Prometheus Fuels Slashes Costs: Pioneers Affordable E-Fuels in Santa Cruz

Prometheus Fuels has achieved a breakthrough in clean energy technology by reducing the cost of Direct Air Capture (DAC) of carbon dioxide to less than $50 per ton. This marks an 80 percent cost reduction compared to typical industry ranges of $200 to $600 per ton, establishing a pathway to carbon-neutral fuels that can compete directly with fossil fuels.

The company is demonstrating this achievement with the construction of a new 200-ton-per-year DAC system at its Santa Cruz headquarters. This system expands capacity beyond the 16-ton-per-year prototype already in operation at the Titan Forge Alpha pilot plant. Together, these facilities showcase the scalability of Prometheus’ approach, which integrates air capture directly with fuel production.

Unlike traditional DAC systems that rely on multiple energy-intensive steps, Prometheus captures carbon dioxide directly from ambient air into water and routes it into its proprietary Faraday Reactor. This streamlined process eliminates costly infrastructure for purification, compression, and desorption, significantly lowering both energy use and capital costs.

The result is a modular, off-grid system that can be sited anywhere renewable electricity is abundant and inexpensive. By decoupling fuel production from industrial smokestacks or bio-derived carbon, Prometheus’ technology enables the production of liquid fuels that can be stored, transported, and used globally. These fuels have the potential to power data centers, heavy industry, aviation, shipping, and even stabilize electrical grids with 24/7 carbon-neutral energy.

Independent validation by engineering firm Ramboll has confirmed the company’s cost and production economics. With its new system scheduled for completion this year, Prometheus is positioning itself as a leader in affordable e-fuels, providing a commercially viable alternative to fossil fuels at global scale.