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BioFlux™ Thermal Pretreatment for SAF: How It Lowers Costs and Unlocks Low‑Cost Feedstocks

  • cemnar0
  • Sep 19
  • 2 min read
Thermal Pretreatment for SAF

Introduction — The Fast Lane to Competitive SAF


Sustainable aviation fuel (SAF) economics hinge on two variables: feedstock cost and hydrotreating efficiency. Sulzer’s BioFlux™ Thermal Pretreatment Technology (TPT) unlocks low-cost feedstocks including used cooking oil (UCO), distillers corn oil (DCO), and Category 1 tallow by drastically lowering contaminants (up to 96% metals, 99% phosphorus, 99.9% chlorides) and removing up to 50% oxygen before hydrotreating. The result is reliable, lower-cost SAF with reduced carbon intensity.


What BioFlux™ TPT Does Differently


Thermal Conversion vs. Conventional Physical Refining

Unlike conventional pretreatment that aims to separate out impurities, BioFlux™ applies a thermal cracking approach to convert difficult fats, oils, and greases (FOGs) directly into hydrotreating‑ready feed. This enables efficient processing of high‑impurity animal fats that traditional methods cannot handle including Category 1 tallow.


Hydrotreating-Ready by Design


BioFlux™ almost completely converts triglycerides to free fatty acids (FFAs) and PIONAs (paraffins, isoparaffins, olefins, naphthenes, aromatics), improving downstream hydroprocessing behavior and cutting hydrogen demand by up to 50% thanks to oxygen removal in pretreatment.


Proven Results and Scalable Deployment


  • Contaminant removal at pretreatment: up to 96% metals, 99% phosphorus, 99.9% chlorides, plus ~50% oxygen removal.

  • Economics: Up to 12% lower production costs vs. conventional processes, driven by natural gas savings and renewable naphtha credits; and up to 15% reduction vs. conventional pretreatment + hydrotreating (different baseline).

  • No exotic metallurgy, no catalyst required, and uses familiar refinery equipment.

  • Demonstrated at scale: 10 kt/a demonstration plant in Jackson, Mississippi.

  • Rapid execution: From concept to engineering to modular plant supply within 24 months.

  • Flexible integration: New builds or co‑processing in existing hydrotreaters.


Key Benefits at a Glance


  • Enables low‑cost feedstocks: Efficiently pretreated UCO, DCO, soybean oil, palm by‑products, animal fats, and Category 1 tallow.

  • Superior economics: Lower hydrogen and natural gas usage; additional revenue from renewable naphtha.

  • Operational simplicity: No catalyst, no exotic metallurgy, and standard refinery equipment.

  • Coprocessing-ready: Supports bio‑feedstock co‑processing in existing hydrotreaters to scale SAF volumes sooner.


FAQ — BioFlux™ Thermal Pretreatment


Q1: What makes BioFlux™ different from conventional pretreatment?

A: It uses thermal cracking rather than physical refining, converting impurities instead of removing them unlocking high‑impurity feedstocks for SAF.


Q2: Which feedstocks are proven?

A: UCO, DCO, soybean oil, palm by‑products, and high‑impurity animal fats including Category 1 tallow.


Q3: How does it reduce hydrogen use?

A: By removing up to 50% of oxygen in pretreatment, BioFlux™ lowers hydrotreating hydrogen demand, reducing OPEX and carbon intensity.


Q4: What are the economic gains?

A: Up to 12% lower production costs vs. conventional processes (natural gas savings + renewable naphtha credits), and up to 15% when compared to conventional pretreatment + hydrotreating.


Q5: Is it proven at scale?

A: Yes. A 10 kt/a demonstration plant in Jackson, Mississippi has validated the process.


Ready to Optimize Your SAF Production?

Contact our engineering team today to discuss your project and learn how BioFlux™ Thermal Pretreatment can unlock low-cost feedstocks, reduce hydrogen consumption, and improve your economics.

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