Honeywell and USA BioEnergy Partner on Automation at SAF Refinery

On September 23, 2024, Honeywell signed an agreement with USA BioEnergy (USABE) to implement its Experion PKS Distributed Control System (DCS) and safety system at USABE’s upcoming Texas Renewable Fuels Bon Wier advanced biorefinery. This facility is designed to convert wood waste into sustainable aviation fuel (SAF). This collaboration highlights Honeywell’s focus on three key megatrends: automation, the future of aviation, and energy transition. The Honeywell Experion® PKS will manage the central control and safety operations of the Texas Renewable Fuels plant, ensuring optimal performance, reliability, and safety. Its capabilities in real-time data acquisition, monitoring, and control are set to transform the complex processes involved in converting wood waste into SAF. By integrating these functions, Honeywell aims to significantly improve operational efficiency and help USA BioEnergy meet its production targets with minimal downtime, ultimately reducing airline emissions and promoting more sustainable commercial flights.

“Our choice of Honeywell’s Experion® DCS and safety systems for our Bon Wier facility was a strategic move to ensure maximum efficiency and safety,” stated Nick Andrews, CEO of USA BioEnergy. “Honeywell’s established expertise and innovative solutions will be crucial in achieving our goal of producing sustainable aviation fuel with the industry’s lowest carbon intensity score.”

Located in Bon Wier, Texas, the proposed $2.8 billion greenfield facility is designed to address the increasing demand for sustainable aviation fuel (SAF) from airlines by transforming sustainably sourced forest thinnings into this fuel. Recently, USA BioEnergy secured a 20-year offtake agreement with Southwest Airlines Co., allowing Southwest to purchase up to 680 million gallons of neat (unblended) SAF. When blended with conventional jet fuel, this SAF could yield the equivalent of 2.59 billion gallons of net-zero fuel, avoiding 30 million metric tons of CO2 over the term of the agreement.

“Honeywell’s top-tier automation and safety solutions will be essential for USA BioEnergy’s SAF facility and will contribute significantly to the future of aviation,” remarked Pramesh Maheshwari, President of Honeywell Process Solutions. “Our partnership not only aligns with our vision for a sustainable future but also showcases our dedication to delivering innovative solutions that enhance efficiency through intelligent operations.”

Alongside the DCS and safety systems, Honeywell will deploy the Experion Industrial Security system to enhance the facility's integrated telecommunications infrastructure. This advanced security solution will protect the plant’s critical assets and ensure secure and reliable communications throughout the facility, helping to mitigate potential cyber threats and enhance overall operational resilience.

Honeywell has been a pioneer in SAF production with its Ecofining™ process, which has been commercially producing the fuel since 2016. The company now provides solutions across various feedstocks to meet the increasing demand for renewable fuels, including SAF. In addition to Honeywell Unicracking and Ecofining, its renewable fuels portfolio features ethanol-to-jet technology and eFining™, which converts green hydrogen and carbon.

USABE's Texas Renewable Fuels Bon Wier facility is presently in the detailed design and engineering stage, with Citi providing representation.