Contact us to learn how our advanced solutions can support your co-processing strategy.
Co-processing in Refineries
Learn why filtration enables safe, efficient co-processing of bio-waste into renewable fuels.
What is Co-processing?
- Co-processing is a cutting-edge method that enables the production of renewable fuels by integrating bio-feedstocks—such as used cooking oil, animal fats, and other organic waste—into existing petroleum refinery operations. This process is widely recognized as one of the fastest and most cost-effective pathways to scale up renewable hydrocarbon fuel production.
- By utilizing existing hydroprocessing units, refiners can co-process bio-waste alongside conventional crude oil. The resulting drop-in renewable fuels are fully compatible with current engines and infrastructure, accelerating adoption and reducing the need for new fuel systems.
Why Co-processing in Petroleum Refineries Matters
Many refineries operate below capacity. Co-processing offers a strategic opportunity to:
- Maximize production without major capital investments
- Meet sustainability and emissions reduction goals
- Utilize existing refinery assets more efficiently
Depending on refinery configuration and product goals, co-processing can be implemented in various units—most commonly in hydrotreaters, hydrocrackers, and fluid catalytic crackers.
Typical Co-processing insertion points in a refinery
Challenges of Co-processing Bio-feedstocks
Despite its benefits, co-processing presents challenges—primarily due to the variable and inconsistent nature of bio-feedstocks. Even after advanced pre-treatment, these materials often contain high levels of contaminants. Some contaminants may form gels or semi-solids, complicating standard contamination control efforts.
Typical contamination control solutions used in a co-processing application
| No | Application | Pall Product | Customer Benefits |
|---|---|---|---|
| 1 | Hydrotreater feed filtration | Assured HDT profitability by protection from unscheduled reactor downtime or off-spec product due to exchanger fouling, catalyst bed activity loss or high delta P due to bed fouling | |
| 2 | Hydrotreater feed water removal | Assured HDT profitability by protection from unscheduled reactor downtime or off-spec product due to exchanger fouling, catalyst bed activity loss or high delta P due to bed fouling | |
| 3 | Liquid/liquid coalescer protection | Low operating costs by ensuring long coalescer life while meeting particulate specifications for final products | |
| 4 | Sour water removal from hydrotreated product | Reduced steam stripper corrosion and capacity loss | |
| 5 | Liquid/liquid coalescer protection | Low operating costs by ensuring long coalescer life while meeting particulate specifications for final products | |
| 6 | Water removal from stabilized product |
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| 7 | Hydrocarbon removal from sour water |
| Reduced contamination load to sour water stripper reduces stripper maintenance costs, capacity loss and extra loading on water treatment plant |
| 8 | Hydrogen recycle and make-up gas compressors protection |
| Eliminate cost and revenue losses due to compressor rebuilds and unscheduled downtime due to fouling |
| 9 | Low NOx burner protection |
| Elimination of burner tip fouling leading to burner maintenance costs, potential unit downtime or productivity loss due to poor burner performance |
Contamination Control Solutions for Co-processing
Effective contamination control is essential for successful co-processing. Pall offers a specialized range of filtration and separation solutions designed specifically for co-processing applications, including:
- Removal of particulates and gels from bio-feedstocks
- Protection of critical refinery equipment
- Enhanced process reliability and renewable fuel output
If you're facing contamination issues that are affecting your renewable fuel production, our team is here to help. Contact us to learn how our advanced solutions can support your co-processing strategy.
Frequently Asked Questions
Why is co-processing important for renewable fuel production?
Co-processing enables refineries to produce renewable fuels without major capital investments. It helps meet sustainability goals, reduces greenhouse gas emissions, and utilizes underused refinery capacity.
What are the main challenges of co-processing bio-feedstocks?
Bio-feedstocks are highly variable and often contain contaminants—even after pre-treatment. These contaminants can be solid, semi-solid, or gel-like, posing challenges for standard filtration and refinery operations.
How does Pall help address contamination in co-processing?
Pall offers advanced filtration and separation solutions designed to:
- Remove particulates and gels from bio-feedstocks
- Protect critical refinery equipment
- Improve process reliability and fuel yield
Can co-processing extend catalyst life in refineries?
Yes. Effective filtration reduces contaminants that can poison catalysts, helping extend their service life and reduce operational costs.
How can I get support for implementing co-processing?
Pall’s experts can help assess your feedstock quality and recommend tailored filtration solutions. Contact us to learn how we can support your co-processing strategy.