Shell Global Solutions International B.V., Fraunhofer IKTS and AVL are launching a four-year programme to develop a next-generation power-to-liquids (PTL) process aimed at producing synthetic aviation fuel (e-SAF) more efficiently and affordably.

 

The programme will focus on solid oxide co-electrolysis technology and combine high-temperature electrolysis with advanced membrane-based separation, Fischer–Tropsch (FT) synthesis and off-gas utilisation. An integrated pilot-scale testing programme will be conducted at Shell’s Energy Transition Campus Amsterdam (ETCA).

 

The collaboration is designed to address a key challenge facing the emerging e-SAF industry: scaling promising technologies from laboratory development to commercially deployable systems while improving efficiency and reducing production costs.

 

The aviation sector is expected to increasingly rely on e-SAF to reduce its dependence on fossil resources and cut lifecycle greenhouse gas emissions. Meeting that demand will require the deployment of existing power-to-liquids technologies alongside continued technological innovation, the companies said.

 

Shell will contribute its Shell XTL Process, drawing on decades of experience with gas-to-liquids (GTL) technology. Fraunhofer Institute for Ceramic Technologies and Systems IKTS will provide its solid oxide co-electrolysis technology, while AVL will contribute expertise in electrolysis systems engineering and integration.

 

The pilot programme will combine a 24-kW solid oxide electrolysis cell (SOEC) electrolyser configured for co-electrolysis with Shell’s existing FT pilot plant, which also supported the commercialisation of Shell’s GTL process. 

 

The test programme is expected to conclude by the end of the decade, with commercial deployment by industry anticipated during the following decade. The programme is supported by the Dutch government through the DEI Energy Innovation scheme, recognising its potential to advance next-generation e-SAF technologies.

 

HP Calis, General Manager GTL/XTL Technology at Shell, emphasised: “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.”

 

Ing. Erik Reichelt, Group Manager Process Systems Engineering at 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.”