HIGH-ENERGY LIGHTWEIGHT INNOVATIVE OPERATIONAL SYNTHETIC-FUEL (HELIOS)

Archem LLC proposes to develop a high-energy-density synthetic fuel under this SBIR Phase I project, supporting the U.S. Navy’s (USN) mission to enhance cruise missile propulsion efficiency and range. This effort focuses on molecular modeling, computational simulations, small-scale synthesis, and property validation to establish feasibility. The fuel aims to exceed JP-10’s volumetric energy density while maintaining a flash point above 60°C, viscosity below 200cSt at -40°C, and improved thermal stability to reduce coking and enhance combustion efficiency.Phase I will employ an analysis-of-alternatives (AOA) modeling-first strategy, integrating density functional theory (DFT) and molecular dynamics (MD) simulations to evaluate fuel architectures within the C12-C22 hydrocarbon range. These computational models will guide formulation selection, prioritizing molecular structures that optimize energy density, stability, and compatibility with naval propulsion systems. Machine learning-assisted blend optimization and design of experiments (DoE) will refine candidate formulations before laboratory synthesis.Following computational screening, a 250 mL prototype will be synthesized and characterized using GC-MS, NMR, and FTIR to confirm molecular composition. ASTM-compliant testing will assess heat of combustion, density, viscosity, flash point, and freezing point, ensuring alignment with USN operational criteria. Thermal stability and heat absorption capacity will be evaluated using the Compact Rapid Assessment of Fuel Thermal Integrity (CRAFTI) rig at Johns Hopkins University (JHU) Energetics Research Group (ERG) to assess high-temperature decomposition and coking resistance. Comparative testing against JP-10 will quantify energy output, heat absorption efficiency, and reliability under operational conditions.At the conclusion of Phase I (Base Period, 6 months), Archem will deliver 250 mL of synthesized fuel, computational models, and a feasibility report to the USN’s Technical Point of Contact (TPOC). If successful, the Phase I Option Period (6 additional months) will extend laboratory testing, thermal validation, and cost analysis for scale-up feasibility at production-relevant levels. This structured approach ensures a strong foundation for Phase II development and future transition to operational missile platforms while considering environmental impact and maritime suitability.