BioFlux™: The Innovative Reactor for Maximizing Efficiency and Profitability

Introduction

As the renewable fuels industry continues to grow, producers are seeking advanced technologies that deliver both environmental benefits and strong economic returns. Among the most promising innovations is BioFlux™, an advanced reactor technology designed to maximize efficiency and profitability in the production of sustainable aviation fuel (SAF) and renewable diesel.

The Challenge: Traditional Hydroprocessing Limitations

Conventional hydroprocessing units for renewable fuels face several operational challenges:

• High Hydrogen Consumption: Traditional processes require significant amounts of hydrogen, driving up costs and complicating operations.

• Short Catalyst Life: Contaminants and process instability can lead to premature catalyst deactivation.

• Lower Diesel Yield: Over-cracking and side reactions reduce the yield of valuable diesel product.

• Operational Complexity: Managing exotherms and maintaining stable conditions can be difficult, especially with variable feedstocks.

  
  

The BioFlux™ Solution

BioFlux™ technology was developed to overcome these challenges, offering a more efficient, reliable, and cost-effective approach to renewable fuel production.

Key Features of BioFlux™

• Advanced Reactor Design: BioFlux™ utilizes a proprietary reactor configuration that maximizes volumetric flux and ensures complete mixing of feed and hydrogen. This design promotes uniform catalyst wetting and optimal reaction conditions.

• Efficient Hydrogen Management: By recycling a portion of the reactor effluent and premixing it with the feed, BioFlux™ acts as both a diluent and a heat sink. This reduces hydrogen consumption and controls reaction exotherms, enhancing process stability.

• Higher Diesel Yield: The innovative internals and process conditions minimize over-cracking, resulting in a higher yield of valuable diesel product.

• Lower Capital and Operating Expenses: BioFlux™ operates in liquid phase only, eliminating the need for gas recycle and reducing both capital and operating costs.

• Extended Catalyst Life: Superior operational stability and reduced contaminant exposure help prolong catalyst life, further lowering costs.

  
  

Environmental and Economic Benefits

• Reduced Carbon Footprint: BioFlux™ technology achieves the lowest carbon intensity in the industry by maximizing yield, minimizing utility consumption, and utilizing product streams for hydrogen generation.

• Fast Payback and Low Production Costs: With lower hydrogen consumption, reduced capital expenditure, and extended catalyst life, BioFlux™ delivers the industry’s fastest payback and lowest total cost of production.

• Feedstock Flexibility: BioFlux™ is capable of processing a wide range of bio-based feedstocks, including used cooking oil, animal tallow, and distillers corn oil, ensuring adaptability to market conditions.

  
  

Real-World Performance

BioFlux™ has been proven in commercial operations, consistently delivering:

• Ultra-low impurity levels in the product stream

• Stable, reliable operation even with challenging feedstocks

• Significant reductions in hydrogen consumption and operating costs

  
  

Conclusion

BioFlux™ represents a breakthrough in renewable fuel production, combining advanced reactor design with efficient process management to maximize both efficiency and profitability. By addressing the key challenges of traditional hydroprocessing, BioFlux™ enables producers to meet the growing demand for sustainable fuels while maintaining a competitive edge in the market.

Discover how BioFlux™ can transform your renewable fuel operations contact Sulzer Chemtech today to learn more about this innovative technology.