Maximizing Sustainable aviation fuel usage through optimization of distillation cut points and blending

Sustainable aviation fuel pathways do not generally yield selective synthetic blend components in the aviation turbine fuel distillation range. Here we discuss a methodology for maximizing the sustainable aviation fuel yield from a pathway and the respective blend ratio with a petroleum-derived fuel by varying distillation cut points. These cut points are typically unique for each combination of feedstock and conversion technology and are essential independent variables for fuel finishing. The resultant cut point variations create a Pareto front, illuminating a competition between yield and blend ratio limits, i.e., the boundary where key operability properties are on the specification limit. Computational and experimental examples are given herein. In the computational case, eight bulk properties are calculated for a surrogate composition to simultaneously predict the competition between distillation yield and blend limit, with 10 points along the Pareto front experimentally verified. In the experimental optimization example, this methodology has been applied to an actual product stream currently under development. Relative to a third-party distillation cut recommendation, the method here yielded 37 %v more renewable carbon into the SAF fraction, while also affording a greater margin to property specification limits. This article shares the optimization process which can impact SAF qualification, the relative corresponding diesel and gasoline fractions, and business strategy.