8 million metric tons.
From 2026-2030, UR Fuel can prevent 31.68 million metric tons of GHG emissions. (6.6 x 4.8 million metric tons.
Challenge at the Local, National and Global Scope
Local: MOU: Airlines at SFO currently use over 1 billion gallons of jet fuel annually. If sustainable aviation fuel suppliers are able to increase global supply from the current 5 million gallons per year to 500 million gallons per year, the use of SAF could prevent nearly 4.8 million metric tons of greenhouse gas emissions per year – equivalent to taking over one million cars off the roads.
National: MOU: DOE, DOT and DOA: “…government wide commitment to scale up the production of SAF to 35 billion gallons per year by 2050. A near-term goal of 3 billion gallons per year is established as a milestone for 2030.”
Global: Bill Gates: Getting Around, ie. Planes, Trucks, Cargo Ships account for 16% of Global Greenhouse Gas Emissions. Of Transportation Related Emissions, Airplanes account for 10%.
● 51,000,000,000 x .16 = 8,160,000,000 Tons Global Greenhouse Gas Emissions / Getting Around
● 816 Million Tons of Global Greenhouse Gas Emissions are Attributed to Airplanes
UR Fuel project's successful outcome is to prevent nearly 816 Million Metric Tons of global greenhouse gas emissions by producing Net Zero Liquid SAF in a quantifiable and substantial contributing amount towards the 85 Billion Global Gallons SAF needed for Airplanes per year by starting nationationally to provide a contributing amount towards the 3 billion gallon goal by 2030 and the 35 billion gallon goal by 2050.
h) Details on permitting requirements and status. Identify and list all relevant interconnection, siting, approvals and permits and anticipated timelines for regulatory approval. Outline progress toward these permits and identify any risk/challenges/mitigations in achieving these permits. Submissions must include but are not limited to air emissions, liquid and solid waste, interconnection, siting, construction, and local and regional regulatory requirements.
Official permitting process will begin at financial close. FEL engineering for the existing facility and the pre-fabricated scalable modules will begin concurrently. Permitting requirements include updates to occupancy and use to include B (use of a building or space within the building for office transactions, including storage of records and accounts), F-1 Moderate Hazard Industrial and H-3 Hazardous Industrial (use of a building or space within a building for industrial operations that include high hazard materials, processes, or contents; and S-1 Moderate Hazard Storage (use of a building or space within a building for storage that is classified as a hazardous occupancy and does not include S-2 low-hazard, non-combustible materials).
UR Fuel will need to permit at the local, regional and state level. Local and Regional Building Permits are required initially to begin construction on Tenant Improvements to the existing building in December 2022. Once TRL 6 and TRL 7 are complete, State Level prefabrication permits will be sought to rapidly scale and deploy this technology, as plug and play modules for state inspection prior to installation at locations along wastewater pipelines.
i) BEC requests that the Respondent identify any significant federal and/or state legal requirements that are applicable to the Project, whether pending or complete, that have, or could have, a material impact on the schedule and/or cost of the project, including without limitation, the following: All of these regulatory requirements are considerations for this project.
1. National Environmental Protection Act (NEPA)
2. Endangered Species Act
3. California Environmental Quality Act (or similar state law)
4. Buy American Act
5. State Prevailing Wage
6. Collective Bargaining
7. Any other state/federal legal requirements that could impact schedule/cost
Additional interface includes Bay Area Quality Management District, State Water Resources Control Board, as well as local and state building and public works permitting jurisdictions. As well as ASTM and UL Certifications and OSHA.
SAF advocates, successfully lobbied the California Air Resources Board to expand the Low Carbon Fuel Standard (LCFS) to offer the opt-in inclusion of SAF. As a result, since January 1, 2019, the LCFS has offered a ~$1.25 incentive for SAF over conventional fuel. This incentive helps level the playing field between conventional fossil-based aviation fuel and the sustainable alternative, currently making California the world’s most competitive market for SAF. SFO continues to convene a SAF Coalition to advocate for additional incentives at the state and federal level to further decarbonize the industry and help SFO hit its goal of 5% SAF by 2025.
If California could fuel switch to 5% SAF by 2025, the state could reduce aviation GHG emissions 80% on a lifecycle basis, totaling up to 2 million metric tons by 2025. That’s the equivalent of removing 432,000 passenger vehicles per year or ⅔ of those registered in the county where SFO is located - San Mateo. According to the California Air Resources Board, in 2015 commercial aircraft accounted for 8.5% of our state’s greenhouse gas emissions. Without growing SAF use, aviation sector emissions are expected to grow to over 25% of California’s emissions by 2040, as other sectors (e.g., buildings, road transport) already have full decarbonization pathways enabled by robust and perpetual grants, incentives, tax credits and clear permitting pathways not yet focused on serving our skies. SFO SAF
4) Project Risk Assessment (<10 pages)
Project Risk Assessment (<10 pages), including a description and critical assessment of key project risks, along with a description of mitigants to the risks. Topics include may include the following (list is non exhaustive):
a) Technology (pending patents, licensing agreements, etc.)
