Sustainable Aviation Fuel (SAF) Production from Jatropha

Jatropha-based Sustainable Aviation Fuel is produced through the HEFA (Hydroprocessed Esters and Fatty Acids) process, an advanced technology certified under ASTM D7566 standards. This sophisticated refining process converts jatropha oil into high-quality aviation fuel that is chemically identical to conventional jet fuel, ensuring full compatibility with existing aircraft engines and infrastructure.

The HEFA process involves hydroprocessing, where jatropha oil undergoes chemical transformation through the addition of hydrogen at high temperatures and pressures in the presence of specialized catalysts. This removes oxygen molecules and saturates the carbon chains, creating pure hydrocarbons suitable for aviation use. The result is a premium-grade jet fuel that meets or exceeds all international aviation fuel specifications.

HEFA SAF Production Process Flow
SAF Production Process
Complete SAF Production Stages

Stage 1: Feedstock Preparation

  • Jatropha Harvesting: Seeds are harvested when fully mature (dark brown/black color)
  • Oil Extraction: Mechanical pressing of seeds yields 30-40% oil content
  • Pre-treatment: Crude oil is filtered and degummed to remove impurities
  • Quality Testing: Free fatty acid content and moisture levels are analyzed

Stage 2: Hydroprocessing (HEFA Process)

  • Hydrotreating: Oil is heated to 300-400°C under high pressure with hydrogen gas
  • Deoxygenation: Oxygen atoms are removed as water and CO2
  • Hydrocracking: Long-chain molecules are broken into jet fuel range hydrocarbons
  • Isomerization: Molecules are rearranged to improve cold flow properties

Stage 3: Fractionation & Finishing

  • Distillation: Product is separated into different fuel grades
  • Jet Fuel Fraction: SAF is isolated in the aviation kerosene range (C9-C16)
  • Polishing: Final purification and quality enhancement
  • Quality Control: Comprehensive testing against ASTM D7566 specifications
Technical Specifications

The HEFA process produces SAF with exceptional properties:

Energy Density: 43-44 MJ/kg (comparable to Jet A-1)
Freeze Point: -47°C to -40°C (meets aviation cold temperature requirements)
Flash Point: >38°C (meets safety standards)
Aromatic Content: 8-25% (optimized for seal compatibility)
Sulfur Content: <15 ppm (significantly lower than conventional jet fuel)

The resulting SAF can be blended with conventional jet fuel up to 50% under current ASTM D7566 certification, with ongoing research targeting 100% SAF operation. Major refineries worldwide have successfully demonstrated commercial-scale SAF production using the HEFA technology pathway.

Environmental Benefits

The HEFA process for SAF production delivers significant environmental advantages. Compared to conventional jet fuel production from crude oil, jatropha-based SAF reduces lifecycle greenhouse gas emissions by 60-80%. The process is highly efficient, with energy recovery systems capturing waste heat for reuse. Additionally, by-products such as naphtha and diesel can be utilized in other applications, creating a circular economy approach that maximizes resource efficiency and minimizes waste.