New standards in industrial eSAF production Interview with Marc Siegel, Head of Sales – Product offtake at INERATEC

Ineratec operates one of the first plants in Germany, in Frankfurt-Hoechst, to produce e-SAF commercially. What makes the plant unique and why did you choose the Frankfurt site?

What makes ERA ONE special is that we have transitioned power-to-liquid technology from demonstration scale to commercial production. The plant is Europe’s largest commercial power-to-liquid plant and can produce up to 2,500 tons of synthetic fuels annually – including eSAF for aviation. By doing so, we are proving that e-fuels are not just a distant vision but can already be produced on an industrial scale today. Another advantage is our modular system concept, which enables rapid scaling. The fuels produced are also “drop-in-ready”, meaning they can be used in the existing infrastructure and – after the necessary preparation and certification – in modern aircraft engines.

We chose Frankfurt-Höchst because the industrial park offers ideal conditions for a power-to-liquid plant. Both key feedstocks are available directly at the site: the CO₂ comes from a biogas plant that processes waste, and the hydrogen is a by-product of chlorine production. This combination enables short transport distances, efficient material cycles and reliable production, making Frankfurt-Höchst the ideal location for us to demonstrate the transition from an innovative technology to a scalable industry for climate-friendly fuels.

How does Ineratec intend to drive forward the scaling of eSAF production facilities in Germany?

We are driving the scale-up of eSAF in Germany through three key levers: standardised technology, strong industrial partnerships, and reliable regulatory frameworks.

With ERA ONE in Frankfurt-Höchst, we demonstrated that our power-to-liquid technology is fully viable on a commercial scale. Building on this foundation, we want to realise additional, larger production capacities. Our modular plant concept is crucial here: it enables us to standardise proven production units, utilise them across different locations and expand capacities more rapidly and cost-effectively. At the same time, technological developments are allowing us to increase the eSAF yield and thus gradually reduce production costs.

However, building individual plants alone will not create a scalable eSAF industry. That is why we collaborate across the entire value chain with energy suppliers, technology partners, refineries, logistics companies, airports and aerospace customers. Suitable sites with sufficient, affordable renewable energy, green hydrogen and sustainable CO₂ sources are also essential.

To transform pioneering projects to into a competitive industry “made in Germany”, long-term investment and planning security are also required: clear quotas, reliable certification standards, fast approval procedures and suitable financing instruments. ReFuelEU Aviation is creating an important demand catalyst in this regard. Our goal is to significantly multiply production through additional projects by 2030 and make eSAF available, step by step, in industrially relevant quantities.

What parameters are essential for Ineratec when scouting for new locations?

When selecting new locations, we look at the entire value chain. The primary factor is the reliable availability of our core feedstocks: renewable electricity, green hydrogen and sustainable CO₂ – for example from biogenic sources. It is not only the available quantities that matter, but equally the quality, costs and long-term security of supply.

In addition, we examine the legal framework conditions, the availability of suitable land and skilled workers, as well as the site’s expansion potential. We do not plan simply for an initial phase: a site must offer the capacity to scale production capacity in the long term.

There are also a number of softer location factors that can positively influence our decision without being mandatory prerequisites. These include, for example, a well-developed industrial infrastructure, existing storage and logistics capacities as well as geographical proximity to refining partners or to potential customers. Locational advantages like these can shorten transport routes, facilitate cooperation and enhance the profitability of a project. For instance, to promote the use of regionally produced SAFs, Hamburg Airport Helmut Schmidt reimburses airlines flying from Hamburg 300 euros per tonne of pure SAF used in their fuel blend. However, the overall picture is always decisive – not every site has to meet all these criteria equally.

Ineratec is cooperating with Rheinmetall on the Giga PtX project. Can you describe the project and its specifics?

Giga PtX is a solution for the development of a resilient and increasingly independent fuel supply in Europe. Together with Rheinmetall and other technology partners, we want to create a Europe-wide network of several hundred decentralised power-to-liquid plants that will ensure an independent fuel supply for the armed forces of NATO partners.

