SwRI produces, evaluates SAF made from e-fuel

Texas-based independent, nonprofit, applied research and development organisation Southwest Research Institute said it has successfully produced a batch of blended sustainable aviation fuel (SAF) from carbon dioxide and green hydrogen.

“Aviation is difficult to decarbonise due to the fuel density and power required for flight,” said Francesco Di Sabatino, a group leader in SwRI’s Mechanical Engineering Division. “With this project we’re gathering important data for conventional fuel and two different SAFs.”

The process included chemical engineers refining electrofuels, or e-fuels, manufactured with hydrogen that’s produced from electrolysis of water and captured carbon dioxide or carbon monoxide. This was then processed into in-house SAF meeting aviation fuels standards.

Through a series of hydroprocessing reactions over several weeks, process engineers refined the e-fuel into SAF to meet federal specifications.

“All jet fuels, including SAFs, must meet ASTM quality and safety standards, along with emissions guidelines set by the EPA, but conducting a full-scale jet engine test requires millions of dollars and hundreds of thousands of gallons of fuel,” Hsiang Yee Hoekstra, a manager in SwRI’s Chemical Engineering Department said.

SwRI is one of the pioneers in the research of propulsion, aircraft technology, alternative fuels, and emissions characterization. In 2024, the institute invested more than $11m into its internal research and development program aimed at advancing new technology without the narrow scope and expected deliverables of contract R&D.