Shell Global Solutions International

Pioneering sustainable aviation fuel (SAF) through Power-to-Liquids innovation

Shell Global Solutions International B.V. (Shell) is taking an important step toward the large-scale production of synthetic aviation fuel, also known as e-SAF. This sustainable fuel is produced by converting renewable electricity, water, and captured CO₂ into hydrocarbons that can replace conventional kerosene. The pilot project, supported under the DEI+ (Demonstration of Energy and Climate Innovation) scheme, focuses on validating a second-generation Power-to-Liquids (PtL) process that significantly improves energy efficiency and reduces production costs compared to current PtL technologies.

Integration of co-electrolysis and Fischer-Tropsch synthesis

At the core of this pilot lies the integration of high-temperature co-electrolysis (co-SOEC) and Fischer-Tropsch (FT) synthesis, two advanced technologies that together convert CO₂ and water directly into syngas and subsequently into liquid hydrocarbons. This novel configuration allows Shell to cut down process steps, improve heat integration, and reduce the carbon footprint of fuel production. The goal: making e-SAF not only sustainable, but also economically viable for large-scale adoption.

Towards affordable and scalable e-fuels

The demonstration will take place at Shell’s Energy Transition Campus Amsterdam (ETCA). Results from the pilot will provide essential data on the operational stability and efficiency of the integrated system, forming the foundation for future commercial-scale PtL plants with an annual production capacity of up to 200 kiloton e-SAF. These plants could make a substantial contribution to meeting the EU’s ReFuelEU Aviation targets, which require at least 5% synthetic aviation fuel by 2035.

Hezelburcht’s contribution

Hezelburcht supported Shell Global Solutions International in preparing the DEI+ grant application, covering all aspects from the technical project plan to the CO₂ impact analysis, work package definition, and economic perspective. The collaboration resulted in a successful award decision by RVO. In the end we can speak of a pleasant and effective collaboration which we are proud of!