Carbon Neutral Fuels' FlexSAF redesign boosts Project Starling output
- FlexSAF enables simultaneous eSAF (from biogenic CO2, water, renewable electricity) and advanced bioSAF (from biomethane) production on one site.
- Redesign increases Project Starling SAF output by ~70% from 25,000 to approximately 42,000 tonnes per annum.
- Process recycles naphtha and tail gas into the syngas stream and uses a shared Fischer–Tropsch synthesis and upgrading line to maximise jet fuel yield.
- Engineering with io consulting is underway; PPA signed June 2026, public drop-in 15 October 2026, full planning submission targeted Spring 2028 and first fuel Q4 2031.
Design overview
Carbon Neutral Fuels (CNF) has unveiled FlexSAF, a hybrid plant architecture that combines two feedstock pathways into a single facility at Project Starling in Workington, West Cumbria. The design integrates eSAF production (from biogenic CO2, water and renewable electricity) and advanced bioSAF production (from biomethane) into a shared Fischer–Tropsch synthesis and upgrading line, enabling flexible switching of the production mix within equipment limits.
Process and output
Process optimisation and the shared FT/upgrading train increase target SAF output from 25,000 tonnes per annum to roughly 42,000 tpa (around a 70% uplift). By recycling by-products — naphtha and tail gas — back into the syngas stream, CNF says virtually all output is converted into aviation‑grade jet fuel, which is expected to lower production cost per tonne. CNF describes the commercial-scale hybrid as a UK-first.
Schedule and local impact
The project targets reuse of a 40-acre brownfield site and expects to create more than 500 construction jobs and over 150 skilled operational roles. CNF signed a Planning Performance Agreement with Cumberland Council in June 2026 and will hold a public drop-in session on 15 October 2026. Engineering work with io consulting is under way, with a full planning application planned for Spring 2028 and first fuel targeted in Q4 2031.
Source: CNF