Sustainable aviation fuel blends in aircraft piston engine: Comparative analysis of 30 % vs. 50 % SAF on combustion performance and emission reduction

Longfei Chen, Aaqib Zafar, Shenghui Zhong, Kang Pan, Minghua Wang, Yukun Fan, Yang Zhang, Wentao Shi and Zheng Xu

Energy, 2025, vol. 335, issue C

Abstract: The integration of Sustainable Aviation Fuel (SAF) blends into heavy-fuel aircraft piston engines (HF-APE) offers a strategic pathway to decarbonizing propulsion systems in general aviation and unmanned aerial vehicles (UAVs). This study presents a comprehensive comparison of combustion behavior and emission characteristics for SAF-biodiesel and SAF-RP-3 blends, utilizing a hybrid experimental-simulation approach. Emissions were measured according to ICAO Annex 16 protocols using precision instrumentation at varying engine speeds. A validated simulation model accurately replicated combustion, gas exchange, and pollutant formation processes. The 50 % SAF +50 % RP-3 blend exhibited the best emission profile, reducing carbon monoxide (CO) by up to 63 % and unburned hydrocarbons (HC) by 75 % compared to biodiesel-dominant blends. In contrast, the 30 % SAF +70 % biodiesel blend resulted in a 19 % increase in nitrogen oxide (NOx) emissions. Particle size distribution (PSD) analysis showed that RP-3 blends reduced nucleation-mode particles by 30–40 % and total particulate matter (PM) emissions by 38 %. Microscopic examination revealed that RP-3-derived particulates were finer, denser, and less porous, suggesting more complete combustion. A notable strength of this study is the integrated use of differential mobility spectrometer (DMS 500) and environmental scanning electron microscope (eSEM) for comprehensive particulate characterization. Simulations revealed that the 50 % SAF +50 % RP-3 blend achieved superior intake (∼10.7 g/s), exhaust (∼13.8 g/s) mass flow rates, brake power (∼81 kW), fuel efficiency (∼217 g/kWh), and a 28 % reduction in CO2 emissions. These findings suggest that SAF-enhanced RP-3 fuels offer significant potential for improving HF-APE performance and sustainability.

Keywords: Sustainable aviation fuels; Aviation emission reduction; Aviation combustion performance; Particulate matter; Aircraft piston engine; Particle size distribution; Emission index (search for similar items in EconPapers)
Date: 2025
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Persistent link: https://EconPapers.repec.org/RePEc:eee:energy:v:335:y:2025:i:c:s0360544225035248

DOI: 10.1016/j.energy.2025.137882

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