What sets Giga PtX apart is its decentralised, modular approach. Rather than relying on a few large and thus potentially vulnerable refineries, the concept envisions a network of numerous compact, interconnected production sites. These can be built close to strategic consumers and use locally available renewable energy, CO₂ and hydrogen. If necessary, the systems should be able to be operate off-grid and be installed with enhanced protection due to their compact design. This creates redundancy, flexibility and significantly higher security of supply – both in peacetime and in crisis and defence scenarios.

A key advantage is that the drop-in fuels produced can be used in existing vehicles, aircraft and logistics systems, eliminating the need to first roll out completely new fleets or supply structures. Giga PtX thus combines three goals: the resilience of critical infrastructure, greater European energy autonomy and the gradual move away from fossil raw material.

Could military development be a driver for civilian eSAF use?

This is exactly where Giga PtX comes in. In the event of a crisis or defence, these plants strengthen the resilience and independence of Europe’s fuel supply. In peacetime, however, the fuels produced can be used for general or civilian use – for example as eSAF for aviation. As a result, the plants are continuously utilised and create additional production volumes for the growing civilian market.

The decisive factor here is the scaling effect: long-term offtake requirements in the defence sector can secure investments in new production facilities, establish technological standards and help to gradually reduce the costs of synthetic fuels. The civilian market will also benefit from this – especially aviation, which remains dependent on energy-dense, liquid fuels for long-haul flights.

Giga PtX is strengthening Europe’s supply and energy security, while simultaneously making a significant contribution to the reduction of CO₂ emissions and the defossilisation of the aviation industry. In this case, military and civilian use are not mutually exclusive, but together can accelerate the industrial ramp-up of eSAFs.

What do the policy frameworks have to look like for the market ramp-up to succeed?

For the market ramp-up of sustainable e-fuels and other power-to-X products to succeed, long-term, dependable policy frameworks that create investment certainty are essential. The development of new value chains requires substantial initial investments and planning horizons of ten to 15 years. Stable regulatory requirements, clear quota regulations and a cohesive European legal framework are therefore vital. At the same time, incentives should be created to accelerate the market ramp-up of new technologies and support the development of the necessary infrastructure.

Moreover, policy instruments should make a targeted contribution to strengthening local value creation and industrial employment in Germany and across Europe. Investment in the development of a domestic e-fuel industry today does more than just drive climate action – it safeguards technological know-how, fosters innovation and secures high-quality industrial jobs. Funding mechanisms and tendering models should therefore place appropriate emphasis on European value creation.

Another important lever is the public sector as an anchor customer. Government institutions can generate demand at an early stage through targeted procurement programmes and thus accelerate the market ramp-up. In particular, public sector aircraft fleets (“white fleet”), but also applications in areas such as aviation, shipping or critical infrastructure can act as vital lead markets and secure investments.

From INERATEC’s point of view, a triad is therefore essential:

·        long-term regulatory reliability and investment certainty,

·        targeted promotion of European value creation and industrial jobs,

·        and an active role for the public sector as an early buyer of sustainable fuels.

To what extent is cooperation with intermediaries, airlines or airports crucial for your company as a producer? Who is INERATEC currently partnering with and what is the objective of these partnerships?

Collaborations along the entire value chain are vital for the market ramp-up of eSAF. As a producer, we can provide the synthetic fuel, but numerous subsequent steps have to be meshed seamlessly for its integration into regular flight operations: preparation, certification, blending, logistics, commercial distribution and into-plane fuelling. Intermediaries play an important role in bridging the gap between production and the market. Airlines, in turn, generate tangible demand and provide key insights into volume requirements and operational requirements. Airports are indispensable when it comes to integrating eSAF into existing supply and fuelling processes.

INERATEC therefore works with various partners from the aviation, energy, logistics and technology industries, including KLM Cityhopper, Hamburg Airport, MB Energy and ASG-Analytik-Service. Together, they have shown how synthetic kerosene produced in Germany can be integrated into regular flight operations via existing infrastructures.

The overarching objective of all these collaborations is to build a consistent and resilient eSAF value chain: from efficient production and standard-compliant preparation to distribution and use in aircraft. At the same time, we want to create investment certainty, scale production volumes and gradually reduce costs.