How to implement BioFlux™ thermal pretreatment: retrofit, co-processing, or new build
Updated: Oct 1
Introduction - choose your path to SAF scale
Whether you retrofit an existing hydrotreater for co-processing or design a greenfield SAF complex, BioFlux™ TPT integrates smoothly using standard refinery equipment. Modular supply compresses schedules, enabling ≤24 months from concept to modules.
Integration options
1) Retrofit + coprocessing
Leverage the existing hydrotreater to co-process bio-feeds. BioFlux™ prepares FOGs so you can ramp production quickly while validating hydrogen, utility, and naphtha handling strategies.
2) Brownfield upgrade
Add BioFlux™ pretreatment ahead of a dedicated hydrotreater. Benefits include contaminant control, oxygen removal, and hydrogen savings without the need for exotic metallurgy.
3) Greenfield (new build)
Design BioFlux™ into new SAF facilities for optimal utilities integration, hydrogen generation alignment, and naphtha monetization from day one.
Engineering scope & interfaces
Feed handling: UCO, DCO, animal fats, palm by-products, soybean oil
Thermal conversion: triglycerides → FFAs and PIONAs
Contaminant control: up to 96% metals, 99% phosphorus, 99.9% chlorides
Oxygen removal: up to 50%, reduces hydrotreater hydrogen
Downstream tie-ins: hydrotreating, hydrogen generation, naphtha routing
Materials & layout: standard refinery equipment, no catalyst, no exotic metallurgy
Execution timeline & delivery
Concept & Feasibility: feed slate, hydrogen balance, utilities, naphtha route
Basic Engineering: plot plan, integration with hydrotreating and H₂
Modular Plant Supply: within 24 months for accelerated commissioning
Performance KPIs: contaminant and oxygen removal, hydrogen reduction, throughput stability
Operating model & economics
Hydrogen demand drops (up to 50% vs. conventional), lowering OPEX and CI
Natural gas savings add to unit margin
Renewable naphtha provides additional revenue
Total costs: up to 12% lower vs. conventional processes, and up to 15% vs. conventional pretreatment + hydrotreating
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.
