Shell Global Solutions International B.V., Fraunhofer IKTS and AVL launched a four-year collaboration to develop a next-generation power-to-liquids (PTL) process for producing synthetic sustainable aviation fuel (e-SAF). The partners will base the process on solid oxide co-electrolysis technology, which uses carbon dioxide (CO₂) and low-carbon electricity as feedstocks. The programme aims to improve the efficiency and affordability of e-SAF production compared with existing PTL technologies.
Pilot Programme to Combine Key E-SAF Technologies
As part of the collaboration, the partners will conduct an integrated pilot-scale testing programme at Shell’s Energy Transition Campus Amsterdam (ETCA).
The programme will combine several technologies, including:
High-temperature co-electrolysis using solid oxide electrolysis cells (SOEC)
Advanced membrane-based gas separation
Fischer–Tropsch (FT) synthesis
Off-gas utilisation
By integrating these technologies into a single process, the partners aim to demonstrate how high-temperature co-electrolysis can support more efficient synthetic fuel production.
24-kW SOEC System to Support Testing
The pilot programme will use a 24-kW SOEC electrolyser configured for co-electrolysis. The system will operate alongside Shell’s existing FT pilot plant, which has also supported the development and commercialisation of Shell’s gas-to-liquids (GTL) technology. The test programme is expected to run until the end of the decade. Subsequently, the partners anticipate that the technology could move towards commercial industrial deployment during the following decade. The Dutch government is supporting the programme through the DEI Energy Innovation scheme (DEI1250051), reflecting its potential to advance next-generation e-SAF production technologies.
Combining Expertise Across the PTL Value Chain
Each partner will contribute specialised expertise to the project. Shell will provide its Shell XTL Process, which builds on decades of experience with gas-to-liquids technology. Meanwhile, the Fraunhofer Institute for Ceramic Technologies and Systems IKTS will contribute its solid oxide co-electrolysis technology. In addition, AVL will provide electrolysis systems engineering and system integration expertise. Together, the organisations aim to address the technology gap between laboratory-scale innovation and commercially deployable PTL systems. X-to-Liquids (XTL) refers to processes that convert renewable or lower-carbon-intensity feedstocks into liquid fuels.
Supporting the Growth of Synthetic Aviation Fuel
The aviation sector is expected to increasingly use e-SAF to reduce its dependence on fossil resources and lower lifecycle greenhouse gas emissions. However, expanding e-SAF production will require both the deployment of existing PTL technologies and continued innovation. Therefore, the collaboration will focus on improving process efficiency, system integration and cost competitiveness. By advancing solid oxide co-electrolysis-based PTL technology, the partners aim to develop a pathway that could support the future scale-up of synthetic aviation fuel production.
Industry Leaders Highlight Technology Potential
HP Calis, General Manager, GTL/XTL Technology at Shell, said the next-generation PTL technology could help make e-SAF more accessible and affordable. He added that bringing together the complementary expertise of Shell, Fraunhofer IKTS and AVL would enable the partners to rigorously test, optimise and reduce the technical risks associated with the technology. Dr. Ing. Erik Reichelt, Group Manager, Process Systems Engineering at Fraunhofer IKTS, said high-temperature co-electrolysis could improve the efficiency of e-SAF production. He added that the collaboration would integrate the institute’s solid oxide electrolysis technology into a complete PTL process and validate it under realistic operating conditions. Juergen Rechberger, VP Hydrogen & Energy at AVL, said translating high-temperature electrolysis from promising technology into reliable and scalable systems is essential for industrial adoption. As per the press release, AVL will contribute its electrolysis systems engineering and integration expertise to support the transition towards industrial applications of next-generation e-SAF solutions.
