In the patented bioCRACK process, solid biomass (e.g. wood or straw) is converted into short-chain hydrocarbons by liquid-phase pyrolysis, using a hot carrier oil at temperatures up to 400°C and under atmospheric pressure. Due to the interaction between biomass and heat transfer oil, hydrocarbons with a high hydrogen saturation are produced, which originate both from the carrier oil itself and from the biomass.
This innovative approach only gains economic importance through a decisive technical detail: In the bioCRACK process, a low-cost intermediate product from the petroleum refinery (Vacuum Gas Oil – VGO) is used as heat carrier oil. Normally, VGO is converted only to a small extent into diesel fuel and increasingly into short-chain gasoline, which cannot be sold in this quantity in Europe and must therefore be exported.
The bioCRACK technology additionally achieves a significant advantage in increasing diesel production from VGO. We offer this unique, patented technology for petroleum refineries to generate second-generation biofuels.
– Realization with minimum technical effort and cost-effective operation
– High raw material flexibility and fast implementation
– Direct feed of the end product into the refinery
– Direct sales of the produced fuel via existing sales channels
– Greenhouse gas (GHG) savings of up to 85 percent according to a study by Joanneum Research (2015)
– Energy recovery or further processing into valuable by-products such as lean gas and pyrolysis products (pyrolysis oil, coal)
In contrast to conventional BioDiesel processes, the use of BDI RepCAT technology allows us to avoid costly processing of by-products. In addition, the use of a recyclable catalyst significantly improves the quality of the products (BioDiesel and glycerin).
BDI has developed its RepCAT technology for processing raw materials with a high proportion of free fatty acids (FFA). This innovative process can transfer raw materials containing up to 99 percent FFA. The specially developed system allows the catalyst to be reused within the process, which significantly reduces operating costs. A further advantage compared to other industrial processes is the production of absolutely salt-free glycerin of distilled quality. The RepCAT process has been positively evaluated for the use of high-risk fats (definition according to EU Regulation No. 1069/2009) by the European Food Safety Authority (EFSA).
Technological competitive advantages
– Maximum raw material flexibility – no limits to FFA content in the raw material
– Technically maximum yield
– No waste of which to be disposed from the process, but instead reusable or saleable by-products
– Exceeding all applicable BioDiesel quality standards
– Many years of international experience in large-scale industrial implementation
Due to rising prices for fully refined vegetable oils and simultaneously decreasing quality of low-cost residues and waste fat materials, the use of highly flexible technologies is necessary. In addition, there is the environmental political will to make energy supply more independent, to process waste and residual materials into clean energy and to become sustainably “greener”.
Thanks to the implementation of new process steps or an adaptation in the use of operating resources, optimization of original systems can be achieved. Improved raw material pre-processing and adaptation of distillation technology result in a higher output of high-quality BioDiesel.
With BDI’s high-FFA process, raw materials with up to 99 percent free fatty acid content can be used. This results in advantages for the plant operator such as the use of new raw material sources, reduction of total raw material costs and reduced consumption of operating materials. The by-product glycerin can also be processed into a high-quality product.
Every BioDiesel plant is unique. Simple standard solutions to improve individual parameters such as yield, product quality or raw material flexibility are therefore ineffective.
In order to achieve an optimal result, it is necessary to develop an individual overall concept for each plant and to implement optimal technical solutions. The result is a sustained improvement in plant performance.
Our one-stop-shop includes all necessary steps for successