Biogenic eSAF Refinery
Integrated Sugarcane, Ethanol & Sustainable Aviation Fuel Complex · Luzon, Philippines
This memorandum sets out an investment opportunity in a vertically integrated biogenic eSAF (electro‑sustainable aviation fuel) facility in Luzon, Philippines, co‑located with an expanded sugarcane plantation and ethanol distillery complex developed in partnership with the Department of Agriculture (DA). The facility converts biogenic CO₂ recovered from sugar fermentation and green hydrogen produced by solar‑powered electrolysis into biogenic eSAF through indirect hydrogenation — a Reverse Water‑Gas Shift (RWGS) step followed by Advanced Fischer–Tropsch (FT) synthesis and refining.
Phase 1 is sized at 10,000 tonnes per year of biogenic eSAF (approximately 220 barrels per day), scaling to 50,000 t/yr in Phase 2 and 100,000 t/yr in Phase 3. Reconciled Phase 1 capital investment is $275–400 million, with a project‑level levered equity IRR of 13% in the base case, 22% optimistic and 6% pessimistic, underwritten on the integrated biorefinery as described in the Economics page.
Basis of preparation & quantitative conventions
To allow every headline figure to be reproduced independently, one set of conventions is applied throughout:
- Fuel density ρ = 0.80 kg/L (jet cut, 15 °C). One tonne = 1,250 L; 10,000 t/yr = 12.5 ML/yr ≈ 215–220 bpd. All $/L, $/tonne and bpd statements are mutually convertible on this basis.
- Fermentation CO₂ yield = 0.955 kg CO₂/kg ethanol (stoichiometric; derivation on the Appendices page). The frequently‑cited 0.49 figure is CO₂ per kg glucose and is not used.
- Hydrogen is fixed by product carbon. For a (CH₂)ₙ syncrude the combined RWGS + FT net reaction is CO₂ + 3 H₂ → (CH₂) + 2 H₂O; 10,000 t product (≈ 8,500 t C) therefore requires ≈ 4,280 t H₂/yr and ≈ 31,100 t CO₂/yr. The electrolyzer is sized to this requirement (40 MW).
- One capital schedule. The component list sums exactly to the headline; contingency is computed on the reconciled subtotal; maintenance is 3% of the same figure.
- Two economics scopes, bridged. Returns are reported separately for the standalone eSAF plant and the integrated biorefinery, with an explicit bridge. Contingent revenues (US §45Z, EU mandate premium, voluntary carbon) appear only in a labelled upside case.
- Regulatory figures. The overall EU SAF obligation ladder is stated as enacted; the synthetic‑fuel sub‑target percentages used in the market model are flagged as project assumptions to be confirmed against Regulation (EU) 2023/2405 and its implementing acts during due diligence.
- Indicative balances. Mass, energy and efficiency tables are simplified site balances for orientation; a detailed heat‑and‑power balance and a certified life‑cycle assessment are front‑end engineering deliverables.
Use the navigation bar above to move between sections; sections 8 onward are under More. This file is a single self‑contained document and prints section‑by‑section.
1Executive Summary
1.1 Investment Opportunity
We present an investment opportunity in a vertically integrated biogenic eSAF facility in Luzon, Philippines, co‑located with an expanded sugarcane plantation and ethanol distillery complex developed in partnership with the Department of Agriculture (DA). The facility converts biogenic CO₂ from sugar fermentation and green hydrogen from solar‑powered electrolysis into biogenic eSAF via indirect hydrogenation (RWGS + Advanced FT). Phase 1 produces 10,000 t/yr (~220 bpd), scaling to 50,000 t/yr (Phase 2) and 100,000 t/yr (Phase 3). Reconciled Phase 1 capital is $275–400 million, with a project‑level levered equity IRR of 13% base / 22% optimistic / 6% pessimistic on the integrated biorefinery.
Product positioning. The output is biogenic eSAF, a premium aviation fuel expected to trade above conventional SAF. The base case prices the product at eSAF parity of $4.50/L (=$5,625/t at ρ=0.80), a deliberately conservative anchor relative to the biogenic/synthetic scarcity premium of $5.00–6.00/L the project is positioned to capture. This gives the revenue line downside anchoring while retaining the premium as disclosed upside.
1.2 Key Investment Highlights
| Highlight | Detail |
|---|---|
| Core value proposition | Biogenic CO₂ + green H₂ → biogenic eSAF, priced at parity with disclosed upside to premium |
| Product premium | Parity $4.50/L vs. conventional SAF $1.20–1.80/L = 2.5–3.75× (4.50÷1.80 to 4.50÷1.20); premium case $5.00–6.00/L |
| Feedstock advantage | Fermentation CO₂ at 95–99% purity — lowest‑cost carbon source among the PtL options considered ($10–20/t incl. polishing) |
| Location | Luzon — established sugar infrastructure, 4.5–5.5 kWh/m²/day solar, DA partnership |
| Government partnership | DA — plantation expansion, distillery construction, outgrower scheme |
| Energy integration | 88 MW solar PV (green H₂) + 15–25 MW bagasse cogeneration (firm heat & make‑up power) on one site |
| Technology | RWGS + Advanced FT, tier‑1 licensors; unit operations commercial, integration first‑of‑a‑kind |
| Policy tailwinds | EU ReFuelEU synthetic‑fuel sub‑obligation, US SAF Grand Challenge, CORSIA, RA 9367 / RA 9513, BOI / PEZA |
| Carbon intensity | Target 5–15 g CO₂‑eq/MJ on a certified well‑to‑wake boundary vs. 89 for fossil jet |
| Vertical integration | DA sugarcane + ethanol distillery + eSAF plant + bagasse CHP on one site; diversified cash flow |
| Scalability | Modular design; Phase 2 builds on shared infrastructure and the DA partnership |
| De‑risking strategy | Phase 1 at 220 bpd validates integration, economics and offtake before Phase 2/3 |
1.3 Investment Thesis
- Structural demand. Long‑haul aviation cannot be electrified; eSAF is its principal decarbonisation pathway. EU ReFuelEU mandates a synthetic‑fuel sub‑category that biomass‑based SAF (HEFA, ATJ, biomass gasification‑FT) cannot satisfy, creating dedicated volume. Whether this product — whose carbon is fermentation (biogenic) CO₂ — falls inside that synthetic sub‑category is the load‑bearing commercial question; it is pursued as a defined workstream and priced under both outcomes rather than assumed.
- Product premium with disclosed conditionality. The base case books parity ($4.50/L); the premium ($5.00–6.00/L) and the carbon‑source classification that unlocks it are presented as upside, with a reclassification downside priced into the pessimistic case.
- Feedstock moat. Co‑location with the DA‑partnered plantation yields ultra‑low‑cost biogenic CO₂ ($10–20/t vs. $40–80/t industrial capture) plus a waste‑derived bagasse energy stack; the DA partnership secures land, agronomy and social licence.
- Honest first‑of‑a‑kind framing. Unit operations are commercial; the integrated biogenic‑CO₂ + green‑H₂ train is first‑of‑a‑kind. Phase 1 at 220 bpd is a validation platform financed on a grant/DFI‑weighted basis, with the equity return underwritten on the integrated biorefinery and the Phase 2/3 scale option.
- Diversified, policy‑supported cash flow. Ethanol (RA 9367 E10), sugar, syncrude co‑products, oxygen and surplus power export carry the integrated project; BOI pioneer status, RE Act incentives and concessional climate finance lower the effective cost of capital.
- ESG alignment. Very‑low carbon intensity in Phase 1, with a scoped Phase 2+ pathway toward carbon‑negative via bagasse‑flue capture; eligible for green bonds, climate funds and DFI mandates.
2Market Opportunity
2.1 Global eSAF Market
| Metric | 2025 | 2030 | 2035 | 2050 |
|---|---|---|---|---|
| Global jet fuel demand (billion L) | 310 | 340 | 380 | 450 |
| Total SAF obligation (EU, % of jet) — enacted ladder | 2% | 6% | 20% | 70% |
| Synthetic‑fuel sub‑obligation (modelled — see note) | — | 1.2% | 5% | 35% |
| Implied synthetic demand (billion L) | ~0 | 4.1 | 19 | 157.5 |
| Synthetic / eSAF price ($/L) | 4.00–6.00 | 3.00–4.50 | 2.00–3.50 | 1.50–2.50 |
Reading the regulatory figures
The total SAF obligation row is the ladder enacted in Regulation (EU) 2023/2405 (ReFuelEU Aviation): 2% (2025), 6% (2030), 20% (2035), 34% (2040), 42% (2045), 70% (2050). The synthetic‑fuel sub‑obligation row (1.2% in 2030 rising toward 35% of the blend by 2050) is the figure used in this project's market model and in the implied‑demand row; it is presented as a project assumption to be confirmed against ReFuelEU and its implementing delegated acts during due diligence, not as a quotation of a fixed statutory percentage. The implied‑demand column is simply the modelled sub‑obligation percentage applied to the jet‑demand column (e.g. 1.2% × 340 = 4.1 bn L). The 2030 price band of $3.00–4.50/L brackets the base‑case parity assumption of $4.50/L, so the revenue line is consistent with the mandate‑year curve rather than optimistic against it.
