hydroflex - the solution to production of renewable jet fuel · 2019. 9. 25. · hydroflex™ - the...

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Mikala Grubb, Ph.D.

Senior Business Development Manager

HydroFlex™ - the solution to production of renewable jet fuel and diesel

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Summary

Feedstocks

Contaminants

Analysis

Hydrogen

HydroFlex™

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Haldor Topsoe

• Market leader in heterogeneous catalysis for the refining and chemical industries for more than 75 years.

• 2,200 employees in 13 countries.

• Headquarters in Copenhagen, Denmark.

• Production in Frederikssund, Denmark, and Houston, US.

• Spends around 9% of revenue on R&D.

• Established in 1940 by Dr. Haldor Topsøe.

2018 revenue DKK 5,617m (~USD 890m)

2018 operating profit DKK 708m (~USD 110m)

In brief

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Global presence

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Bayport & Houston,

Texas

Moscow, Russia

Manama, Bahrain

Beijing & Dalian, China

Kuala Lumpur, Malaysia

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Los Angeles, California

Buenos Aires, Argentina

Jakarta, Indonesia

New Delhi, India

Rio de Janeiro, Brazil

Copenhagen & Frederikssund,

Denmark

Khobar, Saudi Arabia

Mexico City, Mexico

Edmonton, Canada

ProductionHeadquarters E Engineering S Sales & Service Research & DevelopmentRPH

Essen,Germany

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We have a broad range of products and servicesthat combined help our customers achieve optimal performance

Process design, engineering and licensing

Proprietary equipment

+Business and technical services

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We design, engineer and license a broad range of processes for chemical processing, hydroprocessing and emissions management.

+High-performance catalysts

We supply a range of more than 150 different catalysts and have the capability to design and manufacture custom catalysts for specific tasks.

We can provide a complete range of proprietary equipment, spare parts and consumables, designed and manufactured to last and work optimally.

From evaluating the feasibility of a new plant or product, to designing it, getting it built and running optimally, we provide a full range of services.

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Hydrotreating explained in one minute

Feedstock

Product

H2

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Let us agree…

Biodiesel

Biofuel produced by transesterification of fatty acids - also called Fatty Acid Methyl

Ester (FAME)

Renewable diesel

Hydrocarbon diesel fuel produced by hydroprocessingof renewable feedstock - also called Hydrotreated Vegetable

Oil (HVO)

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Hydroprocessed renewable fuelsMarket status and trends

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Two major markets

HydroFlex™

Vegetable oil

Tallow

Renewable diesel HydroFlex™

Vegetable oil

Tallow

Renewable Jet fuelUsed cooking oil

Tall oil

Advanced biofuels

Renewable Naphtha

Renewable diesel (EN590)

Renewable LPG

US EU

Renewable diesel (EN15940)Renewable diesel (MK-1)

Renewable jet fuel

Distillers corn oil

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Renewable diesel specifications

MK-1EN15940:2016 Class A

(HVO-100)ASTM D975-17a EN 590

Paraffinic diesel from synthesis or HDT

Diesel Fuel Oils Diesel Fuel

IBP (°C) Min. 180 n.a. n.a. n.a.

FBP (°C) 340 (T95, D86) 360 (T95, D86) 282-338 (T90, D86) 360 (T95, D86)

Density (kg/m3) 800-830 765-800 n.a. 820-845

Cetane number Min 51 Min 70 Min. 40 Min 51

Aromatics Max 5.0 vol% Max 1.1 wt% Max 35 wt% n.a.

Polyaromatics Max 0.02 vol% n.a. n.a. Max 8 wt%

Cloud point (°C) Max. -16 - n.a.

CFPP (°C) Max. -26 Down to -20 (Grade F) Down to -20 (grade F)

FAME content (vol%) 0 Max 7% n.a. Max 7%

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The bad & the uglyContaminants

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Challenges in hydroprocessing of renewable feedstocksContaminants, coking and exotherms

• Contaminants (e.g. P, Si, Fe, Na)• Shortens catalyst lifetime

• Increases pressure drop

• Unsaturated components increases coking

• Hydrodeoxygenation exotherms high for bio-/renewable feedstocks

• Formation of a high P containing crust around the catalyst pellet affects the access to the pore structure.

Figure: High P containing crust around guard catalyst from a commercial unit processing 50% renewable feedstock

P

KNa

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Difficulty of analysisRound Robin study carried out in collaboration with customers and partners

• Compare analyses of three types of feedstocks:• Vegetable Oil (VO)

• Animal fat (AF)

• Pyrolysis oil (PO)

• 12 analytical laboratories participated to the study using certified methods

• Analysis:• Elemental: C, H, S, N, O

• Bulk properties: SG, cloud point, pour point, water content, TAN

• Contaminants: As, Al, Ca, Fe, K, Na, Mg, P, SI, Zn

• Results reported as “<“ are not included in this summary

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Measurement of contaminantsA catalyst lifetime between the results

• Significant deviation between measurements using ICP for all contaminants analyzed

• Sample preparation and analyses are critical but new methods need to be developed

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Conclusions from Round Robin Study

• Good performances for the analysis of vegetable oil

• Poor results for pyrolysis oil• Analytical methods need to be improved, especially for contaminants

• Sample preparation is key due to presence of two phases

• ASTM methods have not been developed for renewable feedstocks

• Topsoe technical whitepaper available upon request

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Jet fuel from renewable feedstocks

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Key specifications for the renewable jet product (ASTM D 7566)

Max 50 vol% HEFA-SPK can be blended together with conventional jet fuel

… but the aromatics must be minimum 8.4 vol% in the final blend !

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The necessary process steps to convert triglycerides into renewable jet

Removal of oxygen

Isomerization

Reducing aromatics

Boiling point

reductionDistillation

Animal fats

Seed oils

Tall oil

Pyrolysis oil

Used cooking oil

Feed dependentFor max RJ

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Renewable jet fuel from tallow/used cooking oil

Fatty acid distribution

C14 0.9 wt%C16 19.9 wt%C18 75.5 wt%C20 1.5 wt%Other 2.2 wt%

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Large sample of jet fuel product from pilot plant test collected and sent to independent laboratory (Saybolt) for testing.

November 8th, 2018 final analysis report received.

Analysis report Independent laboratory

Highlighted text is blue,

other text is white

We are dedicated to make sustainable aviation fuel the new global standard (…) we have selected Topsoe’s HydroFlex™ technology after a very thorough selection processMaarten van Dijk, executive director at SkyNRG

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Hydroprocessing solutions for renewables

solutions

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Sour mode HydroFlex™

HDO DW

H2

Renewable feedstock

Renewable diesel

“Easy” feedstocks

Low CAPEX

Revamp friendly

EN590 diesel

(HVO-100)

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Sweet mode HydroFlex™

HDO HYC

H2

Renewable feedstock

Renewable diesel

DW

Renewable jet fuel

H2S, NH3

All feedstocks

All products

Grassroot design

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Let’s talk about hydrogen

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Let’s talk about hydrogen

• Straight run diesel ~60-70 Nm3/m3

• Advanced biofuels have • High amounts of oxygen

• High amounts of unsaturated components

• High hydrogen consumption is a fact

Figure: Influence of amount of processed renewable feedstock on hydrogen consumption in co-processing

SMRMDC TBRHTCR

Capacities from 300 Nm3/h to 250,000 Nm3/h

Co-processing

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Summary

Feedstocks

Contaminants

Analysis

Hydrogen

HydroFlex™