On 28th of November this year, Virgin Atlantic will take a symbolic step on the road to low-carbon aviation, by carrying out a transatlantic flight powered entirely by SAF, using one of its fleet 787 aircraft. Following a conclusive test using a sustainable fuel mixture on a Trent 1000 engine over the summer, the British airline approached EPCOR, AFI KLM E&M’s center of excellence for APU support, to carry out the same operation on an APS5000 – the APU powering Virgin’s Dreamliners.
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The 100% SAF APU: a global first at EPCOR in a full test environment
The 100% SAF APU
A global first at EPCOR in a full test environment
EPCOR BV has performed a ground-breaking test on an APU (APS5000) powered by 100% Sustainable Aviation Fuel (SAF), using a comprehensive testing procedure. Carried out in close collaboration with Virgin Atlantic Airways and the APU manufacturer, Pratt & Whitney Canada, the test represents a historic milestone in terms of creating the responsible, sustainable aviation of the future.
A three-phase operation
Internationally renowned for its technical and operational expertise on a wide range of APUs, EPCOR has provided APU maintenance for the Virgin Atlantic 787 fleet since 2014; the subsidiary was therefore the obvious candidate to carry out this landmark operation. The ground test carried out on 2 October 2023 took place over three phases.
“To start, our technical teams carried out a test using standard A1 kerosene in order to establish the nominal performance values. The second step involved running the SAF through the fuel injection system, without sealing the fuel lines, and leaving the APU to ‘soak’ in the SAF for at least 36 hours. This wait period is essential, since SAF may potentially affect the integrity of joints, linings and O-rings. Finally, the performance test using a 100% SAF configuration was carried out, with the results being compared to the first test (using A1 kerosene) in order to identify any potential anomalies such as elevated combustion temperatures or exhaust gas temperatures.”
Heidi Haveman
Managing Director at EPCOR
Low-carbon aviation in action
In detail, the mixture of SAF used was made up of 88% HEFA/SPK (Hydroprocessed Esters and Fatty Acids/Synthetic Paraffinic Kerosine) and 12% SAK (synthetic aromatic kerosene, a sugar derivative). Following up with the second test is necessary because the first can lead to drying of the joints and linings within the fuel injection system. This high-performance mixture can achieve significant reductions (up to 70%) in greenhouse gas emissions compared to traditional fuels.
“"This potential reduction could be further increased in the future, to the extent that the production of fuel starts to integrate lower-carbon energy sources. The aviation sector is under significant pressure to become more sustainable. In accordance with the objectives set by the Air France-KLM Group, AFI KLM E&M seeks to lead the way in this regard, and this EPCOR test is a reflection of our initiative. With this test, we’ve taken one more step toward the ultimate goal: using 100% sustainable resources instead of fossil-based kerosene.””
Rob van de Graaf
Directeur commercial d’EPCOR
In addition, this operation showcases the dynamics of cooperation at play between the various stakeholders – airlines and MROs, as well as OAM/OEMs – around this shared objective. The success of this trial, and the sharing of its results and reports between the three parties involved (Virgin Atlantic, EPCOR/AFI KLM E&M and Pratt & Whitney), will provide the entire industry with enhanced insight into APU performance levels when powered by 100% SAF.