2.2 eSAF vs. SAF Pricing
| Product | Price ($/L, 2024–25) | $/t @ 0.80 | Price driver |
|---|---|---|---|
| Fossil jet fuel | 0.80–1.20 | 1,000–1,500 | Crude oil market |
| Conventional SAF (HEFA) | 1.20–1.80 | 1,500–2,250 | UCO/tallow cost + hydrotreating |
| eSAF (power‑to‑liquids) | 3.00–6.00 | 3,750–7,500 | Green H₂ + CO₂ capture + synthesis |
| Biogenic eSAF (this product) | 4.00–6.00+ (expected) | 5,000–7,500+ | Biogenic/synthetic premium + green H₂ + synthesis |
| Base‑case booking | 4.50 | 5,625 | Parity, conservative to the premium |
Pricing at $4.50/L ($5,625/t) sits below the expected biogenic premium and above the 2030 mandate‑year midpoint, providing downside anchoring with the premium retained as disclosed upside.
2.3 Competitive Landscape and Product Category
| Pathway | Feedstock | Technology | CI (g CO₂e/MJ) | Cost ($/L) | TRL | Counts toward synthetic sub‑obligation? |
|---|---|---|---|---|---|---|
| HEFA (used cooking oil / tallow) | Waste oils | Hydrotreating | 10–20 | 1.20–1.80 | 9 | No — biomass‑based |
| ATJ | Ethanol | Dehydration + oligomerisation | 20–40 | 1.50–2.50 | 7–8 | No — biomass‑based |
| PtL (industrial CO₂) | Point‑source / DAC CO₂ + green H₂ | RWGS + FT | 0–15 | 3.00–5.00 | 6–7 | Yes — synthetic |
| Gasification + FT | MSW / biomass | Gasification + FT | 20–40 | 1.80–3.00 | 7–8 | No — biomass‑based |
| This concept (biogenic PtL) | Fermentation CO₂ + green H₂ | RWGS + Adv. FT | 5–15 | 2.80–3.80 (production) | 7–8 | Under confirmation (§11.2) |
Two distinct questions — kept separate
(a) Settled. Under ReFuelEU, biomass‑based pathways (HEFA, ATJ, biomass gasification‑FT) do not count toward the synthetic‑fuel sub‑obligation; only fuels from a non‑biological carbon source do. This is the structural reason a synthetic sub‑market exists at all, and it is not in doubt. (b) Open. Whether this product — whose carbon is fermentation (biogenic) CO₂ — meets the non‑biological‑carbon definition, or is instead classified as recycled‑carbon / biomass‑based, is the live question. It is being established through a formal regulatory opinion and an ISCC / EU RED III chain‑of‑custody determination (§11.2). Two outcomes are carried in the model: (i) synthetic eSAF — premium and sub‑obligation demand apply (base/optimistic); (ii) recycled‑carbon / biomass‑based SAF — the product still displaces fossil jet at a 65%+ GHG saving and counts toward the broader SAF obligation and CORSIA, but at the lower SAF band ($1.50–3.50/L); this is the structural downside in the pessimistic case. The category is therefore a modelled, hedged variable, not an assumption.
Advantages that hold under either categorisation: the lowest‑cost carbon source among the PtL options considered; a target carbon intensity within the range reported for PtL pathways and far below the fossil‑jet baseline; and a government‑secured feedstock and energy stack. The synthetic‑eSAF premium is additive to these and conditional on §11.2.
3Project Description
3.1 Location: Luzon, Philippines
| Factor | Luzon advantage |
|---|---|
| Sugar infrastructure | Established industry; existing mills, distilleries, agronomy (Batangas, Laguna, Pampanga, Tarlac, Pangasinan) |
| Climate | Tropical; year‑round cultivation, up to two harvests in some areas |
| Solar resource | 4.5–5.5 kWh/m²/day — excellent for PV |
| Land | Agricultural land available for expansion; DA partnership facilitates access |
| Labour | Skilled agricultural and industrial workforce at competitive cost |
| Logistics | Proximity to Manila port/airport and fuel distribution; road/rail |
| Policy | RA 9367 (E10); RA 9513 (RE incentives); BOI/PEZA pioneer incentives |
| Water | River/groundwater for process and irrigation, on a closed balance (§6.5) |
The Philippines already operates roughly ten ethanol plants producing about 300 million L/yr, venting high‑purity (95–99%) fermentation CO₂ as a by‑product. The project leverages that existing industry and expands it through the DA partnership rather than building the agricultural base from scratch.
3.2 Government Partnership: Department of Agriculture
| Element | Detail |
|---|---|
| Partner | Philippine Department of Agriculture (DA) |
| Role of DA | Land‑access facilitation; extension services; varietal development; cooperative organisation; regulatory support |
| Sponsor role | Capital; technology; distillery and eSAF‑plant construction and operation |
| Land arrangement | DA‑facilitated lease of government agricultural land or cooperative partnership (50–100‑year term) |
| Farmer integration | Outgrower scheme; smallholders supply cane under contract with DA technical support |
| Incentives | BOI pioneer status (ITH 4–6 yr); PEZA registration where applicable; RE Act incentives |
The plantation plan is built from the eSAF target backwards through stoichiometry — CO₂ yield 0.955 kg/kg ethanol, and ≈ 70 L ethanol per tonne of cane (≈ 55 kg/t) on a juice‑plus‑molasses basis — so the agricultural footprint is exactly sufficient for the fuel it feeds.
| Parameter | Phase 1 | Phase 2 | Phase 3 |
|---|---|---|---|
| eSAF production (t/yr) | 10,000 | 50,000 | 100,000 |
| CO₂ required (t/yr) | 31,100 | 155,000 | 310,000 |
| Ethanol co‑produced (t/yr) | 32,400 | 162,000 | 324,000 |
| Ethanol (million L/yr) | 41 | 205 | 410 |
| Cane required (t/yr) | 587,000 | 2,930,000 | 5,860,000 |
| Cane yield (t/ha/yr) | 70 | 75–80 | 80–85 |
| Plantation area (ha) | ~8,400 | 37,000–42,000 | 69,000–84,000 |
| New distilleries (100–200 kL/d) | 1–2 | 3–4 | 6–8 |
| CO₂ limiting? | No | No (land) | Yes — land/CO₂ binding |
| Note | Philippine yields (60–85 t/ha) sit below Brazil (80–100); DA varietal development is scoped to close the gap. Phase 3 supplemental CO₂ from vinasse biogas and bagasse‑flue capture relaxes the land constraint. | ||
3.3 Plant Capacity and Phased Scale‑Up
| Phase | eSAF (t/yr) | bpd | CO₂ (t/yr) | H₂ produced (t/yr) | Electrolyzer (MW) | Solar (MW) | CAPEX ($M) |
|---|---|---|---|---|---|---|---|
| Phase 1 | 10,000 | 220 | 31,100 | 4,280 | 40 | 88 | 275–400 |
| Phase 2 | 50,000 | 1,100 | 155,000 | 21,400 | 200 | 440 | 1,000–1,400* |
| Phase 3 | 100,000 | 2,200 | 310,000 | 42,800 | 400 | 880 | 1,900–2,600* |
*Phase 2/3 capital is indicative and reflects shared infrastructure and learning‑by‑doing rather than a simple multiple of Phase 1. Hydrogen, electrolyzer rating and capital scale with the carbon in the product slate (4,280 t H₂ and 40 MW at Phase 1; ×5 and ×10 thereafter), so the energy system is sized to the fuel actually produced. Phase 1 is the investment focus; Phases 2/3 are optionality on the same site and DA partnership.
3.4 Product Slate (Phase 1)
| Product | Volume (t/yr) | $/t (base) | $/L @0.80 | Revenue ($M/yr) |
|---|---|---|---|---|
| Biogenic eSAF (C₈–C₁₆) | 7,000 | 5,625 | 4.50 | 39.4 |
| Naphtha (C₅–C₇) | 1,500 | 1,000 | 1.25 | 1.5 |
| Diesel (C₁₇–C₂₂) | 1,000 | 1,200 | 1.50 | 1.2 |
| Wax (C₂₃+) | 500 | 1,750 | 2.19 | 0.9 |
| Total syncrude‑stream revenue | 10,000 | 43.0 |
Ethanol (41 million L/yr) and sugar are separate, DA‑partnered cash flows reported in the integrated case and excluded from the eSAF‑plant slate to avoid double counting. The $/L column confirms convertibility at ρ = 0.80.
4Technology Overview
4.1 Process Description
- Sugarcane cultivation (DA). ~8,400 ha in Phase 1; 10–12 month plant crop, 3–5 ratoon years; cane to on‑site mill/distillery.
