Close the feedstock generation gap. And lower greenhouse gas emissions

Today three generations of feedstock are available to produce renewable fuels. But not all feedstocks are equal when it comes to meeting the greenhouse gas (GHG) targets. That is one reason why it is essential to select a processing technology that future-proofs your plants' ability to handle all types of feedstocks. And, as an added benefit, it allows you to become independent of changing feedstock prices and potentially restricted supply of first- and second-generation feedstock. 

Your choice of feedstock is critical for the GHG emissions of biofuels

GHG emissions can be decreased by choosing a feedstock with low cultivation emissions and using low GHG hydrogen for hydroprocessing. As an example, let us look at the use of rapeseed oil for HVO and FAME.

Figure 1: Default values for emissions from Annex V for rapeseed oil. The blue color depicts the GHG emissions from cultivation, orange is oil extraction, grey is the GHG emissions from the process step from oil to renewable diesel and yellow is the transportation.

The majority of GHG emissions originate from the cultivation of the seeds, and the limit on GHG emission is already reached before reaching the biorefinery site. All processes after cultivation add to the GHG emissions, surpassing the limit for allowed GHG emissions for biofuels.

This figure shows that the GHG emissions are the same irrespective of the process used. We can also clearly see that the main contributors to the GHG emissions are the cultivation followed by the process – whether hydroprocessing or esterification.

Figure 2: Example of GHG emission for HVO produced from rapeseed oil

Figure 2 shows us how it is still impossible to reach the RED II directive limits even with a lower cultivation GHG emission part. However, the challenges to stay below the GHG emission target are multiple. First, it is necessary to process a feedstock with a low cultivation emission, but the process also needs to be optimized to stay below the threshold. The example to the right shows how our H2Bridge™ solution, where a hydrogen unit in combination with a HydroFlex™ hydrotreating unit, will significantly lower the GHG emissions to well below the RED II requirements. This is achieved by minimizing the GHG emissions by using the off-gasses from the hydrotreater for hydrogen generation. Read more here

A circular, sustainable solution

With H2bridge™ and HydroFlex™, you gain a circular solution that will provide you with the ability to produce one of the lowest carbon intensity fuels in the world. You can convert low-value feedstocks to renewable fuels that continuously meet changing specifications and legislative requirements. Add a lower energy consumption during operation, resulting in a lower Carbon Index (CI).

See why Seaboard Energy chose our renewable fuel technology to produce extremely clean renewable diesel from tallow and soybean oil.

Be ready for the feedstocks of the future

The price and availability of feedstocks are some of the most crucial factors affecting biodiesel production. So how do you make yourself independent of market fluctuations, unpredictable feedstock pricing, changing regulations, and restrictive blending caps?

One of the most sustainable bets is opting for hydroprocessing and the build-in flexibility it brings to your refinery.

The generation challenge is real

As a FAME producer, you are already familiar with first-generation feedstocks like vegetable oil, animal fat or tallow. Perhaps you have also included second-generation biomass feedstock and have experienced the need for different processes like pretreatments to capitalize on the investment?

At the same time, the ‘food vs fuel’ debate and concerns around land use is likely to limit the use of these types of feedstocks in the future.

To become independent and flexible you can look to the evolving third-generation feedstocks like algae which are generally low cost, high-energy and completely renewable. But the catch is, that you will not be able to process these new advanced feedstocks in a traditional FAME set-up.

Add to that, that the future of biofuels may not rely on one generation of feedstocks alone but the ability to combine the three generations to cope with the increasing demand for renewable fuels.

Get total feedstock flexibility

To achieve maximum feedstock flexibility, you will need the ability to process whatever feedstock you have available. The HydroFlex™ is our tried-and-tested technology for hydrotreating feedstock of varying quality and type.

You can begin hydrotreating the feedstocks you know and build from there. You can change feedstock and take advantage of lower prices, lower quality, better availability and still deliver the specified quality of renewable fuel. And when the third-generation feedstocks become readily available in the market, you will be able to benefit from those too.

