e-SAF Production Control
Metafuels software tunes methanol-to-jet reactor campaigns for higher yield and lower energy use, helping narrow the cost difference between e-SAF and conventional jet fuel.
Process
Renewable methanol from biomethane reforming or green hydrogen routes creates a low-carbon starting point. Feedstock quality is checked against contaminant limits before every campaign.
Our closed-loop optimizer refines temperature profiles, pressure targets, and flow settings between runs. The MtJ reaction cascade reaches better operating points as the model learns from every campaign.
Fractionated jet-range hydrocarbons conforming to ASTM D7566 Annex 7. Quality Assurance identifies off-spec runs before blending, supporting consistent product across campaigns.
Platform
Three connected modules link with your plant DCS and improve after each reactor campaign.
Live sensor data supports yield and selectivity forecasts. The optimizer sets parameters for the next run to raise jet-range share and limit heavy-fraction losses.
Each reactor run gets heat-integration and utility-load forecasts. The module finds lower-cost operating windows and spots energy-heavy off-profile conditions early.
Each batch receives continuous ASTM D7566 compliance scoring. Automated carbon-intensity calculations follow CORSIA documentation needs and support your annual reporting cycle.
In practice
The run-to-run optimizer revealed a temperature pattern we had manually worked around for months. After two campaigns using the Metafuels system, jet-cut yield held steady at levels we had struggled to maintain. The early-access pilot justified every hour spent integrating it.
CORSIA carbon-intensity documentation had become our reporting bottleneck. Metafuels Quality Assurance generates the batch-level lifecycle accounting outputs we require. Our sustainability team moved from spending two weeks preparing a compliance package to reviewing a generated report. That changed our operations.
Research
Six months into the first compliance year, fragmented reporting still challenges fuel producers and airlines. We examine the sources of mandated SAF volumes and the gaps that remain.
Read articleMethanol-to-jet reactor beds have uneven temperature distributions, which measurably influence carbon-chain selectivity. These are our observations from 18 pilot runs.
Read articleWater content and contaminants in green methanol feedstock directly influence catalyst life during downstream MTJ conversion. This guide explains what to assess when qualifying suppliers.
Read articleDiscuss pilot partnerships, licensing, or fuel supply with us.
