Shell Global Solutions International, Fraunhofer IKTS and AVL have launched a four-year collaboration to develop a next-generation power-to-liquids (PTL) process using solid oxide co-electrolysis technology to produce synthetic aviation fuel (e-SAF) from CO2 and low-carbon electricity.

The partners will carry out an integrated pilot-scale test programme at Shell’s Energy Transition Campus Amsterdam (ETCA).

The programme is designed to connect key process elements into a single system, bringing together high-temperature co-electrolysis using solid oxide electrolysis cells (SOEC), advanced membrane-based separation, Fischer–Tropsch (FT) synthesis, and off-gas utilisation.

The parties say the research is intended to improve the efficiency and affordability of future e-SAF production compared with currently available PTL technologies.

Aviation is expected to increase its use of e-SAF to reduce reliance on fossil resources and lower lifecycle greenhouse gas emissions.

However, scaling e-SAF will require not only the deployment of PTL technologies that are already commercially available, but also continued innovation to raise performance and reduce costs.

The initiative aims to help bridge what the companies describe as a critical gap between lab-scale advances and commercially deployable solutions.

Shell will contribute its Shell XTL Process, drawing on decades of gas-to-liquids (GTL) experience.

Fraunhofer IKTS is providing its advanced solid oxide co-electrolysis technology, while AVL will deliver electrolysis systems engineering capabilities.

The pilot-scale set-up will pair a 24-kW SOEC electrolyser configured for co-electrolysis with Shell’s existing FT pilot plant, which previously supported the commercialisation of Shell’s GTL process.

The test programme is expected to conclude by the end of the decade, with industrial commercial deployment anticipated during the following decade.

The project is supported by the Dutch government through the DEI Energy Innovation scheme (DEI1250051), which recognises its potential to advance next-generation e-SAF technologies.

HP Calis, General Manager GTL/XTL Technology at Shell, said: “The next-generation PTL technology has the potential to make e-SAF more accessible and affordable. By bringing together complementary expertise from Shell, Fraunhofer IKTS and AVL, this programme allows us to rigorously de-risk and optimise the technology.”

Dr Ing. Erik Reichelt of Fraunhofer IKTS added: “High-temperature co-electrolysis has the potential to improve the efficiency of e-SAF production. Through this collaboration, we are excited to see our solid oxide electrolysis technology integrated into a complete PTL process and validated under realistic operating conditions.”

Juergen Rechberger, VP Hydrogen & Energy at AVL, stated: “Unlocking the full potential of high-temperature electrolysis requires translating promising technologies into reliable, scalable system performance. Through our expertise in electrolysis systems engineering and system integration, we are helping the transition from technology development to industrial application of next-generation e-SAF solutions.” -OGN/TradeArabia News Service