G2L™ eFuels technology
Why e-fuels matter
e-Fuels, or synthetic fuels, play a critical role in the global transition to sustainable energy systems. Produced using renewable energy sources, water, and captured carbon dioxide (CO₂), they are a cleaner alternative to fossil fuels.
e-Fuels, like e-SAF and e-diesel, can directly replace conventional fossil fuels in energy-intensive industries that are difficult to electrify like aviation, shipping, and heavy-duty trucking without requiring major changes to existing infrastructure.
Because e-fuels can be used in existing combustion engines and fuel distribution systems, they are a "drop-in” solution. Thus, the costs of overhauling energy intensive infrastructure can be avoided enabling the transition into a cleaner energy source.
G2L-cutting-edge meets proven
The G2L e-fuels solution combines cutting-edge technological innovations with a commercially proven process to convert green hydrogen and CO2 into sustainable synthetic fuels and chemicals, such as e-SAF, e-diesel, and e-naphtha. It is a feed-in-to-product-out integrated solution based on leading technologies that can be adapted to specific product needs.
The diagram below outlines how TOPSOE™ and Sasol technologies integrate to deliver this innovative solution:
The combination of technologies in the solution enables you to achieve:
- Can achieve 100% e-SAF selectivity
- An overall carbon efficiency of +95%
- Lowest hydrogen utilization on the market
- High yields of valuable saleable product
Achieve operational flexibility with naphtha recycling
The G2L e-fuels process offers the ability to recycle hydrocarbon streams, such as the light-end and naphtha fractions from the upgrading section, back to the front-end with minimum additional capital investment. This approach enables a 100% e-SAF yield – while maintaining the +95% carbon efficiency – and allows for operational flexibility to balance intermittency in renewable power supply or price by decreasing the hydrogen demand to the process through the addition of the hydrocarbons. Naphtha pre-reforming and reforming are well-established, decades old processes, and when integrated in the G2L e-fuels process make this an excellent choice for maximizing e-SAF output.
Leverage the best technologies in a fully integrated solution
The key technologies enabling the G2L e-fuels process are TOPSOE™’s eREACT™ technology and hydroprocessing technology, combined with Sasol’s LTFT™ (low-temperature Fischer-Tropsch) technology.
Dive into these technologies in more details below.
Powered by eREACTTM
The eREACT technology electrifies the process by allowing syngas production from renewable energy, water and CO2 in a highly compact reactor. This reactor delivers high conversion rates and superior syngas quality and eliminates flue gas.
Sasol LTFTTM: Synthesis solution
The commercially proven Sasol Low Temperature Fischer Tropsch technology (Sasol LTFTTM) relies on a catalytic process to convert carbon monoxide and hydrogen to long-chain, largely paraffinic molecules. These are ideally suited for producing synthetic kerosene for jet fuel and diesel fuels. The technology and catalyst are in commercial operation in various plants across the globe.
TOPSOE™ hydrocracking: leading solution for upgrading Fischer Tropsch liquid to e-fuels
The TOPSOE™ hydrocracking technology breaks down the long chain molecules while saturating and isomerizing to produce final products of exceptional quality. The required product slate can be tailored to market needs.
Boost green hydrogen production with our SOEC electrolysis
Our Solid-Oxide-Electrolysis (SOEC) technology can help you optimize green hydrogen production and integrates seamlessly with the G2L e-fuels solution. The high-temperature electrolysis of SOEC makes it highly efficient compared to alternative technologies which allows more hydrogen to be produced per unit of power.
TOPSOE™ and Sasol: More than 20 years of collaboration
Collaboration between TOPSOE™ and Sasol on GTL projects is not new. Since 1996, we have worked together on several projects and raised the bar for production efficiency and scale-up. Both companies are recognized as global leaders in our fields, and the development of the technologically cutting-edge G2L e-fuels solution is fueled by our combined efforts.
Customers receive all the necessary technology licenses for a complete G2L e-fuels solution along with basic engineering, catalysts, and hardware.
Our single-point-license solution offers the following benefits:
- Fully integrated design: A single license to build and operate a fully integrated fuels production plant.
- Integrated guarantees: Streamline execution, increase energy efficiency, and ensure reliable production.
- Reliable production: The G2L e-fuels solution is built on proven technologies combined with breakthrough sustainable technologies.
- Bankable: Reduce project risks and increase the likelihood of securing project funding.
Produce what's in demand with end-product flexibility
The end-product slate of G2L e-fuels can be tailored (naphtha, kerosene, diesel) to the demands of the market and your wishes. In the G2L e-fuels process, e-naphtha is a by-product regardless of the end-product you choose to produce. You can sell e-naphtha as a premium sustainable feedstock for crackers in the chemical industry, upgrade it further to gasoline or recycle it back to the front end of the G2L e-fuels process thus maximizing your yield of desired product and being able to handle operational intermittency through electricity supply or pricing.
e-SAF
The G2L e-fuels process efficiently produces synthetic kerosene from renewable energy using CO2 and green hydrogen. You will get a clean burning end-product with low NOx, SOx, particulate matter emissions, and reduced contrail formation. It is an ASTM approved pathway for e-SAF production, as outlined in D7566 – Annex A1 and Annex 4. The synthetic kerosene can be blended with conventional Jet A or Jet A1 at ratios up to 50%.
e-Naphtha
e-Naphtha is a valuable by-product from the G2L e-fuels process. You will get a premium cracker feedstock containing no metals or aromatics that can be sold as a sustainable feedstock for crackers in the chemical industry, or recycle it back to the front-end, enabling 100% e-SAF yield while maintaining +95% carbon efficiency.
e-Diesel
If you wish to produce e-diesel from your G2L e-fuels process, you can. You will get a clean-burning e-diesel with low NOx, SOx, and particulate matter emissions.
Current G2L e-fuels projects
Explore the production potential of the G2L e-fuels process by diving into these customer stories.
TOPSOE™ and Sasol selected to provide their G2L e-fuels technology for the initial built-up of the German Aerospace Center’s Technology Platform Power-to-Liquid Fuels
Once commissioned, expected in Q4 2027, the plant will produce, for research purposes 2500 tons per year of e-fuels mainly sustainable aviation fuel (SAF). With €130 million of funding secured from the German Federal Ministry for Digital and Transport (BMDV), the plant will be the largest facility for production of e-fuels for research.
Arcadia e-fuels chooses Sasol and TOPSOE™ as technology providers for the first commercial e-fuels plant in Denmark.
The plant will produce approx. 100 million litres per year of e-fuels. Arcadia e-fuels aims to produce e-fuels around the world to help meet the aviation industry’s decarbonization goals.
The FrontFuel SynFuels demonstration project
The FrontFuel project is a first of a kind! In 2023, TOPSOE™ received a 26.9 million DKK grant from the Energy Technology Development and Demonstration Program (EUDP) to fund the FrontFuel SynFuels demonstration project. The FrontFuel project will operate in close collaboration with Sasol.
