Topsoe from Denmark Supports U.S. Projects for the Production of Alternative Aviation Fuels
Copenhagen (Denmark) - The aviation sector worldwide is increasingly under pressure to reduce emissions and use alternative fuels. Alongside bio-based fuels, synthetic fuels and fuels derived from waste are coming more strongly into focus within the industry.
Industrial use of plastic waste planned
At the core of the project is the use of Topsoe’s HydroFlex® technology. The first plant is planned to be built in Baytown, Texas (USA). Once fully operational, each facility is expected to have a production capacity of around 1,500 barrels of renewable fuels per day. In total, three plants are planned.
The final investment decision for the Baytown site is expected by the end of 2026, with production scheduled to begin in 2029.
The plants are intended to use municipal and industrial plastic waste as feedstock, thereby tapping material streams that are currently largely landfilled or incinerated.
Technology for drop-in fuels – economic use of waste streams
The HydroFlex® technology enables the conversion of plastic waste as well as fats, oils, and other residual materials into renewable fuels that can be fed directly into existing infrastructure. These include diesel, chemical feedstocks, and sustainable aviation fuel.
These so-called drop-in fuels can be used in existing engines without technical modifications or blended with conventional fuels. This makes the technology particularly relevant for hard-to-decarbonize sectors such as aviation and heavy transport.
The projects are based on the idea of increasingly using plastic waste as a resource. According to the OECD, around 353 million tonnes of plastic waste are generated worldwide each year, of which only about 9 percent is recycled. The majority is currently not materially recovered.
Through chemical conversion processes, these waste streams are expected to be turned into fuels and chemical products in the future.
Industrial partnership between Topsoe and Abundia
Topsoe provides its HydroFlex® technology as the core process solution for the planned facilities, positioning itself as a technology partner for large-scale waste-to-fuels projects.
Henrik Rasmussen, CEO of Topsoe Americas, said: “Topsoe's technologies and solutions enable the conversion of liquified plastic waste into fuels.”
He added that the projects represent an important step toward unlocking new applications for plastic waste. The company also supports the industrial scaling of renewable fuels derived from waste streams.
Abundia also emphasized the importance of the technology. CEO Ed Gillespie said: “Topsoe’s HydroFlex® technology is globally recognized for its performance, reliability, and ability to consistently produce high-grade renewable products across the waste-to-value economy.”
He highlighted that the partnership is both part of the commercialization plan for 2026 and a long-term component of the company’s multi-project portfolio.
Significance for aviation and the energy transition
With increasing regulation of CO2 emissions in aviation, the importance of sustainable aviation fuels is growing. Technologies that convert waste into SAF are seen as a complementary pathway alongside bio-based and synthetic fuel solutions.
The projects by Topsoe and Abundia are part of a growing global market for alternative fuels, driven both by climate targets and the development of a circular industrial economy.
Source: IWR Online, 30 Apr 2026
