Unifuel’s 100% Drop-in SAF Production Technology Passes First Test in ASTM Qualification Process

A major step for a new patented technology that can potentially produce 100% synthetic drop-in sustainable aviation fuel from multiple renewable feedstocks has been achieved by California-based Universal Fuel Technologies. Ethanol-to-Jet SAF produced by the company’s Flexiforming technology has been accepted into the ASTM D4054 Clearinghouse, which supports the technical evaluation of new aviation fuels, for qualification. Acceptance requires demonstrating, by independent testing, that a fuel is not only technically credible and can be produced at a meaningful scale, but also that it has met strict quality and safety criteria. For the testing, Unifuel produced 100 litres of sample material for four different SAF pathways in a five-month pilot project. The company will now proceed with producing larger fuel samples for detailed Tier 1 and Tier 2 testing required for ASTM qualification, which it hopes can be reached by the end of 2026.

>> In Other News: EU Hopes to Boost Permanent Carbon Removals With New Purchasing Programme

“The acceptance into the D4054 Clearinghouse confirms that Flexiforming can produce high-quality synthetic aviation turbine fuel with a clear route to ASTM qualification,” said Denis Pchelintsev, Co-Founder of Universal Fuel Technologies. “We’re positioned to support the aviation industry’s urgent need for cost-effective synthetic aviation turbine fuel that doesn’t compromise on performance or safety.”

The ASTM D4054 evaluation process is the aviation industry’s framework for ensuring that new fuels can safely power aircraft engines and includes multiple tiers of testing, data collection, and technical review by fuel and aerospace experts.

“We accept candidate fuels into the D4054 Clearinghouse that show strong potential for completing the ASTM qualification process successfully,” said Dr. Zachary West, Director of the ASTM D4054 Clearinghouse. “This marks a significant milestone for Universal Fuel Technologies towards their goal of commercial acceptance.”

The pilot project, carried out at the facilities of RPD Technologies in Texas during August to December last year, focused on converting methanol and ethanol to SAF, and ethanol with paraffinic renewable naphtha made via HEFA to SAF.

The pilot yielded two distinct forms of SAF: Synthetic Aromatic Kerosene (SAK), an essential aromatic blend component for maintaining compatibility of paraffinic SAF with the composition of fossil kerosene, and a 100% drop-in, fully-synthetic SAF that contains the correct aromatic content for commercial use.

“As a result, the aromatic component of SAF produced through Flexiforming, made from HEFA and Fischer Tropsch (FT) naphtha, can be blended with the primary paraffinic SAF stream from these units,” said Unifuel. “This creates the opportunity to produce drop-in SAF directly at HEFA and FT units, reducing the costs and complexity of the logistics, and aiding in industry adoption.”

Added Alexei Beltyukov, CEO of Universal Fuel Technologies: “The impact of this pilot project reaches far beyond technical validation. A considerable value of Flexiforming is that it contributes to making SAF fully interchangeable with fossil jet fuel once ASTM approved. Because of its aromatic properties, which are essential for compatibility with today’s aircraft, Unifuel’s SAK can be blended with paraffinic SAF from HEFA or FT and sold directly to airlines without the need for blending with another fuel.

“As the aviation industry faces increasing pressure to reduce its environmental impact and contain costs, technologies like Flexiforming could be crucial in scaling up SAF production to keep pace with demand.”

Samples of Unifuel’s Flexiforming SAF were tested and analysed at Washington State University’s Bioproducts, Sciences, and Engineering Laboratory for Tier 0 screening, the initial step in the SAF certification process.

The technology licensing company says it has spent a decade developing its Flexiforming chemical process. In October 2024, it closed $3 million in a seed funding round led by TO VC, with participation from Alchemist Accelerator, Claire Technologies, and World Star Aviation.

“Today’s SAF production is challenged by feedstock limitations and expense, which are problems Unifuel’s Flexiforming solves,” said Joshua Phitoussi, Managing Partner at TO VC. “Unifuel has engineered a more efficient SAF production method that dramatically cuts costs while getting the most out of limited resources.

“The feedstock flexibility of Unifuel’s technology gives the company the ability to work in multiple SAF pathways, partnering with the best players of whatever pathway makes the most sense in a given geography.”