Unleaded Fuel Process Needs A Reboot

I’m not certain if this is a news story, or if Russ just enjoys throwing rocks at a hornets nest to see all of the commenters get riled up. At this point no news is simply, well, no news.

As an engineer developing new products for market, I understand that a typical, successful development project always includes the following:

  1. Unrealistic demands of what the new product must be able to do.
  2. A never ending system of hurry up and wait.
  3. Unrealistic demands that after everyone sat on their hands burning up the clock, you must now save everyone else’s bacon and get the ball across the finish line in record time.
  4. Individuals who have no understanding of the science, industry, or use case are the ones setting the project priorities.
  5. Self interested individuals continually ignore realities and proclaim “just go with my favorite answer now” because the unresolved concerns fall outside of their very limited set of priorities.
  6. The list goes on ad nauseam - and that is when things go well.

A project that the government gave ten years to resolve is only four years along. From my perspective, I am impressed with the progress that has been made in that amount of time. The fact that Russ is proclaiming all to be lost and we need a complete reboot with the FAA jack boot on the neck of fuel manufacturers to obtain it is just adding himself to the list as another obstacle to getting anything done.

I give kudos to at least one organization being honest enough to say that a “drop-in” replacement is not possible. To accept that statement we have to understand what a “drop-in” replacement entails. It is easy to say “I fly behind a Jabiru engine and I don’t need the same octane as some of the big block engines, so let’s just go with XXX”, but that is not a drop-in replacement for the industry. Whatever replacement we ultimately come to will be a system of compromises. Some of us will come out of this perfectly pleased, and some of us will be left out in the cold.

Consider:
GAMI’s fuel is not approved for rotary wing. You cannot get rid of 100LL and leave all of the rotary wing aircraft grounded. News helicopters, med-evac, offshore platform, the list goes on and on.

GAMI’s fuel is approved by the FAA via STC - this approval only means that if I fly a certificated fixed wing aircraft, I am allowed to use it and not get busted by the FAA. It is not an industry approval, and it by no means is a blanket mandate, indemnification, or adoption. It is not approved by the engine manufacturers, it is not approved by the airframe manufacturers, it is not approved by the insurance companies, and it is not approved by the fuel distributors/sellers. The FAA has no authority to mandate via STC that Lycoming engines must run on GAMI fuel, that distributors must sell it, and insurance companies must indemnify it. The STC only gives permission to the pilot to buy it.

We have one fuel that proclaims itself the elixir of all aviation engines, but refuses to allow the industry to examine it. We have another manufacturer that says we are working on the best solution we can, but there is no silver bullet and our solution will not be a drop-in replacement for 100LL. We have a third that is working on it but is keeping their efforts close to the vest.

I doubt that GAMI’s fuel is as perfect as they claim. There are too many red flags. In the end, there will be compromises.

We may need to move to multiple fuels to provide a simple well performing fuel to those who do not need such high octane, and a “compromise” version of 100LL that the EPA can live with in smaller quantities for the larger engines, rotary wing engines, and any others that absolutely require the higher octane.

We may need to choose a boutique fuel that gets us most of the way there, but only after modifications to the engines that require higher octane.

Likely, we will need to kick the can down the road and extend the 10 years. The amount of lead contributed to the environment by aviation fuel is infinitesimally small when compared to the world’s annual consumption of lead - so small that is not measurable in the environment.

There is no perfect solution, and typically it is not the first suitor to knock on your door. We have 10 years to fully develop every option and then make a well informed decision about the compromises that we will need to make as an industry.

For those who want to see GAMI be central to that solution, my recommendation is that GAMI take advantage of the next few years to continue to perfect their product and completely satisfy the testing requirements of every industry group out there. They should resolve the limitation that excluded rotary wing. They should be testing their fuel with Lycoming, with Continental, with Jabiru, with Rotax, with ASTM, with Cessna, and with Piper. They should include representatives of insurers and distributors in those efforts. Sitting on their secret formula and saying “we don’t trust anyone” is doing themselves no favors while their competitors work diligently for a solution that the industry can openly embrace.

And yet somehow, we ended up with the 737 Max?!

I doubt the scrutiny you anticipate the FAA will put into GAMI’s fuel went into the design and production of a worldwide fleet of aircraft from our flagship manufacturer that represents to the world that FAA oversight is the icon of quality.

Swift’s Unleaded 100R fuel does not meet or match the ASTM Standard for 100LL or their own UL94… They have done all of the necessary testing and submitted results for a new ASTM spec that will cover and define their formulation of 100R unleaded fuel. Swift has a refinery, and distribution setup for a number of airports, including rail transport logistics and transloader in LA area and San Francisco Bay Area to ship rail cars and then deliver truckloads to tanks at (currently) 6 Bay Area Airports. The number of fuels any airport can handle is a function of how many tanks they have, which are hideously expensive to add today. Swift plans to transition for UL94 to 100R as soon as the ASTM spec and FAA STC are signed off, for their existing customers. They will add customers as fast as they can from there, while discussing licensing to major Avgas refiners (like Chevron in western US) to begin brewing 100R and distributing in much larger quantities.

I would suggest that inviting someone to “witness” testing is far different than testing in collaboration. I know that in my field, “observing” a test is nearly meaningless. It only allows the people performing the test to attach my name to it and imply that I am party to the results and support them. If you truly want the endorsement of the engine manufacturers, then you need to involve them fully in the process. You need to share with them the formulation of the fuel, fund the testing, allow the engine manufacturer to design and perform the tests, and stand behind the criteria that the engine manufacturer deams critical. Inviting someone who has credibility in the industry to “witness” a test they have no part in designing or performing is a scam, and they were right in refusing to participate.

Would they not sell off the older tankers as they acquired newer ones, keeping their overall fleet the same size?

After the stuff the Swift team pulled at Osh this year, I don’t trust them until an independent fuel expert says the fuel is OK. It seems Swift has friends in high places and I am afraid they will hide the bad data; especially after the UND 94UL disaster.
In God we trust, everyone else bring data.

I believe it doesn’t technically stand for anything anymore

American Society for Testing and Materials. Formed in 1898. Name changed to ASTM International in 2001.

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