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Sustainable aviation fuel (e-SAF) is clear for take-off

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Everllence and Shell have joined forces to derisk and scale-up technology for e-SAF productions

The challenge is huge – sustainable aviation fuel (also known as synthetic aviation fuel, e-SAF, e-kerosene, PtL-kerosene, or PtL-SAF), is crucial for reducing air transport's climate impact. Aviation currently accounts for around 3% of global CO2 emissions and is projected to more than double by 2050. The work done under this collaboration aims to provide a technology for producing the fuels that are required under the ReFuelEU Aviation regulation. 

Since 2022, Everllence (formerly MAN Energy Solutions) and Shell have been developing a new solution to produce e-SAF based on the Shell Reverse Water-Gas Shift (RWGS) process and Everllence molten-salt reactor technology. RWGS is a key technological building block for the production of e-fuels, as it enables the production of synthesis gas (syngas) from carbon dioxide (CO₂) and hydrogen (H₂). Together, we have paved the way for commercial-scale production.

First EU e-SAF subquota takes effect
2030
e-SAF quota for flights from EU airports in 2050
35
%

What is e-SAF? 

e-SAF is a renewable fuel produced using Power-to-Liquids (PtL) technology that utilizes feedstocks, such as renewable (or nuclear) power, carbon dioxide (CO2), and water to create synthetic hydrocarbons. The solution proposed by Everllence and Shell is based on the Fischer–Tropsch (FT) pathway for making e-SAF. 
The Shell X-to-Liquids (XTL) process leverages lessons learned from Shell’s integrated gas-to-liquids (GTL) technology, as applied at Pearl GTL in Qatar, the world’s 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 decarbonization targets. 

A productive partnership

Shell contributes catalyst formulations (for RWGS, FT synthesis and hydroprocessing steps of the integrated process), technologies for CO2 capture and optimized integrated design of both chemical process and utilities (including optimal use of steam, water, fuel gas, etc.) for making e-SAF, while Everllence provides the reactor equipment for FT and RWGS.

 

 

Everllence key equipment for e-SAF production

With decades of experience in chemical reactors, compressors and electrolyzer technology, Everllence can provide all the key equipment for e-SAF production. Our expertise spans salt-operated reactors, Fischer-Tropsch reactors (for Shell’s FT technology), high-performance gas compression, and green hydrogen production—delivering reliable, efficient, and industry-leading equipment for a sustainable future.

The Everllence subsidiary Quest One can provide the electrolysis equipment that turns renewable energy into green hydrogen. Quest One ensures cost-effective, efficient and large-scale production. CO2 can be captured and handled with our world-leading CCUS technologies.

Illustration of an H2 Electrolyzer
Captured CO₂ from industrial and biogenic sources forms the carbon foundation of sustainable fuel production. Alongside the Air Separation Unit (ASU), process, CO₂, syngas, and recycle gas compressors enable efficient gas compression, circulation, and purification—ensuring optimal conditions for downstream synthesis and maintaining a closed carbon loop within the Power-to-Liquid value chain.



Illustration of ASU and other elements of a carbon capture facility

The DWE® RWGS reactor is an endothermic, molten-salt-operated reactor system for the production of syngas from renewable carbon dioxide and hydrogen. The required process energy is provided as renewable electricity. Key innovations in comparison to standard Everllence molten-salt-operated reactors include:

  • Operating temperature range elevated by more than 100-150°C
  • Increased heat input of up to several 10 MWs

Illustration of a DWE salt bath reactor

The Fischer-Tropsch reactor converts the syngas produced by the RWGS reactor into Fischer-Tropsch wax. The wax made during Fischer-Tropsch synthesis is then passed to a hydroprocessing unit, based on another Shell proprietary technology, where final products are made, such as kerosene. Shell’s commercially mature Fischer-Tropsch technology is used in Shell’s GTL plants, for which Everllence has provided Fischer-Tropsch reactors.

Illustration of Fischer-Tropsch reactor

RWGS pilot plant in Deggendorf achieves first 10,000 hours

Shell and Everllence initiated a close collaboration in 2021 for the development of the Reverse Water Gas Shift (RWGS) process. As part of this effort, a pilot plant was constructed at the Everllence’s research facilities in Deggendorf (see picture). This started operation in early  2023. Since commissioning of the plant, about 10.000 successful operating hours have been achieved.

Pilot-scale RWGS unit with silver tanks and green pipelines inside a modern facility

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