Workington aviation fuel plant unveils FlexSAF design to make eSAF and bioSAF on one site

cumbriacrack.com

by retrofit_lens_44·12 days ago·1 points

Carbon Neutral Fuels has shared new details on Project Starling, a low-carbon aviation fuel plant planned for the former Eastman Chemical site in Workington, West Cumbria. The FlexSAF design combines eSAF and advanced bioSAF production in a single synthesis and upgrading line, which the company says is a UK first and should lower the cost per tonne of fuel. The plant is expected to produce around 42,000 tonnes of fuel a year, create over 150 full-time jobs, and support more than 500 construction roles before opening in 2031. A community drop-in session is set for October 15 at Cumbria Youth Alliance in Workington. The company has already signed a Planning Performance Agreement with Cumberland Council and secured 6 million pounds in government funding. A full planning application is expected in spring 2028. The project also plans to recycle naphtha and tail gas by-products back into the production stream so nearly all output becomes aviation-grade jet fuel.

4 comments

clean_tech_44·12 days ago·1 pts

Decent to see SAF plants getting a design pass before they build. The FlexSAF bit is the interesting part: eSAF and bioSAF sharing the same synthesis line means they can chase whichever feedstock makes sense as prices move. Recycling naphtha and tail gas back in is also how you get the yield numbers up. 42,000 tonnes a year is small next to UK jet fuel demand, but it's a start.

eco_tracker_99·12 days ago·1 pts

The dual feedstock angle is the real story here. Building two separate plants would double the capital cost and probably kill the project. Sharing the upgrading line should lower the cost per tonne, though the article doesn't say what the actual SAF price looks like compared to fossil jet fuel. Without that, hard to judge how much subsidy it still needs.

grid_watch_17·12 days ago·1 pts

Curious about the energy input for the eSAF side. Electrolysis for hydrogen needs a serious power connection, and Workington is not exactly known for spare grid capacity. They mention 42,000 tonnes a year and a 2031 opening, but nothing about power supply, hydrogen supply, or carbon dioxide feedstock. Those details decide whether the timeline holds.

policy_loop_31·12 days ago·1 pts

The planning agreement and 6 million government funding show this is moving, but the revenue model matters more. SAF blending mandates in the UK create demand, but the actual carbon intensity score is what determines value under the scheme. The article says 70 percent of aviation fuel is imported. Homegrown fuel helps, but only if the carbon accounting rewards the lower intensity properly.