Decarbonizing Liquid Fuels with BioFlux™ Technologies: The Path to Cleaner, More Efficient Energy

Introduction

The traditional oil and gas industry is undergoing a profound transformation as cleaner, more sustainable fuels become the new standard. With renewable mandates and clean fuel standards on the rise, the demand for biomass-based fuels is growing rapidly. To meet this demand, producers need innovative technologies that allow for expanded processing capacity while minimizing environmental impact.

The Rise of Renewable Fuels

Renewable fuels made from fats, oils, and greases have emerged as the leading pathway for decarbonizing transportation. While vegetable oils, seed oils, and animal fats remain primary feedstocks, waste materials such as used cooking oil are increasingly sought after. However, feedstock selection is influenced by sustainability, availability, price, and quality. Ultimately, producers seek processes that deliver low production costs and operational flexibility.

The Benefits of Renewable Diesel

The advantages of renewable diesel are well-documented:

• Drop-in Compatibility: Renewable diesel is chemically identical to petroleum diesel, meaning it can be used in existing engines and infrastructure without blending limits.

• Aviation Compatibility: Hydroprocessed esters and fatty acids (HEFA) can be blended directly with fossil jet fuel up to established blending limits.

• Significant Emissions Reductions: Compared to petroleum diesel, renewable diesel can reduce lifecycle carbon emissions by up to 90%.

  
  

BioFlux® Hydrotreating: Overcoming Traditional Challenges

Conventional renewable diesel processes face significant operational hurdles, including high hydrogen requirements, short cycle times, and lower yields of valuable diesel product.

BioFlux® hydroprocessing technology was developed to address these challenges, offering:

• Higher Diesel Yield: Maximizes the production of valuable diesel.

• Efficient Hydrogen Management: Reduces hydrogen consumption and costs.

• Reduced Coking and Over-Cracking: Enhances process stability and product quality.

• Lower Capital and Operating Expenses: Delivers cost-effective solutions for both new and revamped units.

• Reduced Carbon Footprint: Minimizes environmental impact throughout the production process.

  
  

Reducing the Carbon Footprint

BioFlux® technology not only improves process efficiency but also significantly lowers the carbon intensity (CI) of finished fuels. The off-gas generated from BioFlux® hydrotreating contains hydrogen that can be recycled and is rich in light hydrocarbons, which can be used to generate additional hydrogen and fuel fired heaters. Co-products like naphtha can also be used for hydrogen generation via catalytic reforming. In many cases, this makes supplemental natural gas unnecessary, further reducing the plant’s carbon footprint.

With lower operating expenses, longer catalyst life, and higher diesel yield, BioFlux® enables CO₂e emissions per megajoule of diesel to be up to 25% lower than traditional hydrotreating technologies.

Summary

BioFlux® technology, developed by Duke Technologies and licensed by Sulzer Chemtech (GTC Technology), is a low-CAPEX, low-OPEX solution for hydroprocessing bio-based materials. Its advanced design ensures efficient management of the reaction zone, minimizing unwanted byproducts and maximizing the yield of high-value, drop-in renewable diesel. With superior operational stability and extended catalyst life, BioFlux® is suitable for both grassroots and revamp projects, either as a standalone unit or integrated into existing facilities.

Embrace the future of renewable fuels reduce costs, improve efficiency, and decarbonize your operations with BioFlux® technology, for more informations please contact us.