Future-proof your refinery with renewable feedstocks

For more than 20 years, there has been a 20-fold increase in the number of climate change-related laws worldwide. Opportunities have been found amongst these ever-changing regulations. With new technology from Topsoe, refineries can turn feedstock into renewable fuel, reduce emissions, comply with legislation, diversify the business, and expand market share.

Climate change is high on the global agenda, as governments worldwide pass ever-stricter requirements for increasing renewable fuels and lowering emissions. This global trend has far-reaching repercussions for the refinery industry. It also means vast opportunities. By processing renewable feedstocks alongside non- renewables, you can lower emissions and future-proof your refinery.

Opportunities among the legislation

With our HydroFlex™ solution, we created a reliable way to add full feedstock flexibility to your refinery. With our H2bridge™ technology, we complete the process and allow refiners to turn almost any feedstock into on-spec fuel, like gasoline, jet fuel, and diesel whilst reducing emissions.

It’s a solution that we have developed and refined long before the new legislation hit the market. From trash to treasure, these renewables let you diversify your product line, reduce business risk, and support compliance with the new regulations.

One solution. Multiple advantages.

With H2bridge™’s integrated hydrogen unit, refineries gain the last piece of the puzzle to convert renewable feedstocks into fuel. The unit is used in combination with our HydroFlex™ technology to integrate the hydrogen and hydrotreater units. This creates new optimization possibilities and the clear advantages of working with a single licensor.

Reduce production costs and risk, as well as emissions

Significant business advantages from the true integration of the H2bridge™ and HydroFlex™ units.

H2bridge™ doesn’t just lower greenhouse gas emissions. It also reduces expenses for the entire renewables process.

Topsoe’s integration of the HydroFlex™ and H2bridge™ units utilize the recycling of the hydrogen from the off-gasses from the hydrotreating process. This allows the size of the H2bridge™ unit to be reduced, thereby lowering CAPEX and OPEX costs. Renewable naphtha and LPG can also be used as feedstock for hydrogen production, thereby eliminating the use of an external fossil feed.

OPEX costs can be further reduced with H2bridge™ because the process improves heat integration and drops the use of water to the lowest levels in the industry.

Working closely with you, we tailor your process to the layout of your plant, your intended range of feedstocks, and the specifications of the renewable fuels you aim to produce – all while complying with local emission allowances.

Preparing for the future of renewable feedstocks

Processing renewable feedstocks to produce transport fuels can be challenging, largely due to the variety and complexity of the feedstocks. HydroFlex™ allows refiners to produce fuels from feedstocks that are already liquid. Virgin oils, like rapeseed oil or sunflower oil, together with waste oils and fats, like used cooking oil or crude tall oil, can all be processed with our technology without an extra step. However, with the growing demand, we will need even more feedstocks.

Low indirect land-use change (ILUC), rotational, and winter crops such as carinata, castor, or camelina, will possibly have a role to play. The same goes for solid waste, including sewage sludge, algae, or even mixed plastic waste, especially given the legislation.

Driven by legislation

According to the Renewable Energy Directive II (RED II), 32% of energy used in EU-27 will have to come from renewable sources by 2030. As for fuels, 14% will have to be produced from renewable feedstocks, with a minimum of 3,5% produced from waste such forestry residue, organic fraction of municipal solid waste or algae (the so-called “Annex IX part A” list). Undoubtedly, more legislation will follow globally to limit emissions and reduce reliance on non-renewable feedstocks.

Aiming to help that transition and anticipating future needs, we are contributing to various research projects. They focus on identifying the most sustainable and economically competitive technology to transform solid feedstocks into liquid which can then be hydroprocessed with our HydroFlex™ technology.

Solid to liquid

Hydrothermal liquefaction (HTL), that you might have heard about in The Fuel for Thought Podcast, is one of the technologies that could solve the problem of transforming solid feedstocks in the future.

Topsoe has a role in two EU Horizon 2020 projects exploring the process, HyFlexFuel and NextGenRoadFuels. Both projects aim to show that HTL could be an efficient route to produce high-volume and cost-competitive renewable fuels. We are engaged in the hydrotreatment activities in the projects, and advising on technology, development, selection and test of catalyst possibilities to ensure the best and most economical solutions.

©ARTTIC, Unmodified  

Catalytic pyrolysis is another technology where Topsoe is participating in research collaborations. The H₂CAP project with the Technical University of Denmark is exploring hydrogen assisted pyrolysis for production of gasoline and diesel. The collaboration with Research Triangle Institute through projects sponsored by the US Department of Energy is also exploring the topic, where the aim is to treat the biocrude in a similar way to a fossil crude oil.

From R&D to commercialization

Since 2004, when market forecasts first suggested that sustainability would become a major market driver, a good deal of our R&D investment has funded research into processing renewables.

That work still continues. The insight gained through external research collaborations enables us to understand the feedstocks of tomorrow and optimize our own technology and catalysts to accommodate new demands. We are convinced that whatever the feedstock, liquid or solid, we will be able to assist our customers in the most optimal way possible.