How do we know that this will work? We know because our R&D experts for a decade have been analyzing and testing the possibilities. Along with a number of trusted partners, we are leaving no stone unturned, and we can confidently claim to be at the forefront of the technologies needed for the future. Our test labs constantly test various process conditions and unit configurations for specific feedstocks, including solids to liquid which are not far from being commercialized.

Your transformation project, is our commitment

The decision to transform your biorefinery and implement hydroprocessing to meet future market demands is not easy. We understand that. But there are ways to make such a decision safer and less complicated.

Most importantly, you need to have a licensor who is a fully dedicated and competent partner. An experienced ally who understands your business, knows the market, and has the skills to look beyond the obvious when designing and evaluating what is needed. We are that partner.

Get support from the drawing board to full operation

As your project development partner, we offer extensive knowledge and experience. In a close collaboration we will explore what needs to be done to bring your transformation strategy to life. And though no two projects are the same, this process has proven valuable:

NB: Vi skal have lavet grafik ud af de fire emner, så det bliver let at afkode.


Scope & Design

What feedstocks do you have experience with – and access to? What do you want to produce? Which - if any - assets are already in place? These are some of the initial questions.

The next step is the development of a basic engineering design package (BEDP), providing you with the necessary information on exactly how to integrate the hydrotreatment unit with your current set-up. The BEDP is also the foundation for your preferred Engineering, Procurement & Construction (EPC) partner to proceed with detailed Front End Engineering Design (FEED). Regardless of your choice of EPC, we will be there to support, advise and review plans throughout the process.

Perhaps a detailed feasibility study will benefit the decision-making process and provide you with the best possible overview and a solid decision-making platform prior to the BEDP. We can provide that study.

Construction & Commissioning

During the initial construction phase, we will be available for advice and support. Once the plant is ready to install proprietary equipment like reactor internals, we will be present to provide advisory services on any topic within our scope.

Unit start-up

Once the HydroFlex™ unit has been commissioned, the catalysts can be loaded and activated. At this time, everyone from the EPC to the pre-treatment vendor and will be there. And so will we as the licensor. Once a stable operation is achieved, it’s time to conduct the Performance Guarantee Test Run (PGTR) to ensure the unit performs exactly as expected and fulfills the guarantees.

Operation & Optimization
Our services continue long after your HydroFlex™ unit is up and running. We’re always there to help you gain the best possible return on your investment and the highest possible yield in the changing feedstock market.

Catalytic dewaxing.
Improve cold flow properties and gain maximum diesel yield

Hydroprocessing renewable feedstocks is complex. From process design to choosing the optimal catalyst technology, there are many factors to consider. Our research and development programs have been focused on refining HydroFlex™ technologies for more than a decade.

This includes dewaxing which is an important factor when processing renewable feedstock where improving the diesel cold flow properties while ensuring maximum diesel yield is key to running a good business.

For FAME producers adjusting the cloud point is an almost impossible task.

One of the many benefits of hydroprocessing versus FAME is that you can gain control and adjust the cloud point. And you can minimize diesel yield loss per cloud point improvement.

You can also improve the diesel product and ensure it meets any diesel specification, and thereby is sellable, through catalytic dewaxing.

For jet fuel, dewaxing plays an even more prominent role because cloud points are lower, which means that the potential loss will be more significant. Having the right dewaxing catalysts minimizes yield loss and ensures on-spec renewable jet fuel.

Isomerization catalysts make the difference

If the temperature gets sufficiently low, there is a risk of wax crystals in the processed feedstocks which can block fuel filters and lines. The resulting fuel starvation will mean engines stop running. In other words, wax is bad for your business.

Our new generation of dewaxing catalysts are true isomerization catalysts and ensures that wax molecules are not formed when diesel is exposed to cold temperatures, which is essential in many parts of the world.

The isomerization changes long-chain n-paraffins into the same length iso-paraffins (branching). This improves cold flow properties significantly, but only shifts the boiling point slightly, keeping the compound in the diesel and jet fuel fractions.

As a result, there is hardly any loss of yield to lower boiling fractions. This significantly improves yields of higher-value diesel and jet fuel with on-spec cold flow properties.

Get the flexibility you need to deal with changing conditions

We have designed more than 150 diesel hydrotreaters that use feedstocks ranging from easy, straight-run feeds to 100% cracked feedstocks, as well as many kinds of renewable feedstocks.