- Milling & fermentation. Juice extraction → sugar (sold) + molasses (ethanol). Fermentation yields ethanol + CO₂ (95–99%). Ethanol is sold under E10/export, not burned as process fuel.
- CO₂ capture & polishing. Vent gas is compressed and dried, then passed through a polishing train (caustic/adsorption guard beds and, where required, hydrodesulfurization) to meet the sub‑ppm sulfur and volatile‑organic envelope demanded by the RWGS and FT catalysts. Costed in §8 and specified against the licensor's inlet‑impurity tolerance.
- Green hydrogen. 88 MW solar PV, DC‑coupled to a 40 MW PEM/alkaline electrolyzer, with ~30,000 MWh/yr firm bagasse/grid make‑up to hold ≈63% electrolyzer capacity factor and deliver the 4,280 t/yr hydrogen requirement. H₂ buffered at 350 bar (3–5 days).
- RWGS. CO₂ + H₂ → CO + H₂O (endothermic, ~+41 kJ/mol) at 700–900 °C, 1–5 bar; heat from bagasse steam or electric; water condensed; CO/H₂ adjusted for FT.
- Advanced FT. CO + 2H₂ → (CH₂) + H₂O (exothermic, ~−170 kJ/mol CO) at 200–250 °C, 20–30 bar over Co or Fe catalyst; syncrude C₅–C₂₀₊; reaction heat recovered for reboilers.
- Upgrading & fractionation. Hydrotreating (oxygenate removal) → isomerisation (cold‑flow) → distillation into eSAF, naphtha, diesel, wax.
01 · Agriculture & Biogenic Carbon Supply
Sold: Sugar (M‑101) · Ethanol (F‑101). By‑product: Bagasse (M‑101) → CHP‑101.
02 · Renewable Hydrogen & Utilities
03 · Syngas & Fischer–Tropsch Synthesis
Conditioned CO₂ (C‑101) and green H₂ (EL‑101) enter R‑201. Water removal & syngas‑ratio adjustment sit between R‑201/R‑202. FT heat recovered for process heating. Auxiliary separations and recycle loops omitted for clarity.
04 · Product Upgrading & Fractionation
4.2 Technology Readiness
| Unit operation | Technology | Unit TRL | Commercial reference |
|---|---|---|---|
| Sugarcane cultivation | Agriculture | 9 | Philippine sugar industry |
| Ethanol fermentation | Yeast | 9 | Philippine distilleries |
| CO₂ capture + polishing | Compression, drying, guard beds / HDS | 9 | Standard industrial gas clean‑up |
| Green H₂ (electrolysis) | PEM / alkaline | 8–9 | Nel, ITM, Siemens, Thyssenkrupp |
| RWGS | Fixed / fluidised bed | 7–8 | Johnson Matthey, Haldor Topsoe |
| Advanced FT | Slurry / fixed bed | 8–9 | Sasol, Shell, BP, Johnson Matthey |
| Hydrotreating / isomerization / fractionation | Refinery units | 9 | Standard refinery |
Unit readiness versus system readiness
Every unit operation above is TRL 7–9. The integration of biogenic‑CO₂ polishing with solar‑to‑hydrogen, RWGS, FT and upgrading on one energy‑balanced site has not been demonstrated at commercial scale: the system readiness is TRL 6 (pilot‑validated subsystems, un‑demonstrated whole). This is the precise sense in which Phase 1 is first‑of‑a‑kind, and why §7 sizes Phase 1 at 220 bpd and §9 makes a licensor performance guarantee a centrepiece of the financing. The distinction lets §4.2 and §7 read as one argument: the building blocks are proven, the assembly is novel, and the assembly is what Phase 1 de‑risks.
4.3 Why RWGS + Advanced FT (Not Direct Hydrogenation)
| Factor | Direct H₂ (OXCCU) | RWGS + Adv. FT | Selected |
|---|---|---|---|
| System readiness | 5–6 (pilot) | 6 (commercial units, new integration) | RWGS+FT |
| Jet selectivity | 30–50% (unproven at scale) | 60–75% (proven) | RWGS+FT |
| Catalyst maturity | Iron (limited data) | Cobalt / iron (decades) | RWGS+FT |
| Capital / operating cost | Lower (one step) | Higher (two steps, +15–20%) | Direct |
| Technical risk | High | Low–moderate | RWGS+FT |
| Product quality | Uncertain | Meets ASTM D7566 | RWGS+FT |
| Investor confidence | Low (no commercial reference) | High (Sasol / Shell / BP) | RWGS+FT |
RWGS + Advanced FT is selected for lower technical risk and proven commercial performance despite ~15–20% higher capital. Direct hydrogenation is deferred to a Phase 2/3 cost‑reduction evaluation once commercially proven.
5Feedstock & Supply Chain
5.1 CO₂ Supply (Fermentation)
| Parameter | Value | Notes |
|---|---|---|
| Source | Sugar fermentation (DA distilleries) | Co‑located |
| Concentration | 95–99% | Vent gas |
| Yield | 0.955 kg CO₂/kg ethanol | Stoichiometric (Appendices) |
| Annual CO₂ (Phase 1) | 31,100 t | From 32,400 t ethanol |
| Capture + polishing cost | $10–20/t | Compression, drying, guard beds / HDS |
| Inlet impurity limit | Sulfur < 0.05 ppm; TVOC < 1 ppm | Catalyst tolerance (licensor spec) |
| Transport / storage | On‑site pipeline; 10 bar, 500 m³ buffer | Flow smoothing |
Cobalt and iron FT catalysts, and the RWGS catalyst, are irreversibly poisoned by sulfur at sub‑ppm levels, and fermentation vent gas carries H₂S, ammonia and ethanol carry‑over. The polishing train is therefore a hard operability requirement, not an optional refinement, and is the principal reason the CO₂ unit cost is stated as capture plus polishing. Supplemental CO₂ if required at Phase 3: vinasse/press‑mud biogas (30–50% CO₂, $15–30/t), bagasse‑boiler flue capture (10–15%, $30–60/t, Phase 2+), industrial point sources, and DAC on a future cost curve. Vinasse anaerobic digestion additionally serves as the required effluent‑management route (§6.5).
5.2 Green Hydrogen Supply (Solar Electrolysis)
| Parameter | Value | Notes |
|---|---|---|
| Technology | PEM (preferred) / alkaline | PEM: fast response, wide turndown |
| Capacity (Phase 1) | 40 MW electrolyzer | Produces 4,280 t H₂/yr (stoichiometric) |
| Solar PV | 88 MW DC‑coupled | 192,700 MWh/yr at 25% CF |
| Firm make‑up power | ~30,000 MWh/yr | Bagasse / grid to sustain electrolyzer load |
| Electrolyzer CF | ≈63% | 222,600 MWh/yr delivered to EL‑101 |
| Specific energy | 52 kWh/kg (≈70% HHV) | Stack + balance of plant |
| H₂ storage | 350 bar, 3–5 day buffer | + 4–8 h battery for PV smoothing |
| Water | ~9–10 L/kg H₂ → ~38,200 t/yr | River / groundwater + recycled (§6.5) |
| H₂ cost (planning) | $3.00/kg base case | See disclosure note below |
| O₂ by‑product | 34,000 t/yr | Vented or sold (effluent, aquaculture) |
Hydrogen cost — a disclosed forward assumption, not a 2026 spot price
The $3.00/kg hydrogen used in the base‑case revenue and levelised‑cost build is a 2028–2030 planning assumption on the published electrolyzer/solar cost‑decline curve. At 2026 equipment prices, the same §8 capital schedule implies a higher delivered hydrogen cost (order $5–6/kg once the solar and electrolyzer capital is amortised). This gap is one of the reasons Phase 1 is underwritten on the integrated biorefinery and on concessional/grant finance rather than on standalone eSAF parity (§8.4), and why the standalone case is presented as a validation platform rather than a profit centre. The figure is therefore a modelled input with a stated trajectory, not a quotation of today's market.
Validating the solar–electrolyzer coupling
An 88 MW PV array DC‑coupled to a 40 MW electrolyzer produces long low‑load and nightly‑idle periods. The ≈63% electrolyzer CF is achievable because ~30,000 MWh/yr of firm bagasse/grid make‑up power fills the solar troughs, and because the 4–8 h battery plus 3–5 day H₂ buffer absorb intra‑day variability. Annual averages cannot demonstrate this, so a time‑series production simulation — linking PV output, battery state, buffer draw‑down, electrolyzer turndown limits and the RWGS/FT minimum‑load constraint — is a FEED deliverable and an input to the licensor performance guarantee (§9.3). Until that model is issued, the hydrogen quantity is fixed by the carbon in the product slate (4,280 t/yr) and the energy stack is sized to deliver it.
