Eurowings and Greenlyte launch SAF pilot project in Düsseldorf

Germany

Start-up from Essen builds real-world laboratory for power-to-liquid kerosene – Eurowings to take entire output

Düsseldorf Airport is set to host a pioneering energy project. The start-up Greenlyte from Essen is constructing a facility to produce next-generation sustainable aviation fuel (SAF) using power-to-liquid (PtL) technology. In a memorandum of understanding, Eurowings has committed to purchasing the entire production volume exclusively for an initial period of three years and to act as strategic partner. Düsseldorf is the airline’s largest base in Europe.

Innovation in North Rhine-Westphalia

The plant is scheduled for completion by 2028 and will be among the world’s largest direct air capture to SAF (DAC-to-SAF) facilities. It will convert CO₂ extracted directly from the atmosphere and green hydrogen into synthetic kerosene, with part of the electricity demand covered by an on-site photovoltaic system. The annual capacity is projected at 150 tonnes of PtL-SAF – enough for around 60 flights between Düsseldorf and Palma under today’s 50 percent blending limit.

Commercial hurdles remain

So far, PtL-SAF is up to ten times more expensive than fossil kerosene and is produced only in a handful of laboratories. “The future of flying must be both more sustainable and affordable,” says Jens Bischof, CEO of Eurowings. “The Düsseldorf SAF lab shows how the technology can work. But policymakers must help bridge the price gap by supporting investment in production facilities.”

Partners voice their commitment

Lars Redeligx, CEO of Düsseldorf Airport, calls the agreement a milestone: “Eurowings’ declaration to purchase SAF produced here is a strong signal. To lower prices in the long run, production must be ramped up and processes improved through innovation. This project is a crucial step.”

Greenlyte’s co-founder Florian Hildebrand adds: “With Eurowings and Düsseldorf Airport, we have two partners who share our belief in the potential of our technology. Our goal is to prove that eSAF can be produced cost-effectively and at scale – becoming a catalyst for climate-neutral aviation.”