The impact of sustainable aviation fuels on aircraft fuel line, ice formation and pump performance

With the aviation industry facing increasing environmental and energy challenges, there has been a growing demand for sustainable aviation fuel (SAF). Previous studies have shown the role of ice accretion, release and blockage in aviation-related incidents and accidents with conventional jet fuel. However, there is no available data that establishes the magnitude of influence new fuel compositions will pose on ice formation and accretion in aircraft fuel systems. A recirculating fuel test rig capable of cooling fuel from ambient to −30°C within 4h was built by Airbus to simulate conditions in an aircraft wing tank and allow characterisation of ice accretion. The key characteristic was the pressure drop across an inline fuel strainer for the different SAF explored but visual analysis of ice accretion on the strainer mesh (filters used in protecting fuel feed pumps) was also performed for individual experimental runs for comparison. Measurements revealed that 100% conventional fuel exhibited a higher propensity to strainer blockage compared to the SAF tested. However, all SAF blends behaved differently as the blending ratio with Jet A-1 fuel had an impact on the pressure differential at different temperatures. Data from this work are essential to establish confidence in the safe operation of future aircraft fuel systems that will potentially be compatible with 100 % SAF.