Enhancing the Blending and Measurement of SAF and Jet A Fuels with Icon Scientific & PAC Process Analysers

In the evolving landscape of aviation fuel, the integration of Sustainable Aviation Fuel (SAF) with traditional Jet A fuel is a critical step in reducing the carbon footprint of the aviation industry. This article outlines the journey of blending SAF and Jet A, highlights opportunities for process optimization, and explores the role of advanced measurement technologies from PAC and Icon Scientific that enable producers to maximize efficiency and reduce costs.

What is Sustainable Aviation Fuel (SAF)?

Sustainable Aviation Fuel (SAF) is an advanced biofuel designed to replace conventional jet fuel, offering a more eco-friendly alternative for aviation. SAF is produced from sustainable feedstocks such as used cooking oils, agricultural residues, and municipal waste. One of the key benefits of SAF is its ability to significantly reduce the carbon footprint of aviation, one of the largest contributors to global greenhouse gas emissions. In fact, SAF can reduce lifecycle greenhouse gas emissions by up to 80% compared to traditional fossil fuels, depending on the feedstock and production process used. SAF is compatible with modern aircraft and can be used in blends with conventional fuel, requiring no changes to the fuel distribution infrastructure or aircraft systems.

In addition to its environmental benefits, SAF is a crucial component of international efforts to decarbonize the aviation industry. Initiatives such as the Carbon Offsetting and Reduction Scheme for International Aviation (CORSIA) and the European Union's Renewable Energy Directive II (RED II) are encouraging airlines to adopt SAF as part of a broader strategy to achieve net-zero emissions by 2050.


Growth in the SAF Market

The global SAF market is experiencing rapid growth, driven by increasing demand for eco-friendly air travel solutions, stringent environmental regulations, and a surge in investments in sustainable technologies. According to market forecasts, the SAF industry is expected to grow from approximately $610 million in 2022 to $3.92 billion by 2028, reflecting a compound annual growth rate (CAGR) of over 56% from 2023 to 2028.

Several factors are fueling this growth. Airlines and airports are increasingly adopting SAF to reduce carbon emissions, and governments are offering incentives to support the transition to sustainable aviation. For example, the U.S. Department of Energy is collaborating with other federal agencies to develop advanced technologies for SAF production. Additionally, airlines like Delta and JetBlue have committed to increasing their use of SAF to meet long-term sustainability goals.

North America currently leads the SAF market due to its large aviation industry and favorable regulatory environment. However, the Asia-Pacific region is also expected to see significant growth as countries like China and India ramp up efforts to reduce aviation emissions.

Overall, the SAF market is poised for substantial expansion as industry stakeholders - including airlines, governments, and environmental groups - work together to create a more sustainable future for air travel​(MarkNtel)​(grandviewresearch).


The Journey of SAF and Jet A Blending

The production and blending of SAF and Jet A fuel involve distinct processes. Jet A fuel is refined to ASTM D1655 specifications from crude oil feedstock, while neat SAF is produced at specialized facilities using various feedstocks, depending on the pathway approved in ASTM D7566.

Once both Jet A and neat SAF are produced, they are transported to a terminal, where they are blended to form the final SAF product. This blended fuel must meet specific criteria in table above of ASTM D7566 before being transported for use in aircraft. If the fuel meets these criteria, it is considered compliant with ASTM D1655 standards, ensuring it can be safely used as jet fuel.


Process Optimization Opportunities

During this journey, there are multiple points where producers can optimize their processes—whether at the refinery, the SAF facility, or the blending terminal. Process analysers play a crucial role in this optimization, providing real-time data that allows operators to adjust the blending and refining processes dynamically.

By incorporating process analysers, producers can move beyond the traditional reliance on laboratory measurements. Real-time analysis helps ensure that the fuel stays within the required specifications, improving yield and reducing costs. In some cases, process analysers are even used to achieve compliance, further streamlining the process and saving time.


PAC's Advanced Solutions for SAF and Jet Fuel

PAC and Icon offer a comprehensive range of analysers that can measure key properties of both Jet A and SAF fuels. These solutions are certified for use in hazardous environments and are designed for robustness, with minimal maintenance required. We have outlined some of PAC and Icon Scientific’s key offerings for Process Measurement:

  • NSure Analyser for Sulfur and Nitrogen: The NSure product can measure sulfur content from percentage levels down to parts per billion (ppb) and includes optional nitrogen detection. Precise sulfur measurement is crucial for meeting regulatory and safety requirements.
  • Icon Freeze Point Analyser: Accurate freeze point measurement is critical for jet fuels, as it determines the fuel’s performance in cold environments. Icons’ Freeze Point Analyser can measure temperatures down to -100°C in under 10 minutes, thanks to a patented cryo-cooler technology that eliminates the need for external chillers.
  • MicroDist for Distillation: Distillation characterization is essential for understanding the stability and volatility of the fuel. PAC’s MicroDist is the fastest analyser available for this process, completing full distillations in under 10 minutes at temperatures up to 430°C. It offers better repeatability than ASTM D86 standards and excellent correlation to atmospheric distillation benchmarks like the OptiDist.
    Meanwhile, Icon’s Distillation analyser performs real-time small-volume D86 tests up to 430°C with high measurement precision and complete versatility of measurement types, all available in detail over Modbus.
  • Icon Flash Point Analyser: The flash point of a fuel is the lowest temperature at which it can vaporize to form an ignitable mixture in air. Icons’ Flash Point Analyser follows the ASTM sparking flash test method, incorporating a unique electrode auto-cleaning system to reduce the impact of carbon build-up. Internal cameras allow for observation of the process without opening explosion-proof doors, and optional solvent wash cycles minimize maintenance by preventing waxy or gum buildup.


Ethanol Blender: A Parallel Technology

Although not directly related to SAF, Icon's Ethanol Blend Optimiser is a noteworthy innovation that gasoline producers use to optimize ethanol blending at the terminal, rather than the refinery. Ethanol, like SAF, is added after the refining process.

By blending ethanol at the terminal and measuring its impact in real-time, producers can optimize gasoline production and reduce costs. This same blending technology could potentially be applied to SAF, helping producers fine-tune their processes to reduce over-specification and minimize waste.


Future Prospects for SAF and Jet A Blending Technologies

As the SAF market grows, the need for advanced blending and measurement technologies will become more critical. PAC is exploring opportunities to apply its Ethanol Blend Optimiser and other process analysers throughout the SAF production and blending journey.


Fuelling Sustainability: PAC & Icon Scientific—Precision in SAF and Jet A Fuel Analysis for a Greener Tomorrow

PAC and Icon offer a full ecosystem of solutions for the analysis and measurement of SAF and Jet A fuels, providing lab-based and process-based analysers that ensure compliance with the latest ASTM standards. From sulfur and nitrogen detection to distillation and flash point analysis, PAC and Icon Scientific technologies support producers in optimizing their fuel blending processes, reducing costs, and improving safety.

With the aviation industry’s increasing focus on sustainability, PAC and Icon Scientific are committed to helping producers meet their SAF goals and take flight with confidence.