Biofuel and SAF production facilities - Engineering, planning & permitting

With ambitious targets set under the Climate Change Act, the UK aims to achieve net zero emissions by 2050. Biofuels, particularly second-generation biofuels made from waste or non-food biomass, have gained prominence as part of this solution. They offer a renewable alternative to traditional fuels and can be integrated into existing energy infrastructures with relatively minor adjustments.

A significant development in the biofuel sector is the introduction of mandates for Sustainable Aviation Fuel (SAF). The UK’s SAF mandate, driven by the need to decarbonise the aviation industry, requires airlines to increase the proportion of SAF in their fuel mix over the coming years (2% of the total aviation fuel mix must be SAF in 2025, rising to 10% in 2030 and 22% in 2040). This target increases annually to 10% in 2030 and 22% in 2040[1].

This regulatory shift has created a surge in demand for biofuel production facilities that can supply SAF, sparking a wave of investment and innovation. For biofuel producers, this presents both an opportunity, whilst also bringing in further challenges, such as scaling up production while meeting stringent quality and sustainability standards, more competition for feedstocks, and greater pressure on cost and carbon efficiency requirements.

In addition, the UK government’s Advanced Fuels Fund (AFF) is a significant initiative aimed at accelerating the development and commercial deployment of sustainable aviation fuel (SAF) production technologies. With an allocation of over £135 million, the AFF supports innovative projects that convert waste materials and by-products, such as household waste and industrial gases, into low-carbon fuels.

This initiative is part of the government’s broader strategy to achieve net zero emissions and enhance the UK’s position as a leader in the SAF industry. The fund is expected to create up to 10,000 green jobs by 2035 and contribute approximately £1.8 billion annually to the UK economy[2].

In this dynamic and rapidly evolving biofuel production sector, staying ahead of regulatory requirements and sound engineering practice is more crucial than ever. Successfully developing, constructing, and operating a biofuel production plant involves navigating complex engineering, planning, and permitting processes - requiring careful consideration to ensure both regulatory compliance and overall project success.

Engineering

The engineering of biofuel production facilities involves designing efficient and sustainable systems to maximise yield and minimise environmental impact.

Key considerations:

• Feedstock selection and handling: Different feedstocks, such as agricultural residues, waste oils, or purpose-grown crops, require specific processing methods and storage systems. Proper engineering ensures that feedstock is handled and processed in a way that optimises production while minimising emissions and waste.
• Process technology: Biofuel production can involve biochemical processes (like fermentation and anaerobic digestion) or thermochemical methods (such as pyrolysis and gasification). Selecting the appropriate technology based on feedstock availability and end-product requirements is crucial. Engineering teams must also design systems for efficient energy and resource use, integrating heat recovery and emissions control measures.
• Process efficiency is crucial in a biofuels plant because it directly impacts the overall sustainability, cost-effectiveness, and environmental benefits of biofuel production. Efficient processes ensure that the maximum amount of biofuel is produced from the available feedstock, minimising waste and reducing the consumption of resources such as water and energy.
• Waste and by-product management: Biofuel processes generate by-products like CO2, solid residues, or wastewater. Engineering solutions should address efficient by-product utilisation or safe disposal. Innovations like biogas capture for energy recovery or nutrient recycling in agriculture can add value and improve sustainability.
• Safety and risk management: Handling flammable or corrosive materials requires robust safety measures, including fire suppression systems, chemical containment, and proper ventilation. A well-engineered facility minimises risks to both human health and the environment.

Planning

Key considerations:

The planning system must support innovation while balancing environmental, social and economic impacts. Some key elements that must be considered when planning for biofuel facilities:

1. Site selection and community involvement: Biofuels can be highly localised, meaning site selection plays a critical role in minimising transport emissions and logistical costs. Engaging local communities in the planning process ensures buy-in and mitigates potential objections related to noise, odour, and traffic.
2. Integration with existing infrastructure: Many biofuel projects can be co-located with existing agricultural, industrial, or waste-processing facilities. This can streamline the planning approval process while reducing land-use conflicts.
3. Planning policy: Biofuel projects must accord with both local development plans and national policies, such as the UK's Renewable Transport Fuel Obligation (RTFO), to ensure compliance and long-term viability. Planning professionals must work closely with policy experts to navigate the evolving regulatory landscape.
4. Environmental impact assessments (EIA): Ensuring that biofuel production facilities do not adversely affect biodiversity, local ecosystems, water resources or local amenities. Proper waste management and emission control are crucial to avoid new environmental challenges.

As biofuel technology advances and the demand for renewable energy sources grows, the UK planning system will need to adapt to facilitate these projects while addressing concerns over land use, environmental impact, and community well-being. A proactive approach that fosters collaboration between developers, planners, and local stakeholders is essential for building a sustainable future.

Biofuels are not just a part of the renewable energy puzzle; they offer a way to harness the UK's agricultural potential and waste streams in the journey towards a greener, more resilient energy landscape.

Environmental permitting regulations

As biofuel production facilities become integral to this energy transition, navigating the complex landscape of environmental regulations is essential. Environmental permits serve as a safeguard, ensuring that operations meet the required standards for air, water, and soil quality. However, the process of obtaining these permits is intricate, requiring detailed documentation, technical expertise, and a thorough understanding of the regulatory environment.

