The Shell XTL Process for synthetic aviation fuel鈥�(e-SAF) and bio-SAF
The Shell XTL1 Process provides an integrated solution for producing sustainable aviation fuel using Shell鈥檚 commercially proven Fischer鈥揟ropsch technology. With e-SAF 鈥� also known as synthetic aviation fuel, e-kerosene, PTL kerosene, PTL-SAF or RFNBO-SAF2, made using power-to-liquids (PTL) technology 鈥� gaining prominence as a key decarbonisation option for the aviation industry, the Shell XTL Process offers a flexible pathway to producing both e-SAF and bio-SAF from a range of sustainable feedstocks.
What is e-SAF?
e-SAF is a renewable fuel produced using PTL technology that utilises feedstocks (solar and wind energy, carbon dioxide, or CO2, and water) to create synthetic hydrocarbons through Fischer鈥揟ropsch synthesis. The Shell XTL Process leverages lessons learned from Shell鈥檚 integrated GTL technology, as applied at Pearl GTL in Qatar, the world鈥檚 largest integrated GTL facility. This extensive expertise allows the Shell XTL Process to support large-scale e-SAF production, making it a viable option for meeting long-term decarbonisation targets.
On-demand webinar: The Shell XTL process for bio-SAF and synthetic aviation fuel
In this webinar, Shell Catalysts & Technologies Senior Process Engineer Svetlana van Bavel and Senior Engineer Chippla Vandu summarise the decarbonisation levers for aviation, outline various SAF pathways, and introduce the Shell XTL process.
Addressing key industry challenges
The aviation sector is under increasing pressure to reduce greenhouse-gas emissions, but it is one of the hardest industries to decarbonise, owing to the long lifespan of aircraft and the high cost and limited availability of decarbonisation solutions.
Current SAF production is primarily focused on bio-SAF, which relies on easier-to-process feedstocks, such as used cooking oil and animal fats. However, regulations like ReFuelEU Aviation are setting targets that require a growing share of SAF to come from more challenging feedstocks, such as biomass residues, and using renewable power and CO2.
The Shell XTL Process addresses these challenges by offering a versatile solution that uses a range of feedstocks and integrates multiple conversion technologies to produce e-SAF and bio-SAF at scale. Leveraging Shell鈥檚 extensive experience with Fischer鈥揟ropsch technology, the Shell XTL Process provides a versatile solution for meeting both current and future SAF requirements.
Benefits of the Shell XTL Process
The Shell XTL Process provides several key advantages for producers seeking to scale up SAF production. For example, it can help producers to:
- optimise production by using a wide range of sustainable and low-carbon feedstocks, including solar and wind energy, CO2 and biomass residues;
- maximise process efficiency and realise economies of scale by combining e-SAF and bio-SAF production within a single facility; and
- meet evolving regulatory requirements by increasing the share of e-SAF in the production mix.
How it works
The Shell XTL Process integrates multiple technologies, including CO2 capture, the Shell Reverse Water Gas Shift Process, Fischer鈥揟ropsch synthesis and the Shell Wax Hydroconversion Process. The process can be configured to produce e-SAF, bio-SAF or a combination of both, depending on feedstock availability and regulatory needs.
Explore more resources on SAF
Learn more about the economics, scalability, and opportunities for producing SAF.
1 XTL: X-to-liquids, where X stands for anything sustainable, renewable and low carbon.
2 RFNBO: Renewable fuels of non-biological origin.
