A European refinery company with over 90 years of experience in the energy sector has identified biofuels as a critical component of its strategy for decarbonization and sustainability. Recognizing the global demand for cleaner energy solutions, they are committed to transforming their business model to become a leader in the transition to renewable energy. They have placed particular emphasis on biofuels, focusing on:
- Increasing Production Capacity: The company plans to significantly enhance its biofuel production capacity, aiming to produce 2.5 million tons of biofuels by 2030.
- Aviation Fuels (SAF): The ambition is to lead the SAF market by 2030, targeting 0.8 million tons per year, one-third of the total amount required by European regulations.
Problem
In 2023, the refinery invested in two housings for the filtration of vegetable oil to feed their hydrocracking unit for biofuel production. However, upon installation and commissioning, the filters clogged within hours due to particulate contamination levels and gels exceeding specified limits. This operational challenge made it impossible to continue production without sending the contamination to the reactor.
In another production line, the customer bypassed this issue, resulting in the need to stop the unit and replace the contaminated catalyst at a considerable cost. Pall was subsequently approached to assist in finding a solution.
Pall Solution
Following analysis of the situation, Pall offered a solution, providing a 7-element Ultipleat®High Flow filter housing as an immediate measure. The solution was delivered within two weeks of the Pall's service and rental facility request and was operational within days. Initially, High Flow 60", 20 micron absolute rated filters were used, as specified by the reactor. This extended the operation time from 2 hours to one week, although the stop frequency remained high.
Consequently, Pall proposed installing an additional pre-filter, this time a 19-element High Flow Vector™ housing using 60", 25 µm rated nominal filters chosen to protect the 20 µm absolute (99.98%) filters. This extended the operation time sixfold from one to six weeks. Part of the service included sample analysis to confirm the rental units' performance and define the most appropriate equipment that should ultimately be installed. What differentiated Pall was their technical support, business relationship, and quick response time.
Results
- Continuous Processing: The customer achieved continuous processing with vegetable oil in biofuel production.
- Versatility: They gained the capability to process oils from various sources in the same unit.
- Operational Efficiency: The unit was not shut down due to catalyst contamination.
- Cost Improvement: The customer reported significant reductions in operational and maintenance costs.
- The customer is back on track to meet their renewable fuels target.
Conclusion
The customer plans to implement these filtration solutions in other production lines within their refineries and chemical plants.
Pall's added value lies in our analytical capabilities and our ability to offer comprehensive solutions through our service team. This case study underscores the importance of technical support, strong business relationships, and rapid response in overcoming operational challenges and achieving strategic goals in the renewable energy sector.
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