Nov-2022

Decarbonising liquid fuels with BioFlux technologies (ERTC)

The traditional oil and gas industry is transforming as modern fuels become cleaner and more sustainable.

Matthew Clingerman
Sulzer Chemtech

Article Summary

Consumption of biomass-based fuels will continue to increase as more renewable mandates and clean fuel standards come into effect. At the same time, expanded processing capacity using innovative technologies is necessary to achieve a more environmentally conscious energy supply.

Renewable fuels produced from fats, oils, and greases have become the dominant pathway. Vegetable oils, seed oils, and rendered animal fats are the primary feedstocks, but waste feedstocks such as used cooking oil are also in high demand. However, sustainability, availability, price, and quality all influence feedstock selection. Above all, producers of renewable fuels look for a process that will provide low cost of production while ensuring operational flexibility.

Benefits of Renewable Diesel
The benefits of renewable fuels have been well-publicised throughout the market. In short, these benefits include:
• Renewable diesel is chemically identical to petroleum diesel, and therefore the existing infrastructure and engines can accept these fuels without blending limits
• Hydroprocessed esters and fatty acids (HEFA) can be blended directly with fossil jet fuel up to established blending limits
• When compared to petroleum diesel, diesel produced from renewable sources can reduce life cycle carbon emissions by up to 90%

BioFlux Hydrotreating
Traditional renewable diesel process units are beset with operational challenges, including high hydrogen requirements, short cycle times, and lower yield of valuable diesel product. BioFlux® hydroprocessing technology was developed to offer superior performance and overcome the challenges of renewable diesel production. With BioFlux technology, refiners benefit from:
• Higher diesel yield
• Efficient hydrogen management
• Lower propensity for coking and over-cracking
• Lower capital and operating expense
• Reduced carbon footprint

A Reduced Carbon Footprint
Implementing BioFlux helps producers reduce the carbon intensity (CI) of the finished fuels, thus ensuring that they will meet or exceed the CI reduction targets. All renewable diesel processes generate off-gas. The off-gas generated from the BioFlux hydrotreating unit not only contains hydrogen that can be recycled, but it is also rich in light hydrocarbons that can be used to generate additional hydrogen and fuel the fired heaters. By using the produced co-products, including naphtha, hydrogen can be generated by catalytic reforming. If produced in sufficient quantities, the off-gas and naphtha could eliminate the need for supplemental natural gas, which significantly reduces the carbon footprint of the BioFlux process plant.

Furthermore, with lower operating expense, longer catalyst life, and higher diesel yield, the CO₂e per MJ of diesel is up to 25% lower than traditional hydrotreating technologies.

Summary
BioFlux technology, developed by Duke Technologies and licensed by Sulzer Chemtech (GTC Technology), is a low-Capex, low-Opex solution for hydroprocessing bio-based materials. The advanced design features of BioFlux ensure successful management of the reaction zone to minimise formation of unwanted reaction byproducts. This increases the yield of the higher-value, drop-in renewable diesel product with lower hydrogen consumption and reduced carbon footprint. The process offers superior operational stability for extended catalyst life and is suitable for grassroots or revamp units, either standalone or in an integrated facility.

This short article originally appeared in the 2022 ERTC Newspapers, which you can view HERE