October 28, 2026 — Southwest Research Institute (SwRI) is advancing a scalable framework to provide improved monitoring and informed decision-making that accelerates chemical processes during production of synthetic aviation fuels (SAF).
Despite growing interest in SAF as an alternative to traditional petroleum-based jet fuels, high development costs remain a barrier to industry-wide adoption. In 2021, the U.S. Department of Energy (DOE), along with several other federal agencies, created an initiative to increase domestic consumption of SAFs by 2030.
An SwRI-developed chemometric model provides real-time data that integrates chemistry, mathematics and statistics to predict the physical properties of fuel samples during processing. Traditionally, engineers process fuels in batches and rely on data from physical testing to determine if adjustments are needed to achieve fuel standards.
“It can take hours or even days to receive analysis back for a sample. That lag time drives up costs and wastes valuable time, especially if a fuel is unlikely to meet required specifications,” said Morgan Teel, an SwRI scientist and co-investigator on the project. “Our model allows us to make data-driven decisions as we work to fine-tune chemical processes to meet our clients’ requirements.”
Fuel specifications for SAFs are established by standards-making bodies such as ASTM International. For example, fuels must meet strict physical property requirements for density, gravity and freezing/boiling points. SwRI scientists developed nearly four dozen SAF blends to act as surrogates to validate performance metrics of the new framework.
The model uses a Raman analyzer to measure the chemical response of a sample to predict its physical properties. This gives engineers actionable data they can use to ensure fuels are on track to meet specifications. Although it doesn’t eliminate the need for physical testing, Teel says the framework will supercharge process development for faster results with fewer delays.
“Although initially developed for SAF, we can fine-tune the model to work with other hydrocarbon fuels such as diesel or biodiesel as well as other novel fuels and chemicals,” said Zachary Acosta, a research scientist at SwRI. “Given the versatility of this model, we’re excited to create client-specific processes that we can integrate into control systems on pilot projects.”
The project was funded through SwRI’s Internal Research and Development program, which provides resources for future-focused, unproven concepts to advance technology for government and industry clients. In fiscal year 2025, SwRI invested more than $13 million to fund IR&D projects to pioneer new technologies, expand institutional knowledge and capabilities and encourage the professional growth of its staff. Learn more.
For more information, visit Chemistry & Chemical Engineering or contact Camaron Brooks, +1 210 522 2357, Communications Department, Southwest Research Institute, 6220 Culebra Road, San Antonio, TX 78238-5166.