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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
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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™