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Carbon Neutral Fuels FlexSAF Project Starling at Workington

New construction · Workington , United Kingdom · FEED / Pre-FID

Project of the week

14–20 October 2026

Carbon Neutral Fuels has unveiled FlexSAF, a hybrid plant architecture that combines eSAF from biogenic carbon dioxide and green hydrogen with bioSAF from biomethane into a shared Fischer-Tropsch synthesis and upgrading line at Project Starling. The October redesign raises target output from 25,000 to 42,000 tonnes a year through process optimisation that allows flexible switching within equipment limits.

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Hybrid eSAF and bioSAF project on the former Eastman Chemical acetate site at Siddick, Workington. It began as the ASAP-DAC concept using direct air capture and has moved to biogenic CO2. The October 2026 FlexSAF redesign adds a biomethane-based bioSAF route alongside the electrolysis-based eSAF route. Both feed one shared Fischer-Tropsch and upgrading line, and naphtha and tail-gas by-products are recycled into the syngas stream. The scheme is backed by DfT Advanced Fuels Fund grants and supports the UK SAF Mandate and regional jobs. Engineering is led by io, and full planning submission is expected in spring 2028.

Where it stands

FEED / Pre-FID

Front-End Engineering Design is underway (FEL-3). Scope and engineering are being firmed up toward a sanction-quality cost estimate (typically ±10–15%). The project is well defined but not yet financially sanctioned — the "pre-FID" phase.

  1. Announced / Concept November 2023 Source: carbonneutralfuels.com · missionzero.tech · linkedin.com
  2. FEED / Pre-FID July 2025 Source: Carbon Neutral Fuels' Project Starling enters pre‑planning at Workington 20 July 2026 · Carbon Neutral Fuels' Project Starling completes FEL3A, advancing UK eSAF deployment 6 May 2026 · Topsoe and Carbon Neutral Fuels Collaborate on e-SAF Project with SOEC Technology 9 December 2025 · Carbon Neutral Fuels and The Carbon Removers to Develop UK Sustainable Aviation Fuel Infrastructure 28 January 2026 · carbonneutralfuels.com · carbonneutralfuels.com
  3. FID / Sanctioned Ahead
  4. Under Construction 2028 (estimated) Source: Topsoe and Carbon Neutral Fuels Collaborate on e-SAF Project with SOEC Technology 9 December 2025 · Carbon Neutral Fuels' FlexSAF redesign boosts Project Starling output 13 October 2026 · hydrocarbonprocessing.com
  5. Commissioning & Start-up Ahead
  6. Operational / Completed 2031 Q4 Source: Carbon Neutral Fuels' FlexSAF redesign boosts Project Starling output 13 October 2026

Companies involved

Substances

Sources and coverage

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