Honeywell to supply eSAF tech for seven Verso plants

Honeywell has been selected by Verso Energy to supply its eFining methanol-to-jet process for seven planned electro-sustainable aviation fuel (eSAF) plants in France, Finland and the United States.

Once operational, the facilities are expected to produce about 200 million gallons of eSAF a year. The build-out is part of a broader industry push to expand synthetic aviation fuel supply as regulators and airlines seek lower-carbon options.

Verso Energy describes itself as an integrated energy company focused on producing low-carbon molecules. It has a project pipeline across Europe and the US, targeting aviation as well as industrial and maritime markets.

Process choice

Honeywell's eFining process converts methanol into jet fuel. The methanol is produced using carbon dioxide from biological sources, renewable electricity and hydrogen. Honeywell says the process can also produce other electrofuels.

The resulting fuel can be blended with conventional jet fuel and positioned as a drop-in option for existing aircraft and fuel logistics. Honeywell says eSAF produced through this pathway can reduce greenhouse gas emissions by 88% versus conventional jet fuel, based on its carbon-intensity analysis and a third-party study of bio e-methanol made from green hydrogen and carbon dioxide captured from biomass processing.

Multi-plant programmes offer technology suppliers scale and repeatability. Honeywell says a standardised design across the seven sites would reduce capital expenditure and shorten delivery timelines, while increasing global sustainable aviation fuel supply.

Policy backdrop

Expectations for eSAF demand are closely tied to policy, including the EU's ReFuelEU Aviation initiative. The measure sets targets for the share of sustainable aviation fuels supplied in the bloc over time and includes a sub-target for synthetic fuels, referred to as eSAF. Honeywell pointed to an expectation that aviation fuel supply would reach 35% eSAF by 2050 under the initiative.

Airlines and fuel suppliers are assessing multiple production routes and feedstocks as they prepare for blending mandates and voluntary procurement. Electrofuels have drawn attention because they can use carbon dioxide and renewable hydrogen, though economics depend heavily on electricity and hydrogen costs and on access to reliable carbon dioxide sources.

Verso projects

Verso Energy has secured EU Innovation Fund awards for two projects, DEZiR and ReSTart. It says these would be among the first large-scale European facilities dedicated exclusively to eSAF production.

DEZiR has also received funding from the French government. Verso has said it expects the project to be among the earlier entrants in eSAF supply when it starts operating in 2030.

Verso Energy Chief Executive Antoine Huard linked the investment case to the policy environment and to production costs for synthetic fuels.

"Efficient and cost-effective eSAF production will be crucial for helping airlines comply with regional adoption requirements," said Antoine Huard, CEO, Verso Energy.

Honeywell Low Carbon Energy Vice President Barry Glickman said the company is focusing on costs and feedstock access, and pointed to carbon dioxide as a potential input stream for scaling supply.

"Honeywell's innovative SAF technology portfolio is designed to address two of the biggest challenges in renewable fuel production-cost and feedstock availability," said Barry Glickman, Vice President of Honeywell Low Carbon Energy.

Broader portfolio

Honeywell has expanded its renewable fuels portfolio in recent years across several conversion pathways. Alongside eFining, it lists Ecofining, FT Unicracking, Biocrude Upgrading and Ethanol to Jet technologies.

Verso's selection adds a multi-site reference for the methanol-to-jet route as project developers weigh options for sustainable aviation fuel production. The seven facilities are planned across three countries, with the first two flagship projects in Europe moving forward with public funding support.

Verso says its first two projects, DEZiR and ReSTart, will be part of the initial wave of large-scale European facilities focused exclusively on eSAF production.