Calumet and Topsoe Propel North America to the Forefront of Sustainable Aviation Fuel

A major leap forward for clean aviation

In a pivotal development for low-carbon aviation, Calumet has officially become the largest producer of sustainable aviation fuel (SAF) in North America. Through a successful revamp of its Great Falls, Montana refinery, Calumet is now manufacturing both SAF and renewable diesel (RD), thanks to Topsoe's cutting-edge HydroFlex™ technology.

The move isn't just about volume—it's about vision. With a capacity of 15,000 barrels per day, the Montana-based facility is answering a growing call from the global aviation industry to decarbonize, and doing it with practical, scalable solutions.

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Why SAF matters more than ever

The International Air Transport Association (IATA) has projected that the aviation sector will need 120 billion gallons of SAF annually by 2050 to achieve net zero CO₂ emissions. That figure dwarfs the 75 million gallons produced in 2022, highlighting the urgency to ramp up credible supply.

SAF offers a unique advantage: it performs just like traditional jet fuel but is made from renewable feedstocks like waste oils, animal fats, and used cooking oils. It integrates seamlessly into existing infrastructure without the need for engine modifications.

Calumet's Great Falls refinery: a model for scalable change

What makes Calumet’s Great Falls site exceptional is not just its capacity, but its technological adaptability. Using Topsoe’s HydroFlex™ process, the refinery was revamped from a traditional petroleum-based unit into a modern SAF and RD production facility with significantly reduced emissions.

Henrik Rasmussen, Managing Director of the Americas at Topsoe, shared, "It’s great to see the successful production of sustainable aviation fuel by Calumet. Actual production of SAF is crucial for decarbonizing aviation and demand for SAF will only grow the next many years."

What makes HydroFlex™ so effective

Topsoe’s proprietary HydroFlex™ technology is designed to convert low-value feedstocks into high-performance, drop-in fuels. These fuels meet stringent global standards for SAF and RD, all while achieving lower capital expenditure and reduced energy consumption.

This innovation means operators can both retrofit existing plants and deploy HydroFlex™ in brand new facilities, making the technology highly flexible and scalable. It’s not just about producing SAF—it’s about doing it with a lower carbon index and smarter economics.

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A powerful collaboration built for expansion

The success of the Great Falls plant is a testament to what happens when industrial experience meets cutting-edge innovation. The partnership between Calumet and Topsoe is paving the way for further developments.

Bruce Fleming, CEO of Montana Renewables and EVP of Corporate Development at Calumet, stated, "The production of renewable jet is another step toward our company’s strategic goal to help decarbonize the airline industry. It has been a good collaboration between the Calumet and the Topsoe team and we are presently planning an expansion and a further increase to our SAF yield."

The broader impact on North America’s renewable fuel landscape

Beyond Montana, Calumet serves markets throughout Canada and the U.S. West Coast, strategically supplying regions with high demand for clean fuel alternatives. This regional influence is critical for achieving national climate targets, especially in hard-to-abate sectors like aviation.

The Great Falls plant also sets a precedent for other mid-sized refineries seeking to diversify their output and invest in renewable capabilities.

Growing momentum in the sustainable fuels ecosystem

This announcement follows a series of high-profile SAF initiatives across North America, signaling a clear trend toward decarbonizing aviation. From major airlines signing SAF offtake agreements to regulatory incentives on both federal and state levels, the ecosystem is being built fast—and Calumet and Topsoe are at its core.

In fact, global SAF production is expected to hit 8 billion gallons per year by 2030, according to the U.S. Department of Energy. For context, the Great Falls refinery’s annual output alone contributes significantly to that pipeline.

Looking ahead

The momentum doesn’t stop here. Calumet is actively planning to increase SAF yields at its Great Falls facility, a move that could further cement its leadership in renewable fuel production.

With reliable technology from Topsoe and a growing market demand driven by climate commitments, Calumet's role in decarbonizing aviation is only getting stronger. As SAF gains ground globally, this partnership represents what effective climate action looks like in real terms.

The bottom line: This isn't just fuel for planes. It's fuel for the future.