ReThink waste processing

Converting waste to fuel with HydroFlex™

The underestimated power of industrial waste processing

World Bank statistics show that the world produces 2 billion tons of municipal solid waste annually. At least a third of that is not managed optimally. With numbers like that, the message is clear:

It’s time to Re-Think waste processing.

HydroFlex^TM - converting waste to fuel

The billions of tons of tires, plastic, and municipal solid waste that make their way to landfills and incinerators each year make up one of the world’s most undervalued and forgotten resources.

See industrial waste processing as a resource with Hydroflex™, the reliable way to add full feedstock flexibility to your refinery.

HydroFlex™ technology is a vital part of the three-step waste to fuel process that converts mixed-waste feedstock into diesel, jet fuel and gasoline. Once the waste is clear of contaminants, HydroFlex™ works to upgrade the material to meet all required fuel specifications, including ASTM, D7566, and EN 590, EN 15940, and ASTM D975. You can also convert it to plastic pyrolysis oil.

With HydroFlex™ you can transform your waste processing when you:

• Recycle low-grade waste into valuable feedstock
• Reduce dependency on fossil-based resources
• Decrease your carbon footprint by using carbon more efficiently
• Create a stronger market position and optimize offerings

A most sustainable fuel for planes and ships

In recent years, there has been much focus on electricity as a fuel source for vehicles. While electric cars and trucks are an increasing reality for the auto industry, the same cannot be said for shipping and aviation.

Ships and planes will depend on fuel for many years to come, and the source of that fuel must be as renewable as possible. By converting existing waste to fuel in the form of diesel, jet fuel, gasoline, and naphtha, you can create a renewable solution for the aviation and shipping industries and stay on the right side of future regulation and market pressure.

The early adopters

Waste to fuel initiatives are nothing new to scientists at Topsoe. For the past 16 years, we have led research and development programs aimed at renewable feedstocks for the refinery industry.

The results of these efforts led to the creation of new and innovative solutions for converting industrial waste into both plastic and fuel.

Want to turn waste to fuel?

Learn how HydroFlex™ can help turn industrial waste into a resource. Book a meeting today.

Renewables: four options for greater market share and profitability

The refineries industry is facing profound changes. In the EU, RED (Renewable Energy Directive) requires member countries to meet at least 10% of their transport fuels with renewable sources by 2020. In the US, RFS2 (Renewable Fuel Standard 2) requires refineries to blend 36 billion gallons of renewable fuel into the country's total transportation fuels consumption by 2022.

If your business is based outside Europe or the US, there is no need to feel left out. Legislation will be on the way. Because wherever there is a need for on-spec transport fuel, there will be accompanying legislation to limit emissions and reduce reliance on non-renewable feedstocks just around the corner.

That might sound like a major challenge for the industry. And an expensive one. However, the news is not all bad. Far from it.

Meet the challenge. Take the opportunity.

The new legislation is creating greater market demand for renewable fuels. Those refineries who expand their operations to embrace a wider range of feedstocks will not only increase market share, but will also future-proof their business. Best of all, processes for refining renewable and fossil feedstocks can run alongside each other. In effect, refineries would be adding greater diversity and capacity to their operations and, ultimately, an opportunity for business growth.

But, exactly how complex is it to process renewable feedstocks into fuel? And how profitable?

From R&D to commercialization

While it’s true that processing a large, diverse range of feedstocks introduces greater complexity, the technologies involved are well understood. Topsoe invests 9% of annual turnover in R&D. And since 2004, when market forecasts first suggested that sustainability would become a major market driver, a good deal of this investment has funded research into processing renewables.

Since 2010, this research has enabled several successful commercial projects, including a renewable diesel refinery for Preem in Sweden, which helped rebrand the company as the nation’s go-to supplier of green diesel, and Sky NRG in the Netherlands, who are leading the way with competitive renewable jet fuel which meets all EU legislative demands.

The greater the divergence, the bigger the differences

Although the processes for non-renewable and renewable feedstocks can run alongside each other, they have some significant differences. In fact, the greater the divergence from conventional feedstocks, the greater are the differences – and the more complex the processes. So, before you set your level of ambition, you’ll need to look at local supply (feedstock availability and quality) and demand (balancing legislation with market trends).

Once you have established a clear view of the market conditions specific to your region, there are four big factors to consider:

• Target product
  EN590 diesel will make fewer demands on the design of an existing plant than jet fuel, but will have fewer market applications and so provide limited opportunity for growth. For example, in the EU, EN590 diesel would be ideal for blending with fossil fuels to meet the basic requirements of the RED II legislation.
• Feedstock types
  Of course the feedstock itself is important because some types require much more processing than others. But it’s also crucial to identify a reliable supply, know the contaminant level and how much corrosion you are going to have to counteract.
• Processing technicalities
  You need to consider the cycle length and the optimal catalysts to get the highest yield from the process.
• Hydrogen availability
  Processing renewables requires more hydrogen than fossil feedstocks do, so you need a reliable, plentiful supply to ensure success.