Provisional patent on an earlier technology has been filed. We will file patents. Certainly, to mitigate this we would file them as soon as possible with a patent attorney and legal counsel. Currently we do not anticipate any licensing agreements.
b) Development (land/site, long-lead time for equipment, construction cost, performance, schedule, force majeure, etc.)
Long lead time development items include the Prefabricated ATJ-SPK fermenter modules. We are mitigating this risk by phasing that part of the construction and working through TRL six and seven with adapted off-the-shelf fermentation and septic tanks as well as other equipment adapted for use, testing and certification.
c) Operations (performance, including guaranteed output failures/force majeure)
We will need to dance a fine line between not biting off more than we can chew and setting aggressive objectives and key results. We are also trusting that our business model using a closed loop system will allow us to tie our production outputs back to the source urine inputs, which will be monitored to provide real time data and feedback to our customers.
d) Market price risk(s) and feedstock supply and cost risk
Using urine, partnering with airports and municipal wastewater treatment plants could be a first to market risk. Agricultural agreements throughout California could also be a risk. This is mitigated by moving fast to secure agreements.
e) Environmental & safety (EHS)
This is always a risk in working with sustainable aviation fuel and hazardous materials. This is mitigated by having a dedicated team to ensure the environmental and safety measures of the company, people and equipment.
f) Credit risk (Sponsor credit risk, Transaction party credit/payment risk, etc.)
Advice in this area would be appreciated.
g) Political risk (legal, regulatory, project financial, tax incentives, etc.)
The father of the project developer’s childhood best friend has 38 years experience as an attorney in energy and power plant construction law and litigation on a national basis, including transmission EPC and renewable EPC contracting with values totaling between $15-$20 billion. We will bring him on at various stages in this project.
h) Geographic risk (economic, currency controls, foreign currency exchange, etc.)
UR Fuel plans to source directly from the US (except for the Yarrowia expression kit from Taiwan). We realize local supply chain sourcing may increase difficulty in reaching retail jet fuel rate goals. Currently, it is the most sustainable option. If we find this local sourcing ideal to be problematic, we will pursue financial market and legal advice on this matter.
i) Disputes (litigation, investigation, or threats from any third party or regulatory body or court against or impacting the Project or its schedule/cost).
Alternative dispute resolution will be prioritized. The father of the project developer’s childhood best friend has 38 years experience as an attorney in energy and power plant construction law and litigation on a national basis, including transmission EPC and renewable EPC contracting with values totaling between $15-$20 billion. We will bring him on at various stages in this project.
j) Permitting risk (including opportunities for intervention by third parties or discretionary reviews)
This is reasonably well understood by the project developer as an architect. Experts in hazardous materials and oil and gas projects will be brought in to mitigate some of these risks.
Alternative dispute resolution will be prioritized. The father of the project developer’s childhood best friend has 38 years experience as an attorney in energy and power plant construction law and litigation on a national basis, including transmission EPC and renewable EPC contracting with values totaling between $15-$20 billion. We will bring him on at various stages in this project.
5) Project Maturity (3 pages): Provide the following details about the proposed Project.
a) FEL and justification - The project developer is also an architect; who prioritizes preplanning, scientific research, design and engineering, project scheduling, financial and construction feasibility prior to execution. FEL, front end loading and FEED, Front end engineering and design go hand-in-hand. UR Fuel’s bioreactors are completely re-thought and subsequently redesigned compared to what is existing in the industry; even in the sustainable sector. Engineering is prioritized with a multidisciplinary approach between scientists and engineers, contractors and automation experts. The use of building information modeling and additive manufacturing allows us to economically and rapidly prototype these bioreactors to test them prior to the full scale fabrication and implementation.
b) TRL and justification
TRL5 Large prototype: components proven in conditions to be deployed to reduce overall CO2 and is projected to move to a commercial scale project, with substantial development progress toward implementation of said project.
UR Fuel is proposing an ASTM Qualified Pathway Technology: Alcohol to Jet. Code: ATJ - SPK. Alcohol to Jet (ATJ) ATJ was approved by ASTM for incorporation into ASTM D7566 in April 2016 using isobutanol at blend limit 50%. The ATJ process utilizes dehydration, oligomerization, and hydro processing to convert alcohol feed stocks to a pure hydrocarbon fuel blending component. In April 2018 Ethanol was included as an ATJ feedstock with a blend limit of 50%. Because ethanol was included in April 2018 as an ATJ feedstock with a blend limit of 50%, our UR Fuel project is viable.
Description: Alcohols (ethanol or isobutanol) from any source converted to jet via dehydration, oligomerization, hydrogenation, and fractionation
Feedstock: Any feedstock (sugars, waste gases, etc.)
Max Blend Percent: 50%
c) Identification of any (critical) components still in development and the respective TRL, timeline for maturity, and supply
Critical pathway is in the Connection and Automation of the components to run the entire full prototype system at scale. Thereafter, fine tuning the engineering of the system.