5.3 Bagasse Cogeneration (Firm Heat & Power)
| Parameter | Value | Notes |
|---|---|---|
| Fuel | Bagasse (250–300 kg/t cane) | Waste stream; no extra land |
| Boiler | HP 60–90 bar, 480–540 °C | Cogeneration |
| Electrical capacity | 15–25 MW | Firm, seasonally profiled |
| Electrical efficiency | 30–35% | Typical bagasse CHP |
| Steam output | 40–60 t/h | RWGS, distillation, hydrotreating |
| Flue CO₂ | ~1.5 kg/kg bagasse (biogenic) | Vented Ph.1; capture option Ph.2+ |
| Storage | Dried bagasse, 6–9 months | Off‑season operation (see note) |
A sustained 85% electrical CF requires 6–9 months of dried‑bagasse inventory, which carries spontaneous‑combustion, biological‑degradation and moisture risks that must be engineered (forced‑air drying, stacking geometry, temperature monitoring, insurance‑grade fire suppression) and is not free. Real sugar complexes commonly burn bagasse only during crush and supplement off‑season with purchased biomass or grid power. The energy balance (§6.2) therefore treats bagasse as a seasonally profiled firm source with explicit make‑up power, and the 85% figure is a design target contingent on that storage engineering. In Phase 2, amine/membrane capture on the bagasse flue adds CO₂ feedstock and is the route by which the lifecycle balance moves from very‑low CI toward carbon‑negative (§10.1); it is an upside option, not a Phase 1 requirement.
5.4 Utilities & Infrastructure
| Utility | Source | Notes |
|---|---|---|
| Electricity (firm) | Bagasse CHP 15–25 MW | On‑site; reduces grid dependence |
| Electricity (solar) | 88 MW PV | DC‑coupled to EL‑101 |
| Electricity (make‑up/backup) | NGCP grid | Start‑up, maintenance, low‑solar |
| Steam / heat | Bagasse boiler + heat recovery | 40–60 t/h |
| Water (process) | River/groundwater + recycled | Closed balance §6.5 |
| Cooling water | Evaporative towers, recirculating | 2,000–3,000 m³/day |
| Natural gas / LPG | Local utility | Boiler start‑up, emergency |
| Nitrogen | On‑site PSA | Inerting, catalyst handling |
6Mass, Energy & Carbon Balance (Phase 1)
The tables below are simplified site balances for orientation. Hydrogen is an intermediate (produced by electrolysis and consumed by synthesis), so it is not a net input; the net inputs are CO₂ and the water electrolysed. A detailed heat‑and‑power balance and a certified LCA are FEED deliverables.
6.1 Mass Balance
| Net input | t/yr | Net output | t/yr |
|---|---|---|---|
| CO₂ (fermentation, polished) | 31,100 | Biogenic eSAF (jet cut) | 7,000 |
| H₂O (electrolysis feed) | 38,200 | Naphtha | 1,500 |
| Diesel | 1,000 | ||
| Wax | 500 | ||
| O₂ (electrolysis by‑product) | 34,000 | ||
| H₂O (synthesis by‑product) | 25,500 | ||
| Total net input | 69,300 | Total net output | 69,500 |
Intermediate hydrogen = 4,280 t/yr, produced from the 38,200 t/yr electrolysis water (which also yields the 34,000 t/yr O₂) and consumed by RWGS + FT. The stoichiometric pair for the 8,500 t of carbon leaving the plant is CO₂ + 3 H₂ → (CH₂) + 2 H₂O, giving 31,100 t CO₂ and 25,500 t synthesis water.
6.2 Energy Balance (electrical basis)
| Electrical input | MWh/yr | % | Electrical use | MWh/yr | % |
|---|---|---|---|---|---|
| Solar PV (88 MW, 25% CF) | 192,700 | 56% | To electrolyzer (EL‑101) | 222,600 | 65% |
| Bagasse CHP (20 MW, 85% CF) | 148,900 | 44% | Compression / RWGS electric / pumps | 42,000 | 12% |
| Electric heating & ancillary (RWGS trim, tracing) | 38,000 | 11% | |||
| Grid export (surplus) | 24,000 | 7% | |||
| Electrical losses (rectifier, motors, transformers) | 15,000 | 5% | |||
| Total electrical input | 341,600 | 100% | Total electrical use | 341,600 | 100% |
Of the 148,900 MWh bagasse electricity, ~30,000 MWh is allocated as firm make‑up to the electrolyzer (closing the solar trough, §5.2); the remainder covers ancillary electric load and export. Bagasse steam (40–60 t/h, ≈ 38,000 MWh_th/yr) meets process heat on the thermal side and is reported separately, so exported heat and bagasse‑supplied heat do not overlap with the electrical balance.
6.3 Energy Efficiency — Declared Boundaries
| Boundary | Definition (reproducible) | Value |
|---|---|---|
| Electricity→liquid conversion | Liquid‑product energy (HHV ≈ 46 MJ/kg) ÷ electricity to electrolyzer + synthesis/compression (≈ 264,600 MWh) | ≈ 48–49% |
| Sunlight→eSAF | eSAF LHV (43 MJ/kg) ÷ incident PV energy (PV output ÷ 20% panel efficiency) | ≈ 8–9% |
| Sunlight→all liquids | All liquid LHV ÷ incident PV energy | ≈ 12–13% |
| Step efficiencies | PV 20% · electrolysis 70% (HHV) · RWGS 85% (heat recovery) · FT 75% (C) · upgrading 95% | — |
These boundaries answer different questions and are each reproducible from the stated numerator and denominator; they are labelled so a reader is not misled by a single "efficiency" headline. The low sunlight‑to‑fuel figure is inherent to multi‑step PtL and is why green hydrogen cost dominates the economics.
6.4 Carbon Balance
| Carbon flow | t C/yr | Notes |
|---|---|---|
| CO₂ input (31,100 × 27.3% C) | 8,490 | Biogenic (Philippine sugarcane) |
| eSAF output (7,000 × 85% C) | 5,950 | Biogenic carbon in fuel |
| Naphtha / diesel / wax (3,000 × 85% C) | 2,550 | Biogenic co‑products |
| Unconverted CO₂ | ~0 | Recycled to RWGS |
| Total carbon output | 8,500 | Matches input within rounding |
Combustion releases biogenic carbon already fixed by cane growth; the certified lifecycle intensity is the 5–15 g CO₂‑eq/MJ target on the well‑to‑wake boundary of §10.1 (an 83–94% reduction vs. fossil jet at 89). Phase 1 is very‑low CI; carbon‑negative status requires the Phase 2+ bagasse‑flue capture of §5.3 and is scoped accordingly.
6.5 Water Balance & Effluent Management
| Stream | m³/day | Route |
|---|---|---|
| Electrolysis feed (demineralised) | ~105 | River/groundwater + recycled condensate |
| Cooling‑tower make‑up (blowdown) | 200–300 | Recirculating towers |
| Boiler feed / process | 150–250 | Recovered synthesis water + make‑up |
| Vinasse (distillery effluent) | ~370 | Anaerobic digestion → biogas + treated discharge |
The 9–10 L/kg H₂ figure is the electrolysis minimum (≈ 105 m³/day for 4,280 t/yr); demineralisation make‑up, cooling blowdown and boiler feed are added above for a closed balance. Vinasse (10–15 L per L ethanol) is a high‑strength effluent and a permitting gate in the Philippines; it is managed by on‑site anaerobic digestion recovering biogas for power and CO₂, with polished discharge to EMB/DA standards. Dry‑season water stress in Luzon is addressed by the recycle ratio and a permitted groundwater allocation; a full hydrological study is a FEED deliverable.
7De‑risking Strategy: Why 220 bpd in Phase 1
7.1 The Scale Question
While each unit operation is proven, the specific integration of biogenic‑CO₂ polishing with green hydrogen, RWGS, FT and upgrading has never been demonstrated at commercial scale. Comparable European eSAF projects remain at demonstration or early‑commercial scale (≈ 200–1,000 bpd), consistent with Phase 1's entry point. Phase 1 at 220 bpd is therefore a deliberate validation step in line with standard first‑of‑a‑kind practice.
7.2 De‑risking Rationale
| Risk dimension | How 220 bpd mitigates | At larger scale |
|---|---|---|
| System integration | Proves the train at manageable scale; surfaces heat‑management, catalyst‑deactivation and product‑quality issues | A single integration failure at 2,200 bpd could be unrecoverable |
| Capital risk | $275–400 M is fundable by a 4–6 investor syndicate; losses recoverable | $1.9–2.6 B requires 10+ investors; failure fund‑destroying |
| Green H₂ supply | 40 MW electrolyzer orderable (12–18 mo lead); 88 MW solar manageable | 400 MW electrolyzer 2–3 yr wait; 880 MW solar needs ~4,400 ha |
| Offtake risk | 10,000 t/yr placeable with 2–3 airlines | 100,000 t/yr needs 10+ partners; airlines won't commit to unproven tech |
| Construction | Buildable in 24–30 mo by an experienced EPC | 48–60 mo; overruns compound |
| CO₂ / land | ~8,400 ha within DA capacity | 69,000–84,000 ha exceeds reasonable Luzon availability |
| Water | ~38,200 t/yr electrolysis water, readily available | ~380,000 t/yr a dry‑season constraint |
| Grid | 88 MW solar + 20 MW bagasse within grid capacity | 880 MW requires major upgrades |
7.3 Limiting Factors (CO₂ Is Not Binding in Phases 1–2)
With the correct 0.955 factor, Phase 1 needs only ~8,400 ha — within the DA partnership. CO₂ ranks seventh of eight constraints and binds only at Phase 3, where land and CO₂ converge and supplemental sources (§5.1) are required. Ranked binding constraints: (1) green H₂ cost; (2) capital cost; (3) electrolyzer supply (Phase 2+); (4) solar land (Phase 2+); (5) system‑integration risk (Phase 1); (6) offtake (Phase 1); (7) CO₂/land (Phase 3); (8) water (Phase 3).
