CleanJoule, a leader in sustainable fuel innovation, has entered the ASTM International approval process for its groundbreaking CycloSAF fuel—a synthetic jet fuel designed to achieve 100% sustainable aviation fuel (SAF) use. This marks a major leap forward in the aviation industry’s efforts to decarbonize, with CycloSAF aiming to bypass the current 50% blending limits that have restricted SAF’s potential for full adoption.
Why 100% SAF Matters
Currently, most SAF is limited to a 50% blend with conventional jet fuel (Jet A/A-1), a mix of hydrocarbons that include both straight-chain and ring-chain molecules. The limitation is due to challenges like fuel density and the absence of aromatic hydrocarbons, which are necessary for optimal engine performance and fuel system integrity. CleanJoule’s CycloSAF, however, is composed exclusively of cyclo-paraffinic hydrocarbons derived from biomass, which allows for a higher density and replaces the need for traditional aromatics. This could pave the way for 100% SAF use, removing the need for fossil-based jet fuel entirely.
According to CleanJoule CEO Mukund Karanjikar, “With a 50% blend limit, you can never get to 65% decarbonization. The math doesn’t work.” The aviation sector has long recognized that reaching its net-zero CO2 emissions target by 2050 will require 100% SAF use. The International Air Transport Association (IATA) estimates that achieving this goal will contribute up to 65% of the industry’s required decarbonization.
What Makes CycloSAF Unique?
CycloSAF boasts several key advantages over existing SAF technologies:
- Higher Density: Unlike other SAFs, which have a density of 0.75 g/cc, CycloSAF weighs 0.82-0.84 g/cc, well above the minimum jet fuel density of 0.775 g/cc. This ensures that airlines can maintain the same energy efficiency, even when using SAF, without the performance penalties typically associated with lower-density fuels.
- Aromatic Replacement: CycloSAF replaces the aromatic hydrocarbons found in fossil fuels, ensuring proper engine and seal function. This has been a critical hurdle for other SAFs, as the absence of aromatics has limited their blending potential.
- Energy Efficiency: CycloSAF is 10% more energy-dense than other SAFs, offering more megajoules per liter or gallon. This could result in significant fuel savings for airlines, making the switch to SAF more economically viable in the long term.
CycloSAF is produced through a two-stage process, starting with the breakdown of biomass into intermediate hydrocarbons, which are then cyclized into the final fuel product. This streamlined process results in higher carbon efficiency and promises to make the fuel cost-competitive with conventional jet fuel once production scales up.
Approval Process and Future Outlook
CleanJoule is currently seeking ASTM approval for a 10% blend under the Fast Track process. While the initial approval is for a lower blend percentage, the ultimate goal is to achieve certification for 100% unblended SAF, a milestone that would revolutionize the industry.
The company plans to scale up production rapidly, starting with a pilot plant and an industrial demonstration facility in Salt Lake City. Full-scale commercial manufacturing is expected within two years. This timeline aligns with the aviation industry’s growing demand for SAF as it prepares for global mandates like the International Civil Aviation Organization’s (ICAO) CORSIA, set to begin its mandatory phase in 2027.
VURDHAAN’s Role in Supporting SAF Development
At VURDHAAN, we are committed to advancing sustainable practices across the aviation industry. As global mandates like CORSIA come into effect and SAF becomes an integral part of decarbonization strategies, we are actively working with airlines, fuel producers, and regulatory bodies to help drive the adoption of SAF technologies.
Through our Support, Educate, and Implement approach, VURDHAAN assists airlines in understanding the complexities of SAF integration, regulatory compliance, and optimizing their carbon reduction efforts. As innovations like CleanJoule’s CycloSAF move closer to full-scale adoption, VURDHAAN is well-positioned to guide the aviation industry through this transformative shift.
The Future of Aviation: 100% SAF
CleanJoule’s progress toward 100% SAF approval represents a significant breakthrough in the aviation industry’s quest for sustainability. With the potential to eliminate fossil-based jet fuel from operations entirely, CycloSAF offers a pathway to drastically reduce aviation’s carbon footprint. As SAF technologies evolve and production scales up, airlines will be able to meet their ambitious decarbonization goals without sacrificing efficiency or performance.
The road to net-zero emissions by 2050 is long, but innovations like CycloSAF bring us one step closer to that future. As SAF becomes more affordable and accessible, the aviation industry will have the tools it needs to make meaningful progress toward a greener, more sustainable future.