Based on our worldwide comparative studies and technical documentation, we know what works and what doesn't and can help you make a well-supported decision. So, if you want to include dewaxing capabilities, we can help you analyze and compare possible configurations and recommend what is best suited to meet your exact requirements.

Trends in advanced biofuels and hydrogen: where are we heading?

The European Green Deal and the Renewable Fuel Standard in North America have set up significant new standards for refinery emissions. All the while, new feedstocks are emerging, and technologies are being increasingly improved. Are we on the verge of the ultimate breakthrough for advanced biofuels and hydrogen in refineries and biorefineries?

Though the future is hard to predict, we see some tangible moves towards achieving lower GHG emissions. Recent developments in the legislative sphere are not to be ignored though the goals and means differ from region to region.

The European Green Deal…

This initiative is all about transforming the EU’s economy for a sustainable future. It is a growth strategy that aims to change the EU and ensure a resource-efficient economy, with one of the elements being a no-net emission of greenhouse gasses in 2050. Here explained by the European Commission:

“Further decarbonizing the energy system is critical to reach climate objectives in 2030 and 2050. The production and use of energy across economic sectors account for more than 75% of the EU’s greenhouse gas emissions. Energy efficiency must be prioritized. A power sector must be developed that is based largely on renewable sources, complemented by the rapid phasing out of coal and decarbonizing gas” (1)
(1) https://ec.europa.eu/info/sites/default/files/european-green-deal-communication_en.pdf.

Also, the Renewable Energy Directive from 2018 (RED II) sets the target for consumption of renewables to 32%. This includes the transport sector, which for the road and train requires a minimum of 14% of the energy consumed by 2030 as renewable energy. The 14% target is also the minimum for eligibility for financial support from public authorities. In particular, the RED II introduces sustainability for forestry feedstocks and GHG criteria for solid and gaseous biomass fuels.

National renewable action plans are being implemented to meet the targets and progress is measured every two years. (2)
(2) https://ec.europa.eu/jrc/en/jec/renewable-energy-recast-2030-red-ii

The cap on blending limits will be the game-changer

Biofuels produced from feedstocks with "high indirect land-use change-risk" (ILUC risk) are limited by a restrictive cap of at least 10% for fuels for transportation. From 31 December 2023 until 31 December 2030, at the latest, the limit shall gradually decrease to 0%.

Few countries offer 100% renewable fuel as an option for transportation. In most countries, it is a matter of blending. As the blending limits for FAME do not seem to be rising, both biorefineries and countries must look for alternatives to meet the targets set by the European Commission.

The answer is not surprisingly renewable diesel and renewable jet fuel with no caps.

The transport sector is leading the way in the US

In the US, there is a growing interest in renewable fuels. The RFS2 (Renewable Fuel Standard 2) requires refineries to blend 36 billion gallons of renewable fuel into the country's total transportation fuel consumption by 2022. At the forefront are states like California, Oregon, and Washington, with the Low Carbon Fuel Standard (LCFS) designed to decrease the carbon intensity of transportation fuel and provide an increasing range of low-carbon and renewable alternatives. New York is also aiming for a net-zero emission by 2050.

Despite oil prices dropping significantly, the renewable volume obligation still stands. Some companies are building new renewable diesel plants to meet future demand for renewable diesel. One driver for the transition is the authorities' economic incentives and tax deductions for refineries producing a certain number of barrels of renewable fuel. And with more states looking to adopt the LCFS protocol, the US market for renewable diesel and jet fuel will continue its growth.

Another US trend is the increased focus on waste-to-fuel. The FAME process is not ideal for this due to the structure of the molecules, but hydroprocessing provides a versatile and manageable solution allowing refiners and biorefiners to produce renewable diesel and renewable jet fuel and benefit from the incentives.

South America has enormous potential

Some people say that South America can become the new Saudi Arabia when it comes to renewable fuel production. Simply because the amount of feedstock in the region is vast. The climate, the growth rate of feedstocks, the bio-economy, the option to grow winter crops like brassica carinata or canola does not replace feed crops but allows countries to deploy the resources available to produce renewable diesel and renewable jet fuel.

