Carbon Neutral Fuels, io consulting and Mission Zero Technologies have completed FEL3a for Project Starling, marking an important step forward in the development of a flagship UK-based eSAF facility planned to deliver over 25,000 tonnes of fuel annually by 2031.
During this phase, the Workington-based project has moved into a more advanced level of technical definition. This has included integrating licensor technology packages into a single integrated facility design, completing key safety studies, and developing a detailed 3D model of the plant. Together, this work underpins a robust Class 3 cost estimate and provides increased confidence in the project’s deliverability.
For a first-of-a-kind eSAF facility, this level of definition is critical. Project Starling will produce synthetic hydrocarbons using captured CO₂, water and low-carbon electricity, creating a pathway to significantly reduce lifecycle emissions compared to conventional jet fuel. In an increasingly volatile market for traditional hydrocarbons, the project’s planned ability to produce up 25,000 tonnes per annum, sufficient to meet approximately 35-40% of the UK’s mandated Power-to-Liquid SAF supply in 2030, while achieving an 95% reduction in greenhouse gas emissions compared to conventional Jet A-1.
Progress to this stage has been enabled in part through the UK Department for Transport’s Advanced Fuels Fund (Window 3), alongside previous funding secured to accelerate development. This support reflects the strategic role projects like Project Starling can play in advancing the UK’s sustainable aviation ambitions.
The focus throughout has been on translating ambition into something tangible, developing a facility that balances technical innovation with operational reality, while embedding capital efficiency and constructability early in the design process. At the same time, there has been a strong emphasis on aligning technology, project development and delivery expertise across all partners.
It’s worth noting that how this has been delivered is just as important as what has been delivered. Close collaboration between Carbon Neutral Fuels, io consulting and Mission Zero Technologies has underpinned progress, bringing together complementary capabilities to move the project forward with clarity and pace.
“Project Starling is an important step towards delivering commercial-scale eSAF in the UK. Completing FEL3A gives us greater confidence in the project’s definition and its pathway towards delivery.”
Stephanie Ng, CNF Project Director.
“FEL3A is where projects move beyond concept into something that can be delivered. By focusing on the right decisions early, around design, cost and execution, we’re helping set a strong foundation for the next phase.”
Richard Dyson, CEO, io consulting.
“This milestone reflects the growing role of Direct Air Capture (DAC) technology in enabling scalable, low-carbon fuel solutions. It’s been valuable to integrate our technology into a defined project context alongside strong delivery partners, and bring yet another project closer to deployment on the ground.”
Nicholas Chadwick, CEO, Mission Zero Technologies.
With this phase now complete, Project Starling moves forward with a clearer pathway towards investment and execution, with the next stage focused on further de-risking, partner alignment and advancing towards the final investment decision.
There is still more to be done, but FEL3a provides a solid platform for the transition from defined concept to delivery.
About Carbon Neutral Fuels
Carbon Neutral Fuels is one of Europe’s leading power-to-liquid companies, pioneering the development of sustainable efuels and building a bridge between today’s aviation needs and tomorrow’s climate considerations. For more information, visit www.carbonneutralfuels.com. For any queries contact izzy@carbonneutralfuels.com
About io consulting
io consulting is a strategic project architect and systems integrator, built to deliver certainty and value in complex energy, chemicals & resources, infrastructure and decarbonisation projects. A joint venture between Baker Hughes and McDermott, we specialise in the front end of project development, providing integrated strategy, engineering and commercial insight across feasibility, concept select & definition, FEED and owner’s engineering. From new developments to transforming brownfield assets, we help clients reduce risk, make better decisions, and accelerate sustainable outcomes. Learn more at www.ioconsulting.com.
About Mission Zero Technologies
Mission Zero is the UK’s leading direct air capture (DAC) company — having deployed the UK’s first two operational DAC systems. We are developing technology that efficiently removes CO₂ from the atmosphere—anywhere, at any scale. By working closely with our customers, we provide a scalable source of sustainable CO₂ directly at the point of use, supporting both high-quality carbon removals and the production of valuable products made from air instead of oil. Learn more at www.missionzero.tech.
