From UCO to Category 1 Tallow: How BioFlux™ De‑Risks Difficult SAF Feedstocks

Introduction — Turning “Problem” FOGs into Opportunity

High‑impurity waste fats and oils are abundant and cheap, but they challenge conventional pretreatment. BioFlux™ converts and cleans these feeds into hydrotreating‑ready material while minimizing contaminants and oxygen content—allowing refiners to reliably monetize hardest‑to‑use streams, including Category 1 tallow.

What Feedstocks Are in Scope?

• Used Cooking Oil (UCO)

• Distillers Corn Oil (DCO)

• Soybean oil and palm oil by‑products

• Animal fats, including high‑impurity streams and Category 1 tallow

  
  

Why Conventional Pretreatment Falls Short

Physical refining routes aim to separate impurities. With very high impurity loads, separation is costly and can still leave problematic levels for the hydrotreater. BioFlux™ uses thermal pretreatment to convert organics, remove oxygen, and drastically reduce contaminants before hydrotreating.

The BioFlux™ Advantage for FOGs

• Contaminant reduction: up to 96% metals, 99% phosphorus, 99.9% chlorides

• Oxygen removal: up to 50%, lowering hydrogen demand

• Triglycerides → FFAs + PIONAs, improving downstream stability

• No catalyst, standard equipment, no exotic metallurgy

• Coprocessing‑ready for rapid SAF scale‑up

  
  

Operational Risk Reduction

• Catalyst protection in hydrotreating

• Lower fouling and corrosion risks from chlorides and metals

• Smoother start‑ups and steady‑state operations

• Better tolerance to feedstock variability

  
  

FAQ — Feedstock & Operations

Q1: Can BioFlux™ handle the dirtiest animal fats?

A: Yes—even Category 1 tallow, which conventional pretreatment typically cannot process for hydrotreating.

Q2: How does it protect the hydrotreater?

A: By reducing metals, phosphorus, chlorides and oxygen, BioFlux™ keeps catalyst loads clean and unit operations stable.

Q3: Is co‑processing supported?

A: Yes. BioFlux™ enables co‑processing of bio‑feeds in existing hydrotreaters.

Q4: What are the main utilities impacts?

A: Hydrogen and natural gas requirements decline versus conventional routes, improving OPEX.

Q5: How fast can we deploy?

A: From concept through engineering to modular plant supply within 24 months.

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.