Decarbonisation Technology February 2026 Issue

incorporates advanced equipment and in-line quality control systems to ensure consistent, high-quality output. The specifications were defined early in development and validated through in-house testing at JM’s Technology Centre in Teesside, enabling a smooth transition to mass production. A collaborative team from JM and the manufacturing partner worked closely during commissioning to address the challenges of scaling up a novel process. The insights gained during this phase will be invaluable as the technology is further refined and optimised. Scaling catalyst production To meet performance targets, the FT catalyst itself had to be scaled up with equal precision. Initial development and testing were conducted at laboratory scale in Billingham, UK, using both microreactors and CANS carriers to model full-scale reactor behaviour. As development progressed, production moved to JM’s Manufacturing Science Centre, where each step of the catalyst preparation process was carefully engineered using scaled-down versions of full- scale equipment to minimise technical risk. The final manufacturing process was transferred to a dedicated production facility in Clitheroe, UK (see Figure 5 ). Special attention was given to raw material quality, and a series of experiments was conducted to understand the impact of trace impurities on long-term catalyst performance. Each batch of catalyst is rigorously assessed against a defined quality assurance specification before being loaded into CANS carriers, streamlining the production timeline and ensuring readiness for commercial deployment. Powering the Synkedia e-fuels plant Repsol and Aramco are deploying FT CANS technology at the Synkedia e-fuels demonstration plant in Bilbao, Spain, marking a significant commercial milestone for the platform ( JM, 2022 ). This facility will be one of the world’s first to produce synthetic fuels using only green H 2 and captured CO₂ as feedstocks. The project also incorporates JM’s HyCOgen technology, which converts CO₂ and green hydrogen into syngas, integrating fully with FT CANS to produce high-quality synthetic crude suitable for upgrading to produce

e-fuels. With a planned capacity of more than 2,100 tonnes per year, the Synkedia plant will demonstrate the scalability of the FT CANS system. It was the second commercial licence for the technology and the first for HyCOgen, demonstrating a fully integrated solution for e-fuel production. Several other projects are underway across the US and Europe, including the world’s largest announced FT SAF plant being developed by DG Fuels in Louisiana, USA. These projects are well poised to help meet the growing demand for renewable transportation fuels over the coming decade. “ Each step of the catalyst preparation process was carefully engineered using scaled-down versions of full-scale equipment to minimise technical risk ” Conclusion By combining catalyst and reactor innovations with scalable, modular design, JM and bp have created a platform that is not only technically robust but also economically viable across a range of project sizes. The Synkedia project in Bilbao intends to demonstrate the potential of fully renewable e-fuel production using green hydrogen and captured CO₂. With additional projects underway, including the FT SAF facility in the US, FT CANS offers a practical, scalable pathway to meet rising demand for SAF while supporting climate goals and energy security. CANS and HyCOgen are trademarks of Johnson Matthey.

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Dan Carter dan.carter@matthey.com Richard Pearson richard.pearson@matthey.com Andrew Coe andrew.coe@matthey.com James Paterson James.Paterson@uk.bp.com