eSAF Project Advances CO₂-Based Aviation Fuel Production

Phelan Green, through its subsidiary Phelan eFuels, has selected process technology from Honeywell for a planned electro-sustainable aviation fuel (eSAF) facility in Saldanha Bay, South Africa. The project forms part of a broader green hydrogen initiative aimed at producing low-carbon fuels at industrial scale.

Fischer-Tropsch processing for synthetic aviation fuel
The facility will utilize Honeywell UOP’s Fischer-Tropsch Unicracking process, which converts synthesis products derived from CO₂ into liquid hydrocarbons suitable for aviation fuel. In this process, Fischer-Tropsch (FT) synthesis produces intermediate liquids and waxes, which are then upgraded through hydrocracking into fuel fractions that meet aviation standards.

This approach enables the production of synthetic fuels compatible with existing aircraft engines and fuel infrastructure, supporting decarbonization of the aviation sector without requiring major changes to hardware.

Integration within a green hydrogen value chain
The eSAF facility is part of the larger Phelan Green Hydrogen Project, which combines renewable energy, hydrogen production, and carbon utilization. CO₂ is used as a feedstock, and when combined with green hydrogen, it enables the synthesis of hydrocarbons with reduced lifecycle emissions compared to conventional fossil-derived fuels.

Such integrated systems are central to the development of e-fuels, where renewable electricity is converted into chemical energy carriers for sectors that are difficult to electrify, such as aviation.

Production scale and market focus
Once operational, the facility is expected to produce more than 140,000 tons of eSAF annually, targeting export markets in Europe, including the European Union and the United Kingdom. This scale positions the project among early commercial deployments of eSAF production.

The project represents an investment of approximately €2.5 billion (R47 billion), reflecting the capital-intensive nature of synthetic fuel production infrastructure.

Industrial and economic impact
Construction is scheduled to begin in the fourth quarter of 2026 and is expected to generate employment across multiple project phases. Beyond direct job creation, the project contributes to the development of a regional e-fuels industry, supporting supply chain growth and industrial capabilities.

By establishing production capacity for sustainable aviation fuel, the initiative aims to position South Africa as an export hub for low-carbon fuels in global markets.

Edited by Romila DSilva, Induportals Editor, with AI assistance.