Our work on renewables has made one thing abundantly clear: there is no one-size-fits-all solution. However, with the need for flexibility first and foremost in our approach from the outset, we have mapped out four options for existing refineries looking to process renewable feedstocks into on-spec transportation fuel:

• Minimum impact
  Taking a co-processing approach that requires loading specialized Topsoe catalysts without the need for a rebuild, you will be able to meet the minimum requirements for the latest legislation. In short, this is your licence to play in the field, at least in the US.
• Minimal revamp
  In addition to loading new catalysts into an existing reactor, you might also need to add new reactor internals. This provides you with the ability to co-process renewable feedstocks in greater quantity.
• Revamp
  To process large amounts of renewable feedstocks, whether co-processing or 100% renewable, you can revamp a hydroprocessing unit. This will enable you to take advantage of upgrading a unit from fossil to renewable service.
• Grassroot
  If you want full feedstock flexibility and you have the available space, you can build a new unit with a layout tailored to processing any kind of renewable feedstock. While this requires a significantly bigger investment, it is also the way to future-proof your refinery business against legislation which will promises to get increasingly tighter over the foreseeable future.

No matter which option makes the most sense to you and your business, we have the solution: HydroFlex™. In fact, at time of writing, we have implemented all four options that make up our HydroFlex™ solution several times. And we are the only company that has multiple commercial renewables projects up and running in refineries all over the world.

Right from the outset

Your first step into renewables is to choose the option that makes the most sense for your business. With proven layouts for producing diesel, jet fuel and a flexible combination of the two, Topsoe can help you make the right choice. And with a track record of working with refineries worldwide, we will go the extra mile to run a renewables project which results in greater market share and profitability for your refinery business.

Legislation creates opportunities for greater market share

There is clearly a trend to apply legislation to reduce emissions. Not only is this trend global, with potentially far-reaching repercussions for the refinery industry, it’s also rapid. Once one law is passed, it seems the next one is already being drafted.

In the US, RFS2 (Renewable Fuel Standard 2) requires refineries to blend 36 billion gallons of renewable fuel into the country's total transportation fuels consumption by 2022. In Europe, RED (Renewable Energy Directive) requires all EU countries to ensure that at least 10% of their transport fuels come from renewable sources by 2020.

Opportunity for greater business diversity

What if you could future-proof your refinery business against the ever-tightening demands of legislation? And what if you could view each new law as an opportunity to meet new market demands and win greater market share?

At Topsoe, we have the technology to produce gasoline, jet fuel and diesel from almost any feedstock for almost any size of plant. In fact, we have been developing and refining our technology since 2004 in anticipation of these new market trends.

Best of all, your renewable feedstock does not replace fossil feedstock, but runs alongside it. In effect, you are adding greater diversity, capacity and the opportunity for growth to your refinery – and your business.

Meet rising demand for high-grade biofuels

We have a track record of developing innovative solutions for clean, competitive fuels from renewable feedstock since 2004.
Although the legislation concerning renewable feedstock is relatively recent, we are ready to help you meet demand for modern, high-grade biofuels today. With HydroFlex™, you can produce renewable gasoline, jet fuel and diesel from almost any feedstock, including tall oil, used cooking oil, animal fats and vegetable oils. The process is complex, very different to refining non-renewable fuels and requires a substantial investment.

But it is also profitable.

Working closely with you, we tailor HydroFlex™ to the layout of your unit, your intended range of feedstocks, and the specifications of the renewable fuels you aim to produce. Renewable feedstocks, for example, all require dewaxing to optimize the cold flow properties of the resulting fuels.

Clean renewable fuels with a high market value

Whether you are refining in sweet or sour mode, we take care of every catalyst selection and specification. So, your HydroFlex™ unit produces an optimal yield, free from contaminants such as potassium, sodium and silicon. Or, put another way, your unit will produce exceptionally clean renewable fuel with a high market value – and the opportunity to raise the profitability of your business.

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).

Access to industry-leading renewables knowhow

With HydroFlex™, investing in full feedstock flexibility is substantial but sound.

The culmination of years of dedicated research into catalysts and hydroprocessing plant, HydroFlex™ gives you access to catalytical processing technologies that are leading edge. Yet, because of fast-changing market demands, they are already tried and tested.

When it comes to full feedstock flexibility, Topsoe has the in-depth chemical processing expertise and experience to deliver the complete package. Working closely with us on future-proofing your plant gives you not only a one-stop shop for the necessary technologies and catalysts, but also immediate access to the knowhow and services that will turn a major project into a long-term strategic collaboration – and business success.

Hydrogen integration

Processing renewable feedstocks is more complex than processing non-renewables. For one thing, it requires extra hydrogen. We are the only provider able to integrate the hydrogen unit with the hydrotreater – and we license both technologies.

High-yield catalysts

With our Sour mode design, you can achieve CAPEX savings of up to 35% compared to standard designs. The catalysts we use favor a hydrodeoxygenation (HDO) route which, in combination with our highly selective dewaxing catalysts, results in a higher yield.

HydroFlex™ provides you with a comprehensive package, including a level of catalysis and process expertise that no other provider can match. The next section explains how we work closely together with you to achieve the most efficient processes, the highest performance and the best possible outcomes for your refinery – and your business.