BioFlux™ Technology for Sustainable Aviation Fuel (SAF)
Low-carbon SAF and renewable diesel from biobased feedstocks
Sulzer BioFlux process transforms biobased fats, oils and greases - including used cooking oil (UCO), animal tallow, and distillers corn oil (DCO) - into premium sustainable aviation fuel (SAF) and renewable diesel.
Whether you're a refinery planning your renewable fuels transition, an ethanol producer seeking diversification, or an investor evaluating sustainable fuel opportunities, BioFlux delivers the industry's fastest payback and lowest total cost of production with its cutting edge efficient liquid full reactor design and advanced internal mixing.
Sulzer licenses the BioFlux technology under an exclusive cooperation with Duke Technologies LLC.
Fast Payback & Low Production Cost
Lowest cost, quickest ROI
Cut CAPEX & OPEX for rapid returns
Integrated Hydrogen Generation
Boost efficiency and reduce wastage by integrated H2 generation
High Yield, Low Carbon Intensity
Best in class feed to fuel yields with lowest carbon intensity up to 80% reduction in GHG emissions
Main benefits
Achieves the lowest cost of production and quick payback (<3 years)
Integrated hydrogen generation for better efficiency and reduced dependency on external supply
Innovative Liquid Full Reactor Design reduces both capital and operational expenditures
Converts DCO, UCO, tallow and other waste feeds into high quality SAF/renewable diesel
Lowest carbon intensity fuel products that meet global SAF standards and mandates
Key characteristics
High SAF and Diesel yields with minimal by products
Rapid deployment from concept to engineering to modular plant supply within 24 months
Effective for any grassroots plant sizes from 15 KTA to 500 KTA with favorable economics
Reforming off gases from BioFlux unit with integrated hydrogen production
Improved operational stability and lower maintenance needs
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Our technical specialists are ready to help you find the optimal solution for your specific application
Luis Hoffmann
Global licensing director
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Business Guide
SAF market with Sulzer BioFlux™
2 pages
Flyers
BioFlux™: Transforming Biobased Feedstock
2 pages
Brochure
Keep on moving with lower carbon intensity
6 pages
White Paper
Hydrotreating solution for the challenges of renewable feeds
8 pages
Select a resource
Choose from 4 documents
Business Guide
2 pages
Growing your business was never easier!
Overview
Air travel connects people, powers economies, and opens global
markets. But with climate change accelerating, the aviation industry must decarbonize fast. Sustainable Aviation Fuel (SAF) is the most scalable near-term solution, and feedstock producers like you are at the heart of this transformation. Download now to see how to take off to the booming SAF market with Sulzer BioFlux™
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BioFlux can process a wide range of lipid-based feedstocks, including used cooking oil (UCO), animal fats, tallow, and distillers corn oil (DCO). Its flexible design allows seamless integration of multiple feed types to meet sustainability goals and feedstock availability.
The deployment of a BioFlux unit typically takes ≤24 months from concept to operational modules. This timeline applies whether retrofitting an existing facility or designing a new sustainable aviation fuel (SAF) complex.
BioFlux delivers low total cost of production, rapid ROI (<3 years), 25% CAPEX reduction, and 15–20% OPEX reduction compared to conventional solutions. It’s designed for both operational efficiency and long-term profitability.
Yes. BioFlux is suitable for both new (grassroots) installations and revamp projects. Its integration flexibility enables deployment within existing sites with minimal modification.
BioFlux produces Renewable Diesel (RD), Sustainable Aviation Fuel (SAF), and optionally bio-naphtha or bio-propane, depending on the configuration. These fuels meet or exceed industry standards such as ASTM D975 and EN590.
By processing low-carbon feedstocks like UCO, Tallow, DCO and with integrated hydrogen production, BioFlux helps achieve lower lifecycle carbon intensity, supports compliance with global SAF regulations, and reduces dependency on fossil-based hydrogen.
As opposed to a conventional trickle bed hydrotreatment reactor design, BioFlux uses a novel innovative liquid full reactor design with proprietary internals design which allows to operate the reactor in a single continuous liquid phase, maximizing the volumetric flux through the reactor. This helps in improved hydrogen availability in the reactor, better thermal heat management, lower tendency for cracking/fouling and overall lower capital and operating costs of the production.