The Environmental Permitting Regulations (EPR) 2016 (as amended) and similar devolved regulations require operators of specified activities to obtain and comply with the conditions of an environmental permit.

Once obtained, the environmental permit will contain conditions on management, operations, emissions & monitoring and record keeping/reporting. Monitoring of emissions, effluents, and other environmental parameters is often required to ensure ongoing compliance with permit conditions. This includes submitting regular reports to the relevant regulatory agencies and maintaining accurate records.

Key considerations:

• Air pollution
  • Odour emissions: Biofuel facilities often handle odorous materials such as feedstock and run-off lagoons. If these sources are not adequately enclosed or treated, they can release unpleasant odours into the atmosphere, affecting local air quality and community well-being. Effective odour management strategies, including proper enclosure and treatment systems, are essential to mitigate this risk.
  • NOx and SOx emissions: The combustion of biogas in Combined Heat and Power (CHP) plants or other combustion sources can release nitrogen oxides (NOx) and sulfur oxides (SOx). These emissions contribute to air pollution, leading to respiratory issues and environmental degradation. Implementing advanced combustion technologies and emission control systems can help reduce these pollutants.
  • Ammonia emissions: Depending on the type of fuel and combustion efficiency, biofuel production can result in ammonia (NH3) emissions. Ammonia contributes to nitrogen deposition and acidification of ecosystems, which can harm plant and animal life. Monitoring and optimising combustion processes are crucial to minimise ammonia emissions.
  • Dust and particulate matter (PM): Dust can be generated from various stages of biofuel production, including feedstock handling, vehicle movement, and processing. The nature of the material and its moisture content can influence dust levels. Dust control measures, such as water sprays and dust suppressants, are necessary to prevent airborne particulate matter from affecting air quality and human health.
  • Bioaerosols: Bioaerosols are airborne particles that contain biological material, such as bacteria and fungi. These can be released during feedstock handling, especially when open sources are present, and from vented emissions. Inadequate abatement systems can exacerbate this risk. Proper ventilation and filtration systems are essential to control bioaerosol emissions.
• Land pollution
  • Spills and leaks: The storage of raw materials, fuels, and processed biofuels poses a risk of spills and leaks. These incidents can contaminate the surrounding land, leading to soil degradation and potential harm to local ecosystems. To mitigate this risk, facilities must use bunded tanks that can contain 110% of the maximum capacity of the largest tank within the bund. Regular inspections and maintenance of storage infrastructure are also critical.
  • Hazardous by-products: The biofuel production process can generate hazardous by-products, including wastewater that may contain harmful substances. Proper treatment of process effluent on-site before discharge is necessary to prevent land contamination. Facilities must adhere to strict waste management protocols to handle and dispose of hazardous materials safely.
• Water pollution
  • Run-off and effluent: Run-off from biofuel production sites can carry pollutants into nearby water bodies, affecting water quality and aquatic life. This includes run-off from feedstock storage areas and processing sites. Implementing effective run-off management practices, such as containment systems and treatment facilities, is essential to prevent water pollution.
  • Wastewater treatment: The production process generates wastewater that may contain organic and inorganic pollutants. This wastewater requires treatment before it can be safely discharged into sewers or surface water bodies. Advanced wastewater treatment systems are necessary to remove contaminants and ensure compliance with discharge regulations.
• Operational noise: The equipment and processes used in biofuel production can generate significant noise, which could be disruptive to local communities. Permit applications may involve producing a Noise Impact Assessment and Noise Management Plan, as well as implementing noise reduction measures, such as soundproofing, operational limits, or buffer zones.
• Waste management regulations: Biofuel production can generate by products and wastes, including spent biomass, ash, and chemical residues. Regulators will enforce compliance to ensure that by-products and wastes are properly classified, stored, and disposed of correctly.
• Energy consumption: Biofuel production can be energy-intensive. BAT requirements may mean that facilities are required to implement an energy efficiency savings plan.

How can we help?

SLR offers a comprehensive and unique service to our clients, supporting every stage of a facility’s lifecycle – from initial design and engineering, through securing planning consents, preparing environmental permit applications (including any required technical assessments), to providing ongoing technical and regulatory advice.

We bring together a wide range of environmental specialist services, including expert engineers, air quality and noise consultants,, carbon and greenhouse gas reporting specialists, ecologists, land contamination specialists, GIS professionals and, sustainable waste management specialists..

This breadth of in-house expertise enables SLR to deliver integrated, high-quality support tailored to the specific needs of each project.

Our services include:

• Feasibility & market entry & readiness assessments
• Planning permission including all potential environmental assessments as well as EIA
• Due diligence including technical, commercial, and ESG
• Preparation of bespoke environmental permit, including all technical assessments and BAT assessments

References

[1] https://www.gov.uk/government/collections/sustainable-aviation-fuel-saf-mandate

[2] https://www.gov.uk/government/news/uk-saf-industry-goes-from-forest-waste-to-new-heights-with-53-million-boost