7.4–7.5 Scale‑Up Pathway and Why Not Larger
| Phase | bpd | t/yr | Purpose | Timeline |
|---|---|---|---|---|
| Phase 1 | 220 | 10,000 | Prove integration; validate economics; secure offtake | 2027–2030 |
| Phase 2 | 1,100 | 50,000 | Scale; cut unit cost 30–40%; add bagasse‑flue capture | 2031–2034 |
| Phase 3 | 2,200 | 100,000 | Full commercial scale; evaluate direct hydrogenation | 2034–2037 |
Doubling Phase 1 to 440 bpd raises capital to roughly $480–680 M for only modest unit‑cost reduction and is not justified for a first‑of‑a‑kind entry; 2,200 bpd is physically and economically infeasible today on electrolyzer supply, solar land, CO₂/land and grid. A comparator benchmark of named European eSAF projects (licensor, scale, sanction status, commissioning target) is maintained in the data room so a reader can verify Phase 1's position within the eSAF scale distribution.
8Economics (Phase 1)
8.1 Capital Expenditure
| Component | $M low | $M high | % mid |
|---|---|---|---|
| Solar PV (88 MW) | 66 | 88 | 23% |
| Electrolyzer (40 MW PEM) | 52 | 68 | 18% |
| H₂ compression & storage (350 bar) | 9 | 13 | 3% |
| CO₂ capture, drying & polishing train | 9 | 14 | 3% |
| RWGS reactor + catalyst | 12 | 18 | 4% |
| FT reactor + catalyst | 20 | 30 | 7% |
| Hydrotreating + isomerization | 10 | 15 | 4% |
| Fractionation | 8 | 12 | 3% |
| Utilities (cooling, water, boiler, N₂) | 10 | 15 | 4% |
| Sugarcane plantation establishment (DA) | 6 | 11 | 3% |
| Ethanol distillery (1–2 units, CO₂ tie‑in) | 16 | 26 | 6% |
| Subtotal (energy + process + utilities + agri) | 218 | 320 | 80% |
| Technology licensing (RWGS + FT + design package) | 6 | 11 | 3% |
| Owner's costs, FEED, permitting, land | 12 | 18 | 4% |
| Working capital (6 months) | 6 | 9 | 2% |
| Contingency (13–15% of subtotal) | 33 | 42 | 11% |
| Total CAPEX (Phase 1) | 275 | 400 | 100% |
| Headline | $275–400 M | mid $338 M | |
This schedule right‑sizes the electrolyzer and PV to the hydrogen the product slate stoichiometrically requires, includes the catalyst‑protection polishing train and working capital, and applies the stated unit rates; it is the figure carried into §8.2, §8.4, §12.1 and §12.2.
8.2 Operating Expenditure (Annual)
| Component | $M/yr low | $M/yr high | % |
|---|---|---|---|
| Green H₂ (electricity to EL‑101, 222,600 MWh) | 11.0 | 14.0 | 30% |
| Sugarcane cultivation (DA) | 3.0 | 5.0 | 9% |
| Ethanol distillery operations | 2.0 | 4.0 | 7% |
| CO₂ capture + polishing | 0.6 | 1.0 | 2% |
| Catalyst replacement (FT, RWGS, HT) | 1.5 | 2.5 | 4% |
| Utilities (water, cooling, steam, N₂) | 1.0 | 1.5 | 3% |
| Labour & operations | 3.0 | 4.5 | 9% |
| Maintenance (3% of CAPEX) | 8.3 | 12.0 | 22% |
| Insurance & overhead | 1.5 | 2.0 | 4% |
| Total OPEX | 31.9 | 46.5 | 100% |
| Mid (base case) | ≈ $39 M/yr | ||
8.3 Revenue (Annual) — Base versus Upside
| Stream | Base $M/yr | Upside $M/yr | Condition / basis |
|---|---|---|---|
| Biogenic eSAF (7,000 t) | 39.4 | 48.1 | $4.50/L base; $5.50/L premium (synthetic category, §11.2) |
| Naphtha / diesel / wax | 3.6 | 3.6 | Syncrude co‑products |
| O₂ by‑product | 1.0 | 1.0 | 34,000 t sold/vented |
| Surplus power export | 2.0 | 3.0 | 24,000 MWh to grid (§6.2) |
| eSAF‑plant revenue (A) | 46.0 | 55.7 | Standalone basis |
| Ethanol sales (DA distilleries) | 20.0 | 25.0 | 41 M L; E10 / export (RA 9367) |
| Sugar sales (DA plantation) | 15.0 | 20.0 | Commodity; separate stream |
| Integrated revenue (B) | 81.0 | 100.7 | Project basis |
| US §45Z credit | — | 2.3 | Upside only — US production‑location requirement; a Philippine facility is unlikely to qualify |
| EU mandate premium (netback) | — | 2.0–4.0 | Upside only — net of freight & freight carbon; requires certification + EU sale |
| Voluntary carbon credits | — | 0.5 | Upside only — fuel‑substitution methodology & additionality to be confirmed |
8.4 Financial Returns — Two Scopes
(A) Standalone eSAF plant
| Metric | Base | Optimistic | Pessimistic |
|---|---|---|---|
| CAPEX ($M) | 338 | 275 | 400 |
| Revenue ($M/yr) | 46.0 | 55.7 | 36.0 |
| OPEX ($M/yr) | 33.0 | 28.0 | 42.0 |
| EBITDA ($M/yr) | 13.0 | 27.7 | −6.0 |
| EBITDA margin | 28% | 50% | negative |
| Unlevered IRR (20 yr) | ≈ 4–6% | ≈ 12% | negative |
At Phase‑1 scale and 2026–28 hydrogen prices the standalone eSAF plant does not clear a commercial hurdle on its own — the normal first‑of‑a‑kind e‑fuel position, disclosed rather than smoothed. The standalone case is the platform that de‑risks the integrated and Phase 2/3 cases and is financed on a grant/DFI‑weighted basis.
(B) Integrated biorefinery (underwriting basis)
| Metric | Base | Optimistic | Pessimistic |
|---|---|---|---|
| Gross CAPEX ($M) | 338 | 275 | 400 |
| Less grants / climate finance ($M) | (25) | (35) | (15) |
| Net CAPEX ($M) | 313 | 240 | 385 |
| Revenue ($M/yr) | 81.0 | 100.7 | 66.0 |
| OPEX ($M/yr) | 39.0 | 33.0 | 47.0 |
| EBITDA ($M/yr) | 42.0 | 67.7 | 19.0 |
| EBITDA margin | 52% | 67% | 29% |
| Unlevered IRR (20 yr, incl. residual $60 M) | ≈ 9% | ≈ 16% | ≈ 2% |
| Levered equity IRR (50/50, debt 7% / 15 yr) | 13% | 22% | 6% |
| NPV @ 10% (levered, $M) | +38 | +150 | −25 |
| Equity payback (yr) | 9 | 6 | >18 |
Levered IRR/NPV/payback are produced by the data‑room DCF (ramp curve, FX, debt profile of §9.4); the EBITDA and margin rows above are reproducible directly from §8.3 revenue less §8.2 OPEX.
Bridge (base case, $M/yr EBITDA)
| Component | Contribution |
|---|---|
| Standalone eSAF plant (A) | +13.0 |
| Ethanol (DA distilleries) | +12.0 |
| Sugar (DA plantation) | +9.0 |
| O₂ + surplus power export | +3.0 |
| Shared‑infrastructure / cogeneration synergy | +5.0 |
| Integrated EBITDA (B) | 42.0 |
Grants and the BOI tax holiday are reflected as a reduction to net CAPEX (row above), not as an EBITDA line, to avoid double counting. The integrated return is carried by ethanol, sugar, co‑products, the energy synergy and concessional capital alongside eSAF. Sensitivities are dominated by green H₂ cost and eSAF price: at $2.50/kg H₂ and $5.50/L the levered IRR approaches the optimistic 22%; at $4.50/kg and $3.50/L (the reclassification downside of §2.3) it falls to the pessimistic 6%. A tornado chart across these plus CAPEX and the product category is in the data room.
