Co-processing in refineries for fast, scalable SAF production Co-processing is a financially attractive decarbonisation option for refineries due to its low capital requirement and access to premium markets
Ignacio Costa and Raju Chopra Topsoe
A s the aviation industry intensifies its efforts to lower its carbon footprint, the production of sustainable aviation fuel (SAF) has become a key focus area. One technology gaining traction due to its relatively low capital and operating costs as well as moderate complexity is the co-processing of renewable feedstocks in existing refineries. For Indian refineries, this straightforward approach allows the incorporation of renewable materials, such as vegetable oils, animal fats, or used cooking oils, into conventional refining operations, blending them with fossil-based feedstocks. The outcome is a drop-in biojet fuel produced largely within existing infrastructure, making co-processing a cost-effective and efficient pathway to expand SAF production without major modifications or investments. Many Indian refiners see co-processing as the most economical and fast option to meet their SAF commitment. Cost-effective implementation using existing refinery infrastructure Co-processing makes use of current refining, transport, and storage assets, which minimises both capital and operating expenses. It also reduces the carbon footprint and sidesteps the need for building new, specialised units. Co-processing can be implemented across various hydroprocessing units in a refinery, including kerosene hydrotreaters, diesel hydrotreaters, and hydrocrackers. Among these, the kerosene hydrotreater and hydrocracker stand out as the most effective units for SAF production, offering flexibility and compatibility with current refinery operations.
Although co-processing may seem like a recent innovation driven by the rise of SAF, it is a well- established and proven technology. Topsoe has been producing renewable fuels through co-processing since 2004, with more than 90 successful implementations across various refinery unit types. The technology and catalysts behind blending renewable and fossil feedstocks are not new; they have been refined, de-risked, and optimised over time. This makes it a reliable and mature solution for refineries looking to scale SAF production quickly and efficiently. Benefits of SAF co-processing Producing SAF through co-processing provides Indian refiners with four key advantages: Rapid market entry : Using existing assets allows SAF production to start within months, rather than years, making it possible to meet near-term mandates and supply contracts. Capital efficiency : Only minor modifications are usually required, reducing financial exposure while still generating compliance and revenue benefits. Operational flexibility : Co-processing allows renewable content to be adjusted in response to market conditions, feedstock pricing, and regulatory changes. Refiners can still enjoy the flexibility to run the unit in fossil mode with the proposed catalyst solution. Enhanced value creation : SAF attracts premium pricing, and production generates credits and incentives that strengthen refinery economics. This combination of speed, flexibility, and profitability makes co-processing a credible strategic option for meeting SAF requirements without overextending capital budgets.
Refining India
23
Powered by FlippingBook