LARTC 2026 LARTC 2025
Capturing crude flexibility opportunities through smarter fired heater monitoring SAF and renewable production with feedstock flexibility and minimised emissions
Aldo Marcelo Peiretti TOPSOE
SINDY STONE and THIERRY TISON Heurtey Petrochem Solutions
and sustainable resource, and when paired with HydroFlex, the impact is amplified.
Latin America’s refining sector is enter- ing a new phase of crude flexibility. Recent geopolitical instability and con- cerns over Middle Eastern crude supply have reinforced the importance of diver- sified, reliable feedstock sources. In this context, South America is gaining visi- bility as a strategic crude supply region, while Argentina’s Vaca Muerta continues to gain momentum through growing pro- duction, export infrastructure, and new investment.¹ , ² , ³ , ⁴ For Latin American refiners, this creates a valuable opportunity to evaluate regional crude alternatives such as Medanito, a light, sweet crude associated with the Neuquén Basin and Vaca Muerta devel- opment.² , ³ However, crude diversification is not only a supply decision. It also raises an important technical question: How will existing refinery assets respond to a dif- ferent crude slate? Recent discussions during LARTC ATE confirmed that this transition is already creating practical operating challenges for refiners, including changes in crude preheat performance, fired heater duty, fractionation pressure, downstream unit loading, catalyst management, and real- time optimisation. Crude flexibility and fired heater response Processing a different crude can shift the refinery heat balance and operating condi- tions across multiple units. Depending on crude properties and unit configuration, the fired heater may experience changes in duty, temperature control, and operat- ing limits, making it important to monitor how the asset responds. 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 ora 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. This is where fired heaters become especially important. They provide the heat required to reach process targets in several refinery units, including crude and vacuum distillation, hydrotreating, reform- ing, hydrocracking, and other conversion or treating services. They are also among the largest fuel users in a refinery, making them a major cost centre and an important lever for energy efficiency and emissions reduction. For this reason, the fired heater should not be seen only as a utility consumer. It is a strategic asset that can influence throughput, product quality, fuel consump- tion, emissions, reliability, safety, and 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 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. 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 offerrefineries the potential fora 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. HydroFlex: Feedstock flexibility without compromise
DID YOU KNOW? For refiners
Biocrude from waste and biomass
Animal fats and used cooking oils
Vegetable oils
ers capture crude diversification oppor- tunities by converting heater operating data into technical insight, actionable recommendations, and improved asset performance. References 1 Reuters, South America’s stealthy ascent to key crude oil swing supplier , June 3, 2026. https://www.reuters.com/commentary/reuters- open-interest/south-americas-stealthy-ascent- key-crude-oil-swing-supplier-2026-06-03/ 2 Reuters, Mideast conflict puts Argentina’s Vaca Muerta shale in focus, analysts say , May 14, 2026. https://www.reuters.com/ business/energy/mideast-conflict-puts- argentinas-vaca-muerta-shale-focus-analysts- say-2026-05-14/ 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. 3 Reuters, Vaca Muerta expected to lift Argentina energy surplus to new record in 2026, February 5, 2026. https://www.reuters. com/business/energy/vaca-muerta-expected- lift-argentina-energy-surplus-new-re- cord-2026-2026-02-05/ 4 Reuters, Chevron applies for Argentina tax break program with $13.8 billion invest- ment plan , June 2, 2026. https://www. reuters.com/business/energy/chevron-applies- argentina-tax-break-program-with-138-billion- investment-plan-2026-06-02/ 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. Contact: Sindy.STONE@heurtey.net and Thierry.TISON@heurtey.net Contact: ALDO@topsoe.com By connecting heater measurements, simulation results, and furnace expertise, HMS supports a clearer evaluation of the fired heater response when the refinery processes a new or less familiar crude slate 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. 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 waterusage, refineries can see significant Opex reductions. However, beyond the numbers, what really sets this approach apart is its adapt- ability. Whether retrofitting an existing unit orplanning a new build, this solution scales with your operation – and with the shifting demands of the global energy market.
Fired heater response Changes in heat balance, duty, temperature control , and operating limits looking to transition smoothly into renewables, the dashboards , and shared operating insight combination of HydroFlex and H2Bridge provides a roadmap Digital monitoring foundation Data capture, HMS remote technical assistance KPIs, heater condition history monitoring recommendations , and FRNC-5PC simulation 4 3
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Crude exibility opportunity Alternative crude s l ates
Pretreatment
HydroFlex processing
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Operational value Faster technical decisions, lower fuel consumption, improved reliability, reduced emissions , and stronger margin resilience Jet fuel
HMS
Gasoline
Diesel
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Technical evaluation Root cause analysis, regular reports , and option al ' What-if ' evaluations
Figure 1 The byproducts created by the HydroFlex process create a circular system
Integrated data and insight
Secure and reliable monitoring
Expert support when you need it
Better decisions, better performance
Recycle
Emissions Renewable fuel product
Hydrocarbon feed
H2 b ridge hydrogen unit
HydroFlex hydrotreating unit
H
Figure 1 Fired heating monitoring workflow for crude flexibility
Renewable feed
history, and monitoring recommendations for corrective actions through a dedicated digital platform. This supports earlier iden- tification of deviations and helps evaluate whether performance changes are related to combustion conditions, heat transfer behaviour, equipment condition, or operat- ing severity. HMS can also support regular reports and optional ‘what-if’ evaluations to fore- cast key parameter behaviour and assess potential operating adjustments. For refin- ers evaluating alternative crude slates, this provides a practical way to move from reactive troubleshooting to proactive heater management, helping teams make faster technical decisions and manage heater operation with greater confidence. Path forward For Latin American refiners, the opportu- nity is not only to process a different feed- stock, but to measure, understand, and optimise the response of important refin- ery assets. As highlighted during LARTC ATE discussions, crude variability requires refiners to know their operating limits, define safe operating windows, and keep the unit close to its optimum. In a market where crude flexibility, fuel costs, and energy efficiency are increas- ingly connected, smarter fired heater monitoring through HMS can help refin- In short, the solution transforms hydrogen from a problematic input into a controlled 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.
onstream factor. In a crude-flexible envi- ronment, monitoring fired heater perfor- mance becomes essential to understand how the equipment reacts, prevent devi- ations away from design limits, and iden- tify opportunities to improve efficiency and margin resilience. This is where a ded- icated heater monitoring solution such as HMS can provide practical value. role of HMS HMS, the Heater Monitoring Solution by Heurtey Petrochem Solutions, is a dedi- cated digital twin and remote technical assistance service. It can be implemented independently or used alongside an existing digital monitoring environment, depending on the refinery’s configuration and needs. 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. For crude flexibility, HMS helps refin- ers move from simply observing a change in heater operation to understanding what that change means. By connecting heater measurements, simulation results, and fur- nace expertise, it supports a clearer eval- uation of the fired heater response when the refinery processes a new or less famil- iar crude slate. By integrating heater instrumentation and distributed control systems (DCS) data with simulation and furnace exper- tise, HMS gives refiners access to key performance indicators, heater condition 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- 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.
Figure 2 H2bridge transforms hydrogen into a controlled and sustainable resource
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