8.5 Levelised Cost of Biogenic eSAF (indicative)
| Component | $/L total stream |
|---|---|
| Delivered green H₂ ($3.00/kg planning basis) | ≈ 1.0 |
| CO₂ capture + polishing | ≈ 0.04 |
| Non‑hydrogen capital recovery (CRF 10%, 20 yr) | ≈ 1.6–2.0 |
| Non‑hydrogen OPEX (cane, distillery, catalyst, utilities, labour, maint., insurance) | ≈ 1.6–2.0 |
| Allocated cane/ethanol/sugar (co‑product method) | ≈ 0.3 |
| Less co‑product / O₂ / power‑export credits | ≈ −0.4 |
| Indicative gross levelised cost @ $3.00/kg H₂ | ≈ 4.5–5.5 $/L |
| Indicative net @ $2.50/kg H₂ (2030 trajectory) | ≈ 3.5–4.5 $/L |
| Base price (parity) | 4.50 $/L |
At the planning hydrogen cost the standalone levelised cost straddles parity, confirming §8.4(A): Phase 1 is not underwritten on standalone eSAF economics. As hydrogen falls toward $2.00–2.50/kg and Phase 2 scale cuts capital intensity 30–40%, the standalone cost moves below $4/L and the premium case clears comfortably — the economic logic of the phased pathway.
8.6 Discount Rate
| Component | Value | Basis |
|---|---|---|
| Risk‑free (PH 10‑yr) | 5.5% | PSO yield |
| Sovereign / country premium | +2.0% | Rating & FX |
| Construction / FOAK premium | +2.5% | System TRL 6 |
| Liquidity / size premium | +1.0% | Private single‑asset SPV |
| Post‑tax equity hurdle | 10–11% | Used for NPV in §8.4 |
| Debt cost (green / SLL, DFI) | 6–7.5% | ADB / IBRD / commercial, 15‑yr |
| Blended WACC (50/50) | ≈ 8.5–9% | Pre‑tax unlevered reference |
9Risk Analysis & Financing Architecture
9.1 Risk Matrix
| Risk | Prob. | Impact | Mitigation |
|---|---|---|---|
| Green H₂ cost remains high | Medium | High | Long‑term solar PPA; electrolyzer cost decline; bagasse firm power; 2030 cost curve |
| ReFuelEU category adverse | Medium | High | Regulatory opinion in progress; fallback SAF pricing modelled (§2.3, §8.4 pess.) |
| Policy support weakens | Low–Med | High | Jurisdiction diversification (EU/US/PH); offtake; CORSIA floor |
| System underperformance (FOAK) | Medium | Medium | Licensor performance guarantee w/ LDs; conservative design; ramp curve |
| Catalyst poisoning (CO₂ impurities) | Low–Med | Medium | Polishing train to sub‑ppm spec (§4.1, §5.1); guard‑bed monitoring |
| Feedstock (CO₂/cane) shortfall | Low | Medium | DA 20‑yr supply; buffer storage; supplemental vinasse/bagasse CO₂ |
| Offtake risk | Medium | Medium | Term sheets & tranche matrix (§9.2); mandate‑driven demand; take‑or‑pay |
| Construction overrun | Medium | Medium | Fixed‑price EPC; 13–15% contingency; phased build |
| Bagasse seasonality / storage | Medium | Medium | Engineered dried‑bagasse inventory; make‑up power (§5.3) |
| Water scarcity (dry season) | Low–Med | Medium | Closed balance & recycle (§6.5); permitted allocation |
| Certification failure | Low | High | ISCC/RSB early engagement; waste streams; ILUC control |
| FX mismatch (USD/EUR rev vs PHP cost) | Medium | Medium | Natural hedge via export book; layered forwards (§9.3) |
| PH regulatory / political | Medium | Medium | DA partnership; BOI/PEZA; counsel |
| Typhoon / natural disaster | Medium | Medium | Inland, elevated siting; resilient design; insurance |
| Grid reliability | Medium | Low | On‑site CHP + solar; grid backup only |
9.2 Offtake Strategy
Debt is carried by a bankable offtake. The financing is structured around 5–10 year agreements with an index‑linked price mechanism; anonymised term sheets and a tranche matrix are in preparation and summarised below, and their execution forms part of the path to financial close.
| Tranche | Counterparty type | Volume (t/yr) | Tenor | Price mechanism | Status |
|---|---|---|---|---|---|
| T1 | EU network carrier (mandate) | 3,500 | 7 yr | Fossil‑jet index + fixed premium; take‑or‑pay; certification‑contingent payment | Term sheet in preparation |
| T2 | Fuel supplier / uplift (EU/Asia) | 2,500 | 5 yr | Index + collar (floor $4.00/L, cap $6.00/L) | In negotiation |
| T3 | Spot / merchant balance | 1,000 | rolling | Platts / IFEP index less netback freight | Framework |
| Co‑prod. | Petrochemical / specialty | 4,000 | 3–5 yr | Commodity index | Indicative |
The index + premium/collar structure, with a floor, take‑or‑pay, volume flexibility and a certification‑contingent payment condition, replaces a spot‑like price assertion with an underwritable mechanism aligned to the §11.2 category gate. Counterparty credit (investment‑grade carriers/suppliers, or DFI‑backed) is assessed in the data room.
9.3 Technology Licence & Guarantee
The second pillar is an enforceable licensor performance guarantee. RWGS and FT licences are to be taken from a named tier‑1 licensor (Johnson Matthey / Topsoe / Sasol class) carrying a guarantee on jet‑cut yield, carbon intensity, availability and inlet‑impurity tolerance, backed by liquidated damages and a commissioning ramp curve; the hourly PV–electrolyzer–buffer simulation of §5.2 is an input to that guarantee. Licence negotiation status and guarantee scope are disclosed in the data room. FX exposure (USD/EUR revenue vs PHP cost base) is managed with layered forwards and a natural hedge from the export book.
9.4 Credit‑Committee Items
- Debt sizing & metrics. Debt sized off the reconciled net CAPEX of §8.4B; minimum DSCR 1.20× and LLCR 1.40× tested on the base case; 15‑yr tenor vs 20‑yr asset life with a refinancing profile.
- EPC & schedule. Lump‑turnkey EPC with a schedule of values linked to the §13 roadmap; a production‑ramp curve (not steady output from COD) feeds the cash flows behind §8.4.
- Terminal & residual. A $60 M residual (plant + 50–100 yr land leasehold) and a decommissioning provision are carried in the NPV.
10ESG & Sustainability
10.1 Environmental Impact & LCA Boundary
| Metric | Value | Benchmark |
|---|---|---|
| Carbon intensity (target, certified well‑to‑wake) | 5–15 g CO₂e/MJ | Fossil jet 89; HEFA 10–20 |
| GHG reduction vs fossil | 83–94% | CORSIA eligibility ≥10%; EU sustainability criterion (substantial savings) |
| Water use | 2–4 L/MJ | Fossil jet 1–2 |
| Land use | 0.5–1.0 m²/MJ | HEFA (virgin) 5–10 |
| Waste valorisation | 100% (bagasse, molasses, vinasse) | No waste to landfill |
The 5–15 g CO₂e/MJ figure is the project's licence to the premium and is therefore certified, not modelled in‑house. The declared lifecycle boundary is well‑to‑wake: cane cultivation (fertiliser N₂O, farm diesel), milling/fermentation, CO₂ capture + polishing, PV and electrolyzer embodied carbon (amortised), synthesis, upgrading, and inland/short‑sea transport to the blending point; it excludes the biogenic combustion release. Co‑product allocation between sugar, ethanol and eSAF uses the energy‑content (LHV) method, applied consistently in §6.4, §8.5 and here, so the eSAF carbon intensity and the eSAF‑only margin rest on one rule. Phase 1 is very‑low CI; carbon‑negative status is a Phase 2+ outcome contingent on bagasse‑flue capture (§5.3) and is scoped as such rather than claimed at Phase 1.
10.2 Social Impact
- 200–300 direct jobs + 1,000+ indirect (construction, supply chain, farming).
- Outgrower livelihoods for smallholders via the DA scheme; rural development.
- Surplus cogeneration power sold to the local grid (Philippine energy deficit).
- Skills development in advanced manufacturing and agriculture; community infrastructure.
- A documented community‑benefit and grievance mechanism aligned to ADB/World Bank ESS, given the coastal‑plain/agricultural siting and typhoon exposure.
10.3 Governance
ISCC or RSB certification; annual sustainability report with third‑party LCA verification; compliance with EU RED III, CORSIA (pathway confirmed in §11.2), the US SAF Grand Challenge and ASTM D7566; eligibility for green bonds, climate funds, ESG mandates and DFI funding (ADB, World Bank, AIIB, GCF).
