ERTC 2025
Vegan technology: low-carbon solution for renewable diesel and SAF
Yvon Bernard AXENS
Thanks to its partners, Axens is capable of delivering a complete turnkey solution.
In a world striving to decarbonise and address the urgent challenges of climate change, innovative solutions in the energy sector have never been more crucial. As the aviation industry seeks viable pathways to decarbonisation, sustainable aviation fuel (SAF) has become a cornerstone solution, offering a practical and scalable alternative to conventional jet fuels and driving inno- vation in renewable fuel technologies. In response to tightening environmental regu- lations and growing market demand for low- carbon fuels, refineries and investors are seeking technologies that combine oper- ational efficiency, economic viability, and environmental performance. Among promising innovations is the Vegan ® technology by Axens – an advanced industrial solution designed to produce renewable diesel and SAF from a wide range of lipid-based feedstocks. This article explores how Axens takes an integrated approach – combining hydrogen production, pretreatment, and the Vegan unit – to deliver a comprehensive solution that not only reduces carbon footprint but also enhances profitability. Through a real- world case study, we highlight the strategic advantages of full system integration and the transformative potential of Vegan tech- nology in shaping the future of clean energy. Understanding the HEFA Pathway The hydrotreated esters and fatty acids (HEFA) route involves the hydrotreatment of pretreated renewable oils and fats, including used cooking oil, vegetable oils, waste oils, and animal fats. Through this process, these lipids are converted not only into renewable diesel and SAF but also into valuable byproducts such as naphtha, liq- uefied petroleum gas (LPG), and light ends. A critical aspect of the process for a hydrotreatment unit is the need for hydro- gen, which interacts with the feedstock in two main sections: • Hydrotreatment: The pretreated lipids are contacted with catalysts, resulting in hydrogenation, deoxygenation, and denitro- genation, essentially removing impurities and transforming the molecular structure. • Hydroisomerisation: In this subsequent step, the molecules are restructured to opti- mise properties like density, boiling point, and cold flow, which are crucial for market acceptance and regulatory compliance. Axens proprietary catalysts play a key role, selectively cracking molecules to achieve required specifications without compromising product yield. Global Reach and Scalability Today, Vegan technology has received 26 commercial awards worldwide, includ- ing 14 process design packages across Europe, the Americas, and Asia. Four units are already operational, with capacities ranging from 160 kilotons to 700 kilotons
Hydrogen production unit
Case Study: Feasibility and Integration for Profitability Axens performed a feasibility study on a European refinery, which demonstrated the benefits of full integration, including: • Utility synergies: Steam produced in the hydrogen unit can supply the entire com- plex’s needs. Fuel gas from the Vegan unit is sufficient for hydrogen production. • Water and cooling: Deionised water is critical, especially for hydrogen units, and cooling water is shared among all three units. • Balanced energy use: Electricity and fuel are optimised, reducing operational costs and carbon footprint. Financial Highlights • Payback period: Less than seven years – a highly competitive benchmark in capital- intensive industries. • Internal rate of return (IRR): More than 20%, demonstrating robust profitability. Carbon Footprint Results The study found a 91% reduction in car- bon footprint compared to the Renewable Energy Directive III (RED III) value, with most emissions linked to impurities removed dur- ing pretreatment and the use of natural gas in hydrogen production. Feedstock origin, collection distance, and processing meth- ods greatly influence the final footprint. Why Choose Vegan Technology? Axens is not just a licensor of the core tech- nology and a partner for HEFA units, but also a single point of contact for the entire project delivery. It can provide compre- hensive, complex integration based on its expertise as the Vegan licensor for HEFA units, as well as collaboration with partners for pretreatment and hydrogen produc- tion units. Its expertise enables seamless integration of units, leading to faster pro- ject timelines, optimised utility and energy use, and reduced capital and operational expenditures. As the world transitions toward sustain- able energy, technologies like the Vegan process for renewable diesel and SAF offer scalable, flexible, and profitable solutions for refineries and investors. With robust integration, proven profitability, and a sig- nificant reduction in carbon footprint, this technology is poised to play a pivotal role in the low-carbon future. If your organisation is seeking to invest in or revamp renewable fuel production, our experience and holistic approach can help your project succeed, delivering value, com- pliance, and sustainability in one compre- hensive package.
HP steam
Hydrogen
Naphtha
HDT o - gas
Fuel gas
HP purge
HP H
H make-up HP stripping steam
Pre- treatment unit
Vegan unit
Water make-up Pretreated feedstock
Sour water + waste water
Figure 1 Vegan pathway
Co-processing Hydrotreatment Vegan Hydrotreatment
Renewable oil & fats
BioTfuel Gasification, Fischer - Tropsch and upgrading Futurol + Jetanol Enzymatic conversion & Ethanol to Jet
Lignocellulosic biomass
Optional
Hydrogen
Carboverseo + Gasel CO production, Fischer - Tropsch
CO
Carboverseo CO production
Jetanol Ethanol to Jet Jetanol Ole n to Jet
CO & CO fermentation
Carbon dioxide
DMX Carbon c apture
Methanol synthesis
Methanol to Ole n
Fumes
Figure 2 All roads to SAF and eSAF
• Sites requiring on-site pretreatment: Some clients need to process raw lipids on-site. Axens partners with other experts to integrate pretreatment steps before feeding the main Vegan technology unit. • Greenfield projects (standalone units): For investors starting from scratch, all components must be developed on-site, including lipid pretreatment and hydrogen production. Axens ensures complete inte- gration for feed, product, and utility flows. Pretreatment and Hydrogen: The Backbone of Integration Pretreatment units remove feedstock impurities, such as solids, moisture, phos- phorus, chlorides, metals, and proteins, in two steps: decoupling and adsorption. Hydrogen production is typically achieved via natural gas or naphtha steam methane reforming (SMR) or even green H₂ from water electrolysis, which involves several chemical steps to yield pure hydrogen. This process also generates CO, which is converted to more hydro- gen through the water-gas shift reaction. Purity is ensured using pressure swing adsorption (PSA).
per year. This flexibility in scale is crucial for clients with varying production needs and infrastructure constraints. Vegan technology efficiently addresses the challenges of securing feedstock and matching production to market needs. This flexible technology is capable of handling all of the feedstocks available on the market. It can operate in either renewable diesel or full SAF mode, as we have a first-of-its-kind unit capable of producing full SAF mode, with several more in development to achieve the same capability. Furthermore, there is also the possibility to co-produce both renewa- ble diesel and SAF simultaneously.
Meeting Diverse Client Profiles with Customised Solutions
Every refinery or investor has unique needs, and Axens has developed three primary project profiles to match: • Existing refineries with pretreated imports: Here, clients already have the necessary infrastructure, including hydro- gen production and utilities, and import pre- treated feedstocks. Axens can provide new (grassroots) units or revamp existing hydro- treatment units.
Contact: Yvon.bernard@axensgroup.com
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