LARTC 2025
SAF and renewable production with feedstock flexibility and minimised emissions
Aldo Marcelo Peiretti TOPSOE
and sustainable resource, and when paired with HydroFlex, the impact is amplified.
For refineries navigating a fast-chang- ing energy landscape, decarbonisation and diversification are often high on the agenda. The shift towards renewable fuels is being driven primarily by the legislative environment, but renewables and sustain- able aviation fuel (SAF) production also offer refineries the potential for a new rev- enue stream and a more diversified busi- ness. Integrating renewable feedstocks is proving to be one of the most effective ways to achieve both emissions goals and business growth. To support refineries transitioning to SAF and renewable fuel production beyond co-processing, Topsoe offers two integrated solutions that provide a robust path forward.
DID YOU KNOW? For refiners looking to transition smoothly into renewables, the combination of HydroFlex and H2Bridge provides a roadmap
Biocrude from waste and biomass
Animal fats and used cooking oils
Vegetable oils
One seamless, self-sustaining system When HydroFlex and H2bridge are inte- grated, their full potential is unlocked. Together, they form a highly efficient, low- emissions production loop that turns renew- able feedstocks into high-quality fuels. This self-contained system operates on a simple but powerful principle: use what you already have. HydroFlex processes a wide array of renewable feedstocks, and the off-gases generated during this pro- cess are captured and routed to H2bridge. There, they are reformed into hydrogen, which is fed back into the HydroFlex unit, creating a near-closed loop with minimal waste, low emissions, and reduced exter- nal dependencies. From an operational standpoint, this integrated setup delivers compelling cost advantages. With better heat integration, less imported hydrogen, and optimised water usage, refineries can see significant Opex reductions. Regulatory benefits are just as strong. Since this system enables the production of fuels with significantly lower lifecycle greenhouse gas (GHG) emissions, it can support eligibility for emissions credits and compliance with renewable fuel stand- ards in key markets. However, beyond the numbers, what really sets this approach apart is its adapt- ability. Whether retrofitting an existing unit or planning a new build, this solution scales with your operation – and with the shifting demands of the global energy market. For refiners looking to transition smoothly into renewables without risk- ing the whole facility, the combination of HydroFlex and H2bridge provides a road- map. It is not just a technical upgrade – it is a strategic one, aligned with both today’s pressures and tomorrow’s possibilities. Built for future-proofing As the energy transition accelerates, refineries face a critical choice: adapt or risk falling behind. With HydroFlex and H2bridge, adapting means getting more from what you already have. These tech- nologies can deliver on emissions compli- ance and also provide an opportunity for refineries aiming to take the lead in a low- carbon world.
Pretreatment
HydroFlex processing
Gasoline
Jet fuel
Diesel
Figure 1 The byproducts created by the HydroFlex process create a circular system
HydroFlex: Feedstock flexibility without compromise
Co-processing has emerged as a low Capex way for refineries to enter the renewable fuel and SAF production space, and Topsoe catalysts and expertise are facilitating a particularly fast and efficient solution for customers globally. For refineries seeking to produce renewables and SAF – either separately or co-processed, from scratch, or by repurposing existing assets – Topsoe’s HydroFlex TM solution offers a reliable and flexible option. It enables refiners to pro- cess a range of approved renewable feed- stocks, including used cooking oil (HEFA). The technology is designed to be flexible and can be implemented in both new and existing refinery units, allowing a wide range of feedstocks to be processed – and alongside fossil fuels if required. If avail- ability or legislations demand a feedstock change, HydroFlex can still deliver. The beauty of the solution lies in its flex- ibility in handling different feedstocks and adapting to the operating conditions and goals of the refinery. Whether it is a new unit or a revamp of an existing hydro- treater, HydroFlex is engineered to inte- grate seamlessly and deliver high-grade, drop-in renewable fuels. The resulting renewable diesel, SAF, and naphtha are low in sulphur and fully compliant with global fuel standards. Since its development in 2004, and with more than 60 licensed units glob- ally and years of industrial use, HydroFlex has a solid record of commercial suc- cess. Its design incorporates high-per- formance, proprietary catalysts tailored
Recycle
Emissions Renewable fuel product
Hydrocarbon feed
H2 b ridge hydrogen unit
HydroFlex hydrotreating unit
H
Renewable feed
Figure 2 H2bridge transforms hydrogen into a controlled and sustainable resource
ated during the HydroFlex process. These are converted into high-purity hydrogen, creating a circular system where waste becomes fuel. This approach not only cuts emissions but also reduces dependency on exter- nal hydrogen sources. That means no natural gas deliveries, no exposure to volatile hydrogen markets, and no extra infrastructure to manage fossil-derived hydrogen. The integration also delivers strong oper- ational efficiencies. Because H2bridge is tightly coupled with the HydroFlex unit, it benefits from advanced heat integra- tion, cutting energy consumption and water usage. The result is a more compact, lower-footprint hydrogen solution with sig- nificant savings. Perhaps most importantly, it future- proofs hydrogen production. As decar- bonisation pressures mount, relying on fossil-based hydrogen becomes less tena- ble. With H2bridge, refineries can decouple from fossil hydrogen without compromis- ing production. In short, the solution transforms hydrogen from a problematic input into a controlled
to withstand the unique contaminants found in renewable feedstocks. These catalysts protect the system from fouling and ensure high yield, long cycle lengths, and reliable product quality. For refiner- ies looking to scale renewable produc- tion without losing operational control or fuel quality, the process provides the ideal foundation. H2bridge: Making hydrogen work smarter Processing renewable feedstocks is not as straightforward as processing non- renewables, and extra hydrogen is usu- ally needed. Hydrogen is essential to renewable fuel production, as the hydro- treating process used to upgrade renew- able feedstocks relies heavily on hydrogen to remove oxygen and saturate carbon bonds. Commonly, that hydrogen comes from fossil sources such as natural gas, which increases carbon intensity in the production phase. H2bridge TM is Topsoe’s solution to this challenge. Rather than importing hydro- gen, it enables on-site production using renewable off-gases, specifically the light hydrocarbons and byproducts gener-
Contact: ALDO@topsoe.com
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