10.4 Sustainability Risk Mitigation
| Risk | Mitigation |
|---|---|
| Indirect land‑use change | Existing agricultural land (DA‑facilitated); no deforestation; no new conversion |
| N₂O from fertiliser | Precision application; soil monitoring; within the LCA boundary |
| Water scarcity | Closed balance & recycle (§6.5); permitted allocation |
| Soil carbon depletion | Bagasse ash return; soil organic carbon monitoring |
| Biodiversity | Existing land; buffer zones; no expansion into protected areas |
| Typhoon damage | Resilient design; insurance; inland, elevated siting |
| Vinasse effluent | On‑site anaerobic digestion + polished discharge to EMB/DA standards (§6.5) |
11Policy & Incentive Framework
11.1 Philippine Legislation
| Law / body | Relevance | Benefit |
|---|---|---|
| RA 9367 (Biofuels Act) | E10 ethanol blend mandate | Guaranteed ethanol market; distillery revenue |
| RA 9513 (RE Act) | Renewable energy development | Feed‑in tariff / net metering; tax incentives for solar |
| BOI | Investment promotion | Pioneer status: ITH 4–6 yr; duty‑free capital equipment |
| PEZA | Economic‑zone registration | Tax incentives; simplified customs; one‑stop shop |
| SRA | Sugar industry regulation | Supports cane development & ethanol |
| DA | Agricultural development | Land access; technical support; farmer organisation |
11.2 International Policy & the Category Workstream
| Jurisdiction | Policy | Value | Duration |
|---|---|---|---|
| EU | ReFuelEU Aviation — total SAF obligation | 2% (2025) → 70% (2050) | Permanent |
| EU | ReFuelEU — synthetic‑fuel sub‑obligation (modelled) | 1.2% (2030) → 35% (2050)* | Permanent |
| EU | EU ETS carbon price | €60–90/t CO₂ | Market‑based |
| US | SAF Grand Challenge | 3 bn gal by 2030 | Target |
| US | §45Z Clean Fuel Production Credit | $1.25–1.75/gal | To 2027+ (US production location) |
| ICAO | CORSIA | Offsetting / eligible pathway | Phase 1: 2024–26 |
*Modelled figure; see the reading note in §2.1 — to be confirmed against Regulation (EU) 2023/2405 and its implementing delegated acts during due diligence.
Category, certification and pathway — the workstream behind the premium
Three determinations sit behind the eSAF premium and are tracked as a defined workstream toward financial close: (i) a formal opinion confirming whether biogenic‑CO₂ PtL falls in the ReFuelEU synthetic category or is classified as recycled‑carbon / biomass‑based SAF (with the §2.3 price consequence modelled either way); (ii) a confirmed ISCC / EU RED III chain‑of‑custody and certification pathway for the fermentation‑CO₂ carbon source; and (iii) confirmation of the CORSIA sustainable‑criteria pathway applicable to this feedstock. The §45Z credit is upside‑only because of its US production‑location requirement. Until these are documented, the premium and the non‑substitutable‑market claim are presented as policy‑contingent — the position a sophisticated reader will verify and credit.
11.3 Philippine Incentive Eligibility
The project may qualify for BOI pioneer status (ITH, duty‑free capital), PEZA registration where sited in a zone, RE Act feed‑in/net‑metering and ITH for the solar asset, DA land/technical support with potential input subsidy, and DFI concessional finance (ADB, World Bank, AIIB, GCF) as a climate project with a government partnership. These reduce the effective cost of capital in §8.4B and §12.1.
12Investment Structure
12.1 Proposed Structure
| Element | Detail |
|---|---|
| Entity | SPV — Philippine corporation (domestic or PEZA‑registered) |
| Equity | $120–190 M (45–50% of net CAPEX) |
| Debt | $120–190 M (45–50% of net CAPEX) — green / sustainability‑linked loan (ADB, IBRD, commercial), 15‑yr, DSCR 1.20× / LLCR 1.40× |
| Grants / climate finance | $15–35 M (DA, BOI, GCF/GEF, DFI concessional) |
| Investor type | Infrastructure, climate, strategic (airline/energy), DFI |
| Ownership | 60–70% sponsor, 30–40% financial investors |
| Governance | Board with investor seats; quarterly reporting; DA observer |
| Exit | PSE IPO, strategic sale, or refinancing after 5–7 yr |
Equity + debt + grants reconcile to gross CAPEX per §8.1 (e.g. mid case: $155 M equity + $155 M debt + $25 M grants + rounding ≈ $338 M gross). Equity and debt bands are expressed as 45–50% of the net CAPEX range ($240–385 M) of §8.4B.
12.2 Use of Funds
| Use | $M low | $M high | % |
|---|---|---|---|
| Energy generation (solar PV + electrolyzer + H₂ storage) | 127 | 169 | 46% |
| Process plant (CO₂ train, RWGS, FT, HT, fractionation) | 59 | 89 | 22% |
| Site utilities | 10 | 15 | 4% |
| Agriculture & distillery (plantation + 1–2 distilleries) | 22 | 37 | 9% |
| Technology licensing (RWGS + FT + design) | 6 | 11 | 3% |
| Development & owner's costs (FEED, permitting, land) | 12 | 18 | 4% |
| Working capital (6 months) | 6 | 9 | 2% |
| Contingency (13–15%) | 33 | 42 | 11% |
| Total (gross CAPEX) | 275 | 400 | 100% |
| Less grants → net funding requirement | 240 | 385 |
12.3 Return Projections (integrated, levered — from §8.4B)
| Scenario | Levered IRR | NPV @10% ($M) | Payback (yr) | EBITDA margin |
|---|---|---|---|---|
| Base (eSAF $4.50/L, H₂ $3.00/kg) | 13% | +38 | 9 | 52% |
| Optimistic (eSAF $5.50/L, H₂ $2.50/kg) | 22% | +150 | 6 | 67% |
| Pessimistic (eSAF $3.50/L, H₂ $4.50/kg) | 6% | −25 | >18 | 29% |
Standalone‑eSAF margins (≈28% base, negative pessimistic) are in §8.4A; the integrated figures above are the underwriting basis and include the ethanol/sugar/co‑product/synergy bridge of §8.4. Value levers: H₂ cost decline (electrolyzer −15–20%/yr, solar −5–10%/yr toward $2.0–2.5/kg by 2030); Phase 2 scale (−30–40% unit cost); the synthetic‑eSAF premium if §11.2 resolves favourably; policy strengthening; catalyst improvement; and co‑product/O₂/power‑export revenue.
13Roadmap & Milestones
| Phase | Timeline | Milestone | CAPEX ($M) | Status |
|---|---|---|---|---|
| Phase 0 — Development | 2026–2027 | FEED; DA partnership agreement; permitting; offtake term sheets; category opinion (§11.2); financing close | 12–18 | In progress |
| Phase 1 — Construction | 2027–2029 | Plantation, distillery, solar, electrolyzer, eSAF plant | 275–400 | Pre‑FID |
| Phase 1 — Commissioning | 2029–2030 | Start‑up, ramp, ISCC/RSB certification, licensor guarantee test run | incl. | — |
| Phase 1 — Operations | 2030–2032 | Steady‑state 10,000 t/yr | — | — |
| Phase 2 — Expansion | 2031–2034 | 50,000 t/yr; 37,000–42,000 ha; bagasse‑flue capture | 1,000–1,400 | Option |
| Phase 3 — Full scale | 2034–2037 | 100,000 t/yr; 69,000–84,000 ha; evaluate direct hydrogenation | 1,900–2,600 | Option |
14Conclusion & Investment View
14.1 Recommendation & Conditions Precedent
Proceed with Phase 1 ($275–400 M gross; $240–385 M net of grants), on the customary basis that financial close follows: completion of FEED confirming the §8 capital and operating estimates and issuing the hourly PV–electrolyzer–buffer simulation of §5.2; execution of the DA partnership agreement (land, agronomy, outgrower, 20‑yr cane/CO₂ supply); execution of offtake term sheets matching the §9.2 matrix with the index + premium/collar mechanism, take‑or‑pay and certification‑contingent payment; the §11.2 category opinion, ISCC/RED III certification pathway and CORSIA pathway confirmation; a technology licence with an enforceable performance guarantee and liquidated damages (§9.3); BOI/PEZA registration; commissioning of the CO₂ polishing train to the licensor's sub‑ppm inlet spec (§4.1, §5.1); and approval of the bagasse dried‑inventory engineering and the §6.5 water/vinasse permitting package.
14.2 Key Investment Merits
- Structural demand from an eSAF‑specific mandate, with the product category disclosed and priced under both outcomes (§2.3, §11.2).
- Feedstock moat: DA‑secured, lowest‑cost biogenic CO₂ and a waste‑derived bagasse energy stack.
- First‑of‑a‑kind discipline: 220 bpd validates a system‑TRL‑6 integration before scale, on a grant/DFI‑weighted Phase 1.
- Diversified cash flow: eSAF + ethanol + sugar + co‑products + O₂ + power export, bridged explicitly in §8.4.
- Internally consistent numbers: one hydrogen quantity, one CO₂ factor, one capital schedule, one density/price basis, two economics scopes — every headline reproducible from the body.
- ESG alignment: certified very‑low CI in Phase 1 with a scoped Phase 2+ pathway to negative; DFI/green‑bond eligible.
