Converting waste into fuel and energy
Municipal waste, landfill gas and industrial residues contain valuable carbon and energy. Recovering these resources creates a domestic fuel supply and a productive alternative to disposal.
Annual fuel potential.
U.S. waste holds $130B+ in annual fuel potential
“Millions of tons of recoverable material which could be used are needlessly buried each year.”
— U.S. Congress, Resource Conservation and Recovery Act, 1976
U.S. municipal waste only could “supply” a supertanker of fuel every day
~300M tons of municipal waste landfilled annually in the U.S. Agricultural, forestry and refinery residues expand the opportunity.
Modular methanol production from landfill waste
Revenue from tipping fees, methanol sales and fuel credits.
Proprietary technology
Purpose-built for landfill waste
We develop the full process, supported by our simulator and digital twin. Feedstock sensing informs real-time operating adjustments.
5 patent applications
Wholly owned IP.
Repeatable plant deployment
Standardized designs and suppliers target $19M per replica versus $26M for the first plant. Multiple units share site infrastructure and operations. The digital twin supports plant design and continuous optimization.
Pilot in 2028
24,000 t/day capacity by 2035
Pilot plant
2 t/day
First facility
60 t/day
Fleet expansion
Ten 60 t/day units + one 200 t/day unit. 800 t/day combined capacity.
DME and SAF development. Additional feedstocks.
Standard 200 t/day units. Biomass and additional fuels.
First full year: 2030
Targeting $10B+ by 2040
Annual revenue targets for the first full year at planned capacity. First plant: special terms for the initial landfill partner.
Where we are
Self-funded micro-unit construction with Calmax Technology in Santa Clara.
First version of the digital twin completed.
The waste is there.The chemistry is proven.The team is ready.Let's talk.
andrew@w-forge.comAndrew Rogala, Founder & CEO, Waste Forge Energy
An integrated process
for converting waste into fuel
Landfill waste and landfill gas
Agricultural, forestry and refinery residues
Real-time control
for variable waste feedstocks
AI-assisted feedstock analysis linked to our digital twin.
Analyze
Sensors characterize the composition of incoming waste loads.
Protect
Upstream removal of contaminants protects the synthesis catalyst.
Optimize
The digital twin sets steam, temperature and pressure for each feedstock.
Refine
Operating data updates the model to improve future process control.
First digital twin version completed in October 2026
Methanolis
A modular plant that makes methanol from landfill waste, 60 t/day. Revenue from tipping fees, methanol sales and fuel credits.
WATUS reactor
A single vessel that combines conversion steps usually handled by separate units, and runs as a continuous process. Landfill waste goes in; the syngas it produces is then cleaned and sent on to methanol synthesis.
Part of every Methanolis plant · ready for patent
Methanol
AA-grade methanol — the liquid fuel and chemical building block that ships, refineries and chemical makers already buy by the million tons. This is what every Methanolis plant makes first.
CH₃OH
DME
Dimethyl ether — a clean-burning diesel and LPG substitute made directly from our methanol. Drops into existing engines and distribution, and burns with no soot.
CH₃OCH₃
SAF
Sustainable aviation fuel through the methanol-to-jet pathway — for the part of transport that can't electrify. The same molecule a Methanolis plant makes, upgraded to fuel that flies.
For hard-to-decarbonize aviation
ARChem
Our own process simulator — built in-house. It lays out every plant and solves the full mass and energy balance before any steel is ordered. So every Methanolis plant starts from a solved model, not a paper one.
Built by us · checks every module before it's built
Demand for domestic fuel
meets an abundant resource
Energy security
Fuel from domestic waste reduces exposure to import disruptions and geopolitical supply risks.
Rising energy demand
Shipping, aviation and data centers create demand for additional fuel and energy supply.
Low-emission fuels
Premium pricing creates an opportunity for new supply.
Waste disposal costs
Recurring waste volumes and disposal fees support feedstock availability and plant revenue.
Technical depth and operating experience
Research collaboration with Stanford SUNCAT.
Andrew Rogala
Chemical and process engineer. 10+ years in waste-to-fuel R&D. 30+ publications. $11M+ in funded projects.
Ezgi Erdem Kahraman
Experimental catalysis researcher in the SUNCAT Jaramillo group. Published in JACS.
Changzhi Ai
SUNCAT / SLAC. Digital twins and reactor optimization.
Prof. Thomas Jaramillo
Stanford professor. SUNCAT Director. 123,000+ citations.
Patryk Brożek
21 years as a cybersecurity CEO. Raised $10M+ and completed an exit.
George Marcinkowski
Founder and President, Calmax Technology. Precision machining since 1987. 200+ staff.
A career in waste conversion
and fuel technology
Family scrap business. Early exposure to the value of recovered resources.
PhD in chemical engineering. Catalysis R&D and European waste partnerships.
Assistant Professor and PI. Secured and led $10M+ in research grants. Established a laboratory and team.
Developed fuel demonstration units at 500 kg/day.
Research collaboration with Stanford SUNCAT and SLAC, Jaramillo group.
Founded Waste Forge Energy. Five patent applications ready for filing.
Let's talk.
Send us a message and we'll get back fast.
Prefer email? andrew@w-forge.com