Automation of the Dehydration -> Oligomerization -> Hydrogenation -> Fractionation process is a critical path.
We expect by March of 2025 to have the Full Prototype at Scale Defining TRL 6.
We would expect to have a Pre-commercial demonstration two months later by May 2023 with our solution working in expected conditions Defining TRL 7. The continued operation defines TRL 8 through June 2024 in the 5,324 SF Facility.
Short Term Nameplate Capacity defines the TRL 6, TRL 7 and TRL 8
TRL 6: Full prototype at scale: prototype proven at scale in conditions to be deployed
TRL 7: Pre-commercial demonstration: solution working in expected conditions
TRL 8: First-of-a-kind commercial: commercial demonstration, full-scale deployment in final form
d) Supply chain maturity detail identifying if all critical components are commercially and readily
available and if suppliers been identified and secured
We are in the process of defining our supply chain detail. We have identified that critical components are readily available. We will budget for ERP to integrate and optimize our supply chain.
e) Outstanding matters such as disputes or controversies
N/A
f) Prototype and/or demonstration detail including name, location, scale, one line of detail, and a brief description of the intent, testing protocol and results, and funding. If the results were verified by an independent third party, please provide contact information for that entity.
Initial experimentation was to verify that urine could provide an actively supported fermentation of Saccharomyces cerevisiae together with glucose and raisins nutrient solution. In addition, Direct Air Capture could be accomplished. The demonstration was successful. The results were tested by Atmospheric Analysis & Consulting, Inc. www.aaclab.com (850) 650 - 1642
6) Market Analysis (5 pages)
6) Market Analysis (5 pages): Explain the market challenge your Project is solving and the value it will provide to the proliferation of the technology under consideration.
a) Provide the key finding of your market analysis including competitors and demand.
Challenge at the Local, National and Global Scope
Local: MOU: Airlines at SFO currently use over 1 billion gallons of jet fuel annually. If sustainable aviation fuel suppliers are able to increase global supply from the current 5 million gallons per year to 500 million gallons per year, the use of SAF could prevent nearly 4.8 million metric tons of greenhouse gas emissions per year – equivalent to taking over one million cars off the roads.
National: MOU: DOE, DOT and DOA: “…government wide commitment to scale up the production of SAF to 35 billion gallons per year by 2050. A near-term goal of 3 billion gallons per year is established as a milestone for 2030.”
Global: UR Fuel project's successful outcome is to prevent nearly 816 Million Metric Tons of global greenhouse gas emissions by producing Net Zero Liquid SAF in a quantifiable and substantial amount towards the 85 Billion Global Gallons SAF needed for Airplanes per year.
Competitors: Chevron, Shell, Neste and LanzaTech
b) Indicate how the analysis demonstrates a market need and gap for your technology solution and the ability to scaleup your solution for large-scale commercial deployment.
In both the National and SFO MOU, these organizations explicitly state the need, short supply and the market readiness for Sustainable Aviation Fuel.
Already, SFO is working on a study to identify the necessary supply chain and infrastructure required to make this expansion of SAF at the Airport a reality, and is preparing an implementation plan to do so. SFO is posturing for increased interest in the California market for SAF producers and suppliers, given the additional incentives likely to be made available, through a California Air Resources Board ruling allowing the opt-in inclusion of SAF in the Low CarbonFuel Standard (LCFS). This is the first sub-national government to offer any incentive for the benefits provided by SAF.
c) Identify the anticipated end use customer(s) and details on product use. Identify if there is a mid-tier customer for processing and delivery of your product. What is the method of transport and the expected distance to the end user?
Anticipated end use customers include SFO Initially, then Regional and other US Airports, as well as airlines and the government. Mid-tier customers may be airports specifically. The final product is ATJ Alcohol to Jet 100% neat SAF. This allows for a max 50% blend with conventional jet. Truck and Rail is anticipated.
d) Identify the status of any and all offtake agreements or refining and/or transportation agreements as relevant including name of entity, status of agreement negotiations, and amount of offtake.
Following are UR Fuel’s anticipated offtake agreements:
Retail
LCFS Inc.
Offtake Agreements
TRL 6,7,8
FLAGSHIP
TRL 8,9
TRL 10, 11
Quantity
Revenue
2.22
1.25
SFO 5,000 Gal/Yr
17,350
2.22
1.25
SFO 150,000 Gal/Yr
520,500
2.22
1.25
SFO 1,000,000 Gal/Yr
3,470,000
2.22
1.25
SFO + US Airports/Airlines + Govt 150,000,000 Gal/Yr
520,500,000
3,643,500,000
6,246,000,000
TOTAL REVENUE
4,007,850
520,500,000
3,643,500,000
6,246,000,000
YEARLY REVENUE BY 2030
$10,414,007,850
In addition, we anticipate the need for transportation agreements. Refining agreements could be a pathway to be determined at the end of TRL 8 prior to flagship.