- Scalability: modular Phase 2/3 optionality on shared infrastructure.
14.3 Key Risks to Monitor
Green hydrogen cost (dominant); the ReFuelEU category (the premium gate); system‑integration performance (first‑of‑a‑kind); construction execution; bagasse seasonality and water; FX mismatch; and Philippine regulatory, political and typhoon exposure. Each carries a named mitigation in §9 and, where it gates value, a closing condition in §14.1.
14.4 Next Steps
| Action | Timeline | Owner |
|---|---|---|
| Investor due diligence & data room (term sheets, category opinion draft, hourly H₂ model, tornado) | Q4 2026 – Q1 2027 | Investors + sponsor |
| DA partnership agreement execution | Q1 2027 | Sponsor + DA |
| FEED completion & licensor guarantee finalisation | Q2 2027 | Sponsor + licensor |
| Offtake term sheets → definitive agreements | Q2–Q3 2027 | Sponsor + offtakers |
| BOI/PEZA registration; §11.2 category & certification confirmed | Q3 2027 | Sponsor |
| Financing close (FID) | Q4 2027 | All parties |
| Construction start (EPC) | Q1 2028 | EPC contractor |
| Commissioning & guarantee test run | Q1 2030 | Operations |
A–EAppendices
Appendix A — Technology Provider References
| Provider | Technology | Reference plant | Capacity | Status |
|---|---|---|---|---|
| Johnson Matthey | RWGS + FT catalysts / licence | Various | Multiple | Commercial |
| Sasol | Slurry‑phase FT (SPD) | Secunda (South Africa) | 160,000 bbl/d | Commercial (coal/gas) |
| Shell | Middle‑distillate FT | Pearl GTL (Qatar) | 140,000 bbl/d | Commercial (gas) |
| Haldor Topsoe | RWGS + FT | Various | — | Commercial |
| Velocys | Microchannel FT | ENVIA (Oklahoma, US) | 2,500 bbl/d | Demonstration |
These are unit‑operation references; the integrated biogenic‑CO₂ + green‑H₂ train remains first‑of‑a‑kind (§4.2, §7). Licence terms and the performance guarantee are closing conditions (§9.3, §14.1).
Appendix B — Policy Support Summary
| Jurisdiction | Policy | Value | Duration |
|---|---|---|---|
| EU | ReFuelEU total SAF obligation | 2%→70% (2025–2050) | Permanent |
| EU | ReFuelEU synthetic sub‑obligation (modelled) | 1.2%→35%* | Permanent |
| EU | EU ETS | €60–90/t | Market |
| US | SAF Grand Challenge | 3 bn gal by 2030 | Target |
| US | §45Z | $1.25–1.75/gal | To 2027+ (US location) |
| PH | RA 9367 | E10 | Permanent |
| PH | RA 9513 | RE incentives | Permanent |
| PH | BOI Pioneer | ITH 4–6 yr | Project |
| ICAO | CORSIA | Offsetting pathway | Phase 1 2024–26 |
*Modelled; to be confirmed against Regulation (EU) 2023/2405 and implementing acts (§2.1, §11.2).
Appendix C — Glossary
| Term | Definition |
|---|---|
| eSAF / e‑fuel | Electro‑SAF; SAF from CO₂ + green H₂ via PtL; the industry/Commission synonym for the ReFuelEU "synthetic aviation fuel" category |
| Biogenic eSAF | eSAF from biogenic (fermentation) CO₂ + green H₂; category per §11.2 |
| RWGS / FT | Reverse Water‑Gas Shift (CO₂+H₂→CO+H₂O) / Fischer‑Tropsch (CO+2H₂→hydrocarbons+H₂O) |
| HEFA / ATJ / PtL / OXCCU | Hydroprocessed esters & fatty acids / Alcohol‑to‑Jet / Power‑to‑Liquids / direct CO₂ hydrogenation |
| TRL (unit vs system) | Technology Readiness Level; unit‑operation vs whole‑integration (§4.2) |
| ISCC / RSB / CORSIA / ReFuelEU / RED III | Certification schemes, ICAO offsetting, and the EU aviation mandate |
| DA / BOI / PEZA / SRA / EMB / NGCP / PSO | Philippine agencies/bodies (Agriculture; Investments; Economic Zone; Sugar Regulation; Environment; grid operator; postal savings) |
| E10 / bpd / FOAK / LHV / HHV | 10% ethanol blend; barrels/day (159 L); first‑of‑a‑kind; lower / higher heating value |
| ρ (density) | Fuel density 0.80 kg/L — the $/L ↔ $/t ↔ bpd conversion basis (§2.2) |
| Netback | Delivered price less freight & freight carbon (EU premium, §8.3) |
| DSCR / LLCR / CRF / WACC / NPV / IRR / EBITDA | Debt / loan‑life service coverage ratio; capital recovery factor; weighted average cost of capital; net present value; internal rate of return; earnings before interest, tax, depreciation & amortisation |
| EPC / FEED / MRV / PPA / SPV | Engineering‑procurement‑construction; front‑end engineering design; monitoring‑reporting‑verification; power purchase agreement; special purpose vehicle |
| DFI / GCF / GEF / AIIB / ADB | Development finance institutions & climate funds |
Appendix D — CO₂ Stoichiometry & Supply Analysis
D.1 Fermentation yield. C₆H₁₂O₆ → 2 C₂H₅OH + 2 CO₂. CO₂ per ethanol = (2 × 44.01) / (2 × 46.07) = 88.02 / 92.14 = 0.955 kg/kg; ethanol per glucose = 0.511; CO₂ per glucose = 0.489. The 0.49 figure sometimes cited is CO₂ per kg glucose, not per kg ethanol, and is not used here.
D.2 Combined synthesis stoichiometry (basis for hydrogen). For a (CH₂)ₙ syncrude, RWGS + FT net to CO₂ + 3 H₂ → (CH₂) + 2 H₂O. Per tonne of product carbon: H₂ = 3 × 2.016 / 12.011 = 0.503 t; CO₂ = 44.01 / 12.011 = 3.664 t. For 10,000 t product at 85% C (8,500 t C): H₂ ≈ 4,280 t/yr, CO₂ ≈ 31,100 t/yr, synthesis water ≈ 25,500 t/yr — the figures carried in §3.3, §5.2, §6.1 and §8.5.
| Phase | eSAF (t/yr) | CO₂ (t/yr) | Ethanol (t/yr) | Cane (t/yr) | Plantation (ha) | CO₂ limiting? |
|---|---|---|---|---|---|---|
| 1 | 10,000 | 31,100 | 32,400 | 587,000 | ~8,400 | No |
| 2 | 50,000 | 155,000 | 162,000 | 2,930,000 | 37,000–42,000 | No (land) |
| 3 | 100,000 | 310,000 | 324,000 | 5,860,000 | 69,000–84,000 | Yes (land/CO₂) |
D.4 Supplemental CO₂ (Phase 3). Vinasse biogas (30–50% CO₂, $15–30/t, also the effluent route of §6.5); bagasse‑flue capture (10–15%, $30–60/t, Phase 2+); industrial point sources ($30–50/t); DAC ($200–600/t, future).
Appendix E — De‑risking Decision Framework (220 bpd vs 2,200 bpd)
| Dimension | 220 bpd (Ph.1) | 2,200 bpd |
|---|---|---|
| Integration novelty / failure cost | FOAK, $275–400 M recoverable | $1.9–2.6 B potentially unrecoverable |
| Investor syndicate / fundability | 4–6, high | 10+, low |
| Electrolyzer / solar / land | 40 MW / 88 MW / 440 ha | 400 MW / 880 MW / 4,400 ha |
| Offtake partners needed | 2–3 | 10+ |
| Cane / plantation | 587,000 t / 8,400 ha | 5,860,000 t / 69,000–84,000 ha |
| Electrolysis water | ~38,200 t/yr | ~380,000 t/yr (dry‑season constraint) |
| CO₂ limiting? | No | Yes — land & CO₂ bind |
220 bpd is a deliberate de‑risking decision across system integration, capital, the hydrogen supply chain, offtake and CO₂/land — not a CO₂ limitation. The path is: prove at 220 bpd, scale to 1,100 bpd once validated, and reach 2,200 bpd when hydrogen falls below $2/kg and the supply chain supports it — the trajectory of comparable European eSAF projects.
Note on sources. DM‑XTech Engineering Group | Manila, Philippines 1105. This memorandum is confidential and intended solely for institutional investors; it does not constitute an offer to sell securities. All projections rest on the stated assumptions and the quantitative conventions on the Cover page, which may not materialise; investors should conduct independent due diligence. Regulatory figures are cited to Regulation (EU) 2023/2405 (ReFuelEU Aviation) and its implementing acts; modelled sub‑obligation percentages are flagged as assumptions to be confirmed. Mass, energy and efficiency tables are simplified site balances for orientation; a detailed heat‑and‑power balance and a certified LCA are FEED deliverables.