top of page
sulzer-chemtech-process-solutions-logo.png

BioFlux™ TPT Economics: Up to 12% Lower SAF Costs and Hydrogen Cuts up to 50%

  • cemnar0
  • Sep 19
  • 2 min read
Lower SAF Costs and Hydrogen Cuts

Introduction — The Business Case for Thermal Pretreatment


BioFlux™ improves both OPEX and product margins by tackling the two biggest SAF cost drivers: feedstock price and hydrogen consumption. It enables use of lower‑cost FOGs and reduces hydrotreating hydrogen demand by up to 50% through oxygen removal. Combined benefits translate to up to 12% lower production costs vs. conventional processes, and up to 15% savings when compared to the combined conventional pretreatment + hydrotreating baseline.


H2: Where the Savings Come From


1) Feedstock Flexibility

The ability to process high‑impurity fats and oils—including Category 1 tallow—widens supply options and lowers average feed cost without compromising hydrotreater reliability.


2) Hydrogen Efficiency

By cutting oxygen content pre‑hydrotreating by up to 50%, BioFlux™ reduces hydrogen consumption, a major OPEX lever and carbon driver.


3) Utilities and Natural Gas

Thermal pretreatment and streamlined hydrotreating translate into natural gas savings, impacting unit energy intensity and cost per barrel.


4) Renewable Naphtha Credits

BioFlux™ enables additional revenues from renewable naphtha by‑product, strengthening overall project NPV.


CAPEX, OPEX, and Risk

  • Standard equipment and no catalyst minimize technical risk.

  • No exotic metallurgy lowers materials cost complexity.

  • Modular deployment compresses schedules and accelerates revenue.

  • Coprocessing in existing hydrotreaters enables phased investment with early returns.


Sustainability and Compliance

Lower hydrogen demand and the ability to utilize waste fats and oils support lower CI SAF pathways. Reduced contaminants help ensure consistent hydrotreater operations, important for meeting offtake reliability and regulatory compliance.


FAQ — Economics & Policy


Q1: What’s the cost reduction potential?

A: Up to 12% vs. conventional processes (driven by natural gas savings and renewable naphtha credits), and up to 15% vs. conventional pretreatment + hydrotreating.


Q2: How predictable are hydrogen savings?

A: BioFlux™ removes up to 50% oxygen in pretreatment, directly reducing hydrotreating hydrogen demand—a major OPEX lever.


Q3: How does it impact CI scores?

A: Lower hydrogen usage and utilization of waste FOGs contribute to lower carbon intensity, improving SAF pathway competitiveness.


Q4: Is specialized metallurgy required?

A: No. BioFlux™ uses standard refinery equipment and needs no exotic metallurgy.


Q5: Can I start with co‑processing?

A: Yes. The technology enables bio‑feedstock co‑processing in existing hydrotreaters, a proven route to ramp volumes and validate economics.


  • Target FOG mix (UCO, DCO, tallow, palm by‑products)

  • Hydrogen balance and utility integration

  • Naphtha handling and monetization route

  • Retrofit vs. greenfield strategy and schedule (≤24 months to modules)

  • Performance KPIs: contaminant removal, oxygen removal, hydrogen savings


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.

bottom of page