ERTC 2024
The technologies opening new opportunities for refineries
Elena Scaltritti CCO, TOPSOE
The global energy land- scape is diversifying, driven by the need to reduce emissions and achieve the goals of the Paris Agreement. Refineries are particularly
notable due to their substantial carbon footprint. According to the IEA, oil and gas operations contribute approximately 15% of global energy-related emissions, equat- ing to 5.1 billion tonnes of greenhouse gases. Fortunately, the refinery industry has a history of adapting to changing regu- lations and market demands. As the focus on energy transition and decarbonisation intensifies, refineries must innovate and adapt to new technol- ogies and regulations. Each refinery faces unique challenges and opportunities based on its specific circumstances. However, the future refinery is certain to be defined by technological advancements, optimal catalysis, and significant flexibility. Throughout the years, a recurring theme for refineries has been the need to nav- igate challenging times, evolving reg- ulations, new product demands, and necessary investments, all amid uncer- tainty about the future. This challenging and uncertain environment is once again confronting the industry today. The chal- lenges faced by our customers in the refin- ery sector are also our challenges as a catalyst and technology provider. Our col- laboration and partnership are crucial to ensuring the refinery industry’s resilience during the energy transition. Diversification and refinery revamps The energy transition and the Covid pan- demic’s impact on demand have led to the closure of several refineries in the US in recent years. In Europe, refinery closures over the past 10-15 years have been pri- marily due to increased competition from large refinery expansions in the Middle East and India. However, some US and European refin- eries have adapted by transforming into biofuel producers, highlighting the impor- tance of flexibility in refinery operations. Interest in renewable diesel and sustaina- ble aviation fuel (SAF) is now spreading to Asia and China. Diversification strategies are taking hold globally. At Topsoe, we have observed significant interest in co-processing for SAF, a cost- effective solution to meet the EU’s 2% SAF requirement by 2025. For instance, TotalEnergies recently chose Topsoe’s isomerisation catalysts for co-process- ing SAF at its Gonfreville refinery in France. This project, Topsoe’s first SAF co- processing initiative, aims to produce 40,000 tons of SAF from used cooking oil by 2025. The interest in co-processing SAF extends beyond Europe, attracting refiners in the Middle East and Asia who plan to export the fuel to Europe.
Future refineries will be defined by technological advancements, optimal catalysis, and significant flexibility
Refinery optimisation remains central Topsoe’s vision is ‘to be recognised as the global leader in carbon emission reduc- tion technologies,’ and we have developed a comprehensive portfolio of decarbonisa- tion solutions tailored to specific customer needs. Beyond helping refineries’ diversi- fication into renewable fuels and SAF, our focus areas include replacing grey fuels in refinery operations with green or low-car- bon/blue hydrogen, reducing air pollution through advanced solutions that minimise volatile organic compound (VOC), sulphur oxide (SOx), and nitrogen oxide (NOx) emis- sions, and enhancing conventional refinery operations. This means helping refiner- ies become more productive and profita- ble while reducing their emissions through improved catalysts, digitalisation, and optimised technology.
in the SynCOR unit is used as fuel in a small furnace upstream of the ATR unit, ensuring that the flue gas emitted is nearly carbon- free, further reducing emissions. The blue hydrogen produced is then used through- out the refinery, replacing all the grey hydrogen traditionally used in hydrotreat- ing and hydrocracking units. It is also used as a decarbonised fuel across the refin- ery, ensuring zero direct carbon emissions from the refinery’s heaters and furnaces. Additional efficiencies SynCOR typically uses the refinery’s fuel gas, which is today used as fuels in the heaters and furnaces. Utilising this low- quality fuel gas as feedstock in SynCOR is a significant and unique benefit, achieva- ble by pretreating the fuels gas in Topsoe’s fuel gas hydrotreating (FGH) solution. Without this step of pretreatment, the fuel gas would be flared (it would not be use- ful in the refining process), resulting in CO₂ emissions. Additionally, the heater in the SynCOR process is markedly smaller than that used in a SMR plant. The required heat in SynCOR is primarily generated within the ATR unit, where natural gas is com- busted with pure oxygen in a highly exo- thermic reaction. Consequently, only a small amount of additional heat is needed to bring the natural gas and steam to the necessary temperature at the ATR inlet, resulting in a much smaller heater in the SynCOR train. In our SynCOR technology, nearly all the carbon from natural gas is captured and sequestered through carbon capture stor- age (CCS), resulting in exceptionally low- carbon hydrogen. In conventional SMR plants, capturing CO₂ from flue gases is challenging due to low partial pressure, low CO₂ concentration, and a higher process flow. However, in advanced systems like SynCOR, CO₂ is captured in process, where it is more concentrated, at a higher pres-
did you know? In our SynCOR technology, nearly all the carbon from natural gas is captured and sequestered through CCS, resulting in exceptionally low-carbon hydrogen sure, and lower total flow, resulting in much lower Capex and Opex. This integration not only enhances CO₂ capture efficiency but also reduces the overall carbon footprint of the hydrogen production process. Fuelling up for the journey ahead The energy transition journey for refiner- ies is filled with complexities. To navigate these, strategic collaborations between refiners and technology providers like Topsoe are crucial. By working together, the industry can identify the most prom- ising future pathways, balancing regula- tory requirements, costs, and technology maturity. Topsoe works closely with its customers, from the initial brainstorming and study phases through to the deploy- ment and operation of various solutions, such as co-processing or hydrogen units. This continuous partnership ensures that refineries can optimise their processes, reduce emissions, and remain competitive in a carbon-constrained world.
Low-carbon hydrogen presents an opportunity for refineries
Refineries are large industrial users of hydrogen, most of which is currently ‘grey’ (sourced from fossil fuels without carbon capture). Hydrogen remains essential for processes such as hydrocracking, hydro- treating, sulphur removal, and upgrading gasoline. However, transitioning from grey to low-carbon or ‘blue’ hydrogen (either produced on-site or acquired) offers a sub- stantial opportunity to reduce emissions. Where CO₂ storage capacity is avail- able, existing hydrogen production facili- ties at refineries can be converted to blue hydrogen. This can be made more effi- cient through the autothermal reform- ing (ATR) production process rather than the traditional steam methane reform- ing (SMR), which is more emissions-inten- sive. Topsoe’s SynCOR™, an ATR process, produces hydrogen with exceptionally low carbon intensity (CI) by capturing up to >99% of the CO₂ generated from the pro- cess side. A portion of the blue hydrogen produced
Contact: Adam Kadhim, Product Line Director, ADSK@topsoe.com
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