How do you want to do that? Fuel is almost entirely used during travel, not combat. 10% seems way to high, most battles are over in a few hours, compared to months of fuel aboard most of my constructions
Depends on role and numbers were only as an example. You can make the difference even bigger so that ships in maximum speed consume say 10 times more fuel, and assume 5% time in combat and then it would look like this:
0.05*10.0 + 0.95*0.53 = 1.00 ( so roughly half fuel consumption at cruising speed ).
FACs, Fighters and system defense forces would probably use max speed closer to 100% of their time for as fast interceptions as possible, ( and only if they totally wipe out the enemy cruise back slow ) so I think they would balance out the use of bigger long range warfleets.
Most my ships don't spend much time patrolling since that is a waste of fuel, they are sitting stationary at a body or outpost.
But I agree with your concern that it is hard to balance with variables that rests primary on playstyle.
Another perhaps even bigger unknown for balancing is if the player is using "inexperienced crew" or not, since that requires all new ships to spend months if not years in training expending fuel in cruise speed mode resulting in much smaller percentage of time in combat.
the much better suggestion to make engine efficiency nonlinear with size, which has a valid point, that there is little point currently in picking a 2HS engine over 2 1HS engines.
Nothing is stopping you from suggesting your own formula or numbers that is more balanced. But as I wrote I don't see how letsdance formula/suggestion of changing the fuel saving from 1% to 3% would impact the choice of a HS 1 or 2 engine a whole lot.
I have been playing around a bit with a formula and think something like this would work good and feel balanced for engine size:
Formula: sqrt(10/HS)
HS Consumption
1,0 316%
1,2 289%
1,4 267%
1,6 250%
1,8 236%
2,0 224%
2,2 213%
2,4 204%
2,6 196%
2,8 189%
3,0 183%
3,5 169%
4,0 158%
4,5 149%
5,0 141%
5,5 135%
6,0 129%
7,0 120%
8,0 112%
9,0 105%
10,0 100%
11,0 95%
12,0 91%
13,0 88%
14,0 85%
15,0 82%
16,0 79%
17,0 77%
18,0 75%
19,0 73%
20,0 71%
22,0 67%
24,0 65%
26,0 62%
28,0 60%
30,0 58%
32,0 56%
34,0 54%
36,0 53%
38,0 51%
40,0 50%
45,0 47%
50,0 45%
55,0 43%
60,0 41%
65,0 39%
70,0 38%
75,0 37%
80,0 35%
85,0 34%
90,0 33%
95,0 32%
100,0 32%
Edit: I also like the idea to remove detail from the bigger engines ( who needs HS47 engines indeed?) and add it to smaller where it matters, or add more even bigger engines to strech the scale further, so both those have gone into my example above