Universal Fuel Technologies unlocks fully synthetic SAF from naptha

US-based Universal Fuel Technologies has demonstrated a pathway to produce fully synthetic, drop-in sustainable aviation fuel by upgrading hydroprocessed esters and fatty acids byproducts, potentially addressing a key limitation in current SAF production, the company said in a statement.

Independent testing by Washington State University validated that the company's flexiforming technology can convert HEFA-derived naphtha into synthetic aromatic kerosene. When blended with paraffinic SAF, the resulting fuel meets critical jet fuel performance standards, the company said on March 17.

The test evaluated a blend comprising 16% flexiforming-derived aromatic SAF and 84% HEFA-based paraffinic SAF. Results showed the fuel performed comparably to conventional jet fuel across key parameters, including density, viscosity, freeze point and flash point.

The development marks a potential breakthrough for the HEFA pathway, currently the dominant SAF production route globally, which produces only paraffinic components. Conventional jet fuel typically contains 8%-25% aromatics, essential for aircraft engine performance and fuel system compatibility.

HEFA naphtha, which can account for up to 20% of output and is often considered a low-value byproduct, is converted through the flexiforming process into the aromatic components required for jet fuel functionality. This could improve project economics while reducing reliance on fossil-derived blending components.

Researchers at Washington State University's Bioproducts, Sciences and Engineering Laboratory said the blended fuel met all screening-stage requirements under ASTM evaluation protocols for candidate aviation fuels.

Current SAF pathways, including HEFA, Fischer-Tropsch and alcohol-to-jet, typically require blending with conventional jet fuel to supply aromatics. The ability to produce both paraffinic and aromatic components from renewable sources could enable 100% drop-in synthetic fuels without fossil inputs.

Universal Fuel Technologies said the flexiforming process can be integrated into existing facilities as a bolt-on solution, allowing producers to upgrade internal byproducts rather than invest in new infrastructure or external supply chains.

The company is also advancing its ethanol-to-jet SAF pathway through ASTM qualification, with its technology having been accepted into the ASTM D4054 clearinghouse in 2025.

The results come as the aviation sector intensifies efforts to scale SAF production while maintaining compatibility with existing fleets and infrastructure.

Platts, part of S&P Global Energy, last assessed SAF California at 970.32 cents/gallon and SAF (H-S) CA (credits det) at 687.81 cents/gal on March 17, based on a spread of neat SAF to jet kero LA CA pipeline of 261.23 cents/gal.

Platts assessed ATF 30/70 CA at 709.75 cents/gal. This reflects a premium of 283.17 cents/gal to jet kero Los Angeles CA Pipeline.

Platts assessed SAF IL at 1,033.61 cents/gal and SAF (H-S) IL (credits det) at 632.81 cents/gal, based on an indicative premium of neat SAF to jet kero Chicago pipeline of 296.23 cents/gal.