XCF Global to double SAF capacity with $300 mil New Rise Reno 2 expansion

XCF Global plans to double its sustainable aviation fuel production capacity to roughly 80 million gal/year with a $300 million investment in a second facility at its New Rise Reno complex in Nevada, the company said Dec. 5.

The company has completed the initial civil works at the New Rise Reno 2 site, including grading and the construction of new access roads, and aims to begin full construction in 202, it said in a statement. The plant will be fully integrated with the existing New Rise Reno facility, sharing utilities, pretreatment, hydrogen supply and logistics infrastructure to reduce capital costs and shorten commissioning timelines.

The expansion comes as XCF continues broader efforts to scale its modular SAF production model across the US and international markets. The company has already invested about $350 million in the original Reno plant, which has been producing renewable diesel during a SAF ramp-up review.

XCF expects to resume SAF output at the first facility in the first quarter 2026.

"New Rise Reno 2 is the next leap forward in our growth strategy," XCF CEO Chris Cooper said. "We're turning New Rise Reno into a major US SAF production center and positioning XCF for sustained, long-term growth."

The project follows XCF's recent memorandum of understanding with global trader BGN to develop a joint distribution and offtake network across Europe, the Middle East and other strategic markets.

The partnership aims to connect XCF's expanding production base with BGN's logistics and trading platform, which the companies claim will be crucial as tightening mandates drive rapid demand growth and structural supply deficits, particularly in Europe, under the ReFuelEU rules.

Mandates accelerate SAF demand outlook

US targets call for 3 billion gal/year of SAF output by 2030 and 35 billion gallons by 2050, while the EU will require airlines to blend 2% SAF in 2025, rising to 6% in 2030 and 20% in 2035. Europe is widely expected to face chronic supply shortfalls as mandates tighten, supporting substantial price premiums for hydrotreated esters and fatty acids-based SAFand next-gen SAF.

XCF has been positioning to capture that demand growth with a multi-site expansion strategy aiming for 160 million gallons/year of SAF and renewable diesel capacity by 2028.

Beyond Nevada, XCF is also advancing projects in North Carolina and Florida and has signed a binding term sheet with New Rise Australia for three renewable fuel plants using its modular platform.

That Australian rollout builds on an earlier MOU to establish a SAF platform across the region.

Challenges continue at first Reno facility

The New Rise Reno facility, commissioned in early 2025 with a nameplate SAF capacity of 38 million gal/year, has yet to reach full output. The plant shifted to renewable diesel in mid-2025 due to catalyst and ramp-up constraints, operating near 2,000 b/d of renewable diesel while XCF works toward restoring full SAF capability.

Despite the operational headwinds, XCF says the Reno complex's modular layout allows faster replication, lower capital intensity and multiproduct flexibility -- features that the company argues will support scalable growth as demand accelerates.

XCF said it will continue to provide development updates as New Rise Reno 2 progresses through engineering and construction milestones.

SAF prices for December loading continued to decline, driven by suppliers covering their 2025 compliance volumes.

Platts, part of S&P Global Energy, assessed the SAF (HEFA-SPK) FOB Farag premium to HEFA barges down $84/metric ton, or 4.3%, week over week, at $1,870/mt. The CIF NWE premium to Jet was assessed at a $10.50/mt premium to FOB FARAG barge levels.