The regions use of renewable jet fuel will most likely soar in the coming years when the aviation industry gets back on its feet. Legislations regarding renewable jet fuel seem to be on their way, and the easy access to feedstock makes the production relatively straightforward and economical.

South East Asia will most likely produce for local markets

The interest for renewable fuels is increasing in the region and feedstocks are plenty. Waste oils can be used to fill the increasing need for sustainable aviation fuel and several countries are looking towards renewable fuels to meet the Sustainable Development Goals. Combined with an increasingly growing plastic industry, this sets the scene for an off-take of high-value naphtha for plastic production.

Conclusion

The regional trends together paint a picture of an emerging industry that will grow to meet the global demands for renewable fuels using a multitude of feedstocks. Each region will have its preferred feedstocks and regional demands, but the overall trend is the need for renewable jet fuel seconded by naphtha and diesel demand. The business case is ready – are you?

What is best for your business? It depends on your long-term strategy and your desire for market share

Producing diesel with a low carbon footprint is not new, and two production pathways exist, resulting in two product categories with quite disparate properties.

FAME (Fatty Acid Methyl Esters) biodiesel is produced from the transesterification of vegetable oils, waste oil, animal fat, or tallow. The production is relatively simple and transforms oil into long-chain mono alkyl esters using liquid (homogenous) catalysts. FAME can be mixed with conventional diesel to decrease carbon dioxide emissions, but globally several legislative blending limits restrict the use of FAME.

Renewable diesel is produced in a catalytic hydrodeoxygenation process followed by a dewaxing step, making it possible to turn virtually any renewable feedstock into an on-spec diesel. The removal of oxygen will produce hydrocarbons molecules similar to diesel constituents, with the renewable diesel being composed of paraffin without oxygen, aromatics, or sulfur and the dewaxing step will ensure good cold flow properties.

Compared to FAME, renewable diesel has the highest cetane content, best cold flow properties, and highest market value as the properties are close to petro-diesel. Not to forget that renewable diesel can be used with no blending limits making it a profitable solution.

The difference between renewable diesel and FAME biodiesel is:

1. The way it is produced. Renewable diesel is produced via catalytic hydroprocessing, while FAME is produced through transesterification.

2. The flexibility you have as a refiner. With FAME, you can only produce biodiesel and glycerol. With hydroprocessing, you have a choice of producing renewable diesel, jet fuel, and naphtha – or a mix. You also have the option to tune and optimize your output and product. For example, you can specify the performance of the diesel with summer and winter modes, control the cloud point and increase yield.

3. The cap on blending limits. Restrictive caps limit the amount of FAME blended into the diesel, but renewable diesel produced with hydroprocessing is a drop-in fuel and can be blended without restriction on the percentage. Which means you can sell more.

Yes, you need hydrogen for hydroprocessing. No, it is not a problem

Yes, you need hydrogen for hydroprocessing.
No, it is not a problem.

That could be the short version of this story, but we recognize that it is both an investment and a significant shift to start using hydrogen to produce renewable diesel, renewable jet fuel and naphtha. However, it is a shift that comes with benefits. Let’s have a look.

Hydroprocessing requires hydrogen to remove the oxygen from the feedstock. Much hydrogen is needed, and you will need a reliable and stable source of hydrogen to succeed. You can choose to buy the hydrogen over-the-fence from a third-party. Or you can consider producing your own hydrogen.

A hydrogen unit can make you self-sufficient

Reliable hydrogen supply is crucial for modern refineries and is essential to the production of renewable fuels. With a hydrogen unit like H2bridge™, you gain an on-premise circular solution that produces the hydrogen you need. Without the use of natural gas. This helps lower the carbon intensity of your renewable fuels and not only does this support you in meeting legislative requirements, but it also creates a seamless feed-in to product-out process.

The future of hydrogen is bright

Hydrogen is currently getting unprecedented political and business momentum, with the number of policies and projects worldwide expanding rapidly. There is even talk of 'the hydrogen economy', and hydrogen is becoming an asset that can enable renewable fuels to provide an even greater contribution to a clean and secure energy future.

More value. Better business

When the price of renewable fuels is linked to greenhouse gas emissions, hydrogen takes on an entirely new role in creating business value. You can use renewable sources to produce the hydrogen you need. These renewable streams offer a reliable method for unprecedented GHG savings. And a tight integration of a hydrogen unit with the hydroprocessing unit allows for the unique opportunity to lower both CAPEX and OPEX.

Recent case

A new 6,500 barrels-per-day renewable diesel unit for Seaboard Energy, Kansas.

Seaboard Energy were looking for a renewable technology solution promising high yield and efficient implementation. Enter the H2bridge™ hydrogen unit integrated with a Hydroflex™ hydroprocessing unit.

Get the facts

In this video Topsoe’s Mikala Grubb, Director, Clean Fuels Technology and Jostein Gabrielsen, R&D Director joined DIGESTCONNECT to explain how it works and the impact on economics, cetane, cold flow and volumes. Have a look at this video from 03:30-33:50 (QnA from 47:40).

Increase your renewable footprint by coprocessing renewable feedstocks

The journey to renewable fuel production can be challenging. One way to start is through coprocessing.

Coprocessing involves the simultaneous processing of fossil and renewable feedstocks. Whether it is to fulfill legislation compliance, grasp new business opportunities, or take a step toward 100% renewable production, coprocessing can help you meet your goals.

Making the switch to renewables

Coprocessing is an umbrella term that covers a range of renewable/fossil ratios.

For refineries looking to start with less than 10 percent of renewable feed sources, solutions often involve a new load of catalysts. Coprocessing with more than 10 percent renewable feed sources mostly involves a revamp.

In addition to a new catalyst load, refineries may also need to update the metallurgy in their reactor to protect it against corrosion. It is also necessary to consider exotherms (heat development) due to the increased heat release from renewable feed hydrogenation reactions and additional hydrogen due to a possible increase in hydrogen consumption.

There is no such thing as a one-size-fits-all approach when it comes to renewable feed coprocessing. Each refinery has its own set of challenges. Those starting with low levels of renewable feed coprocessing require less feedstock, which means a smaller investment and avoidance of significantly increased hydrogen consumption. Higher amounts of coprocessing can be carried out by revamping existing units, which includes upgrading the metallurgy, replacing reactor internals and evaluating hydrogen availability.

Regardless of the challenges, we have the technology and know-how to help produce fuel from almost any feedstock mix for virtually any size plant. By coprocessing, you can begin adding diversity and growth opportunities to your refinery – and your business.

FAME: Biodiesel - good, but not perfect

The not-so perfect solution

Biodiesel production is the production of Fatty Acid Methyl Esters (FAME). This process uses renewable feedstocks like vegetable oil, animal fat, or tallow to produce diesel.

There is a global demand for refiners to fulfill their renewable volume obligations – and biodiesel production can help. But while producing biodiesel is a relatively inexpensive process, the fuel’s oxygen content makes it less valuable than renewable diesel produced from a hydrotreatment process. Today, most countries have restrictions on how much biodiesel can be blended into diesel, since the properties of fossil and biodiesel are not identical. This has led many refiners to revamp their biodiesel production plants and use processes like HydroFlex™.

A renewable alternative

HydroFlex™ transforms any feedstock into drop-in, ultra-low sulfur gasoline while using much of the existing and surrounding infrastructure leftover from FAME processes. This includes storage tanks and pretreatment units, which can be repurposed to lower the implementation cost of the hydrotreatment process. The result is the production of 100% drop-in ready renewable diesel that adheres to all specifications and has no blending maximum.

Outpacing fossil feedstocks

Renewable feedstocks offer you several advantages over first-generation FAME (fatty acid methyl esters) or conventional non-renewable feedstocks. Here’s how conventional diesel, FAME and renewable diesel stack up:

From grassroot units, to revamps or standalone applications, HydroFlex™ offers an easy and flexible way to get started with hydrotreating at your refinery. Overall, the process allows you to transform almost any renewable feedstock into drop-in, ultra-low sulfur gasoline, jet fuel, or diesel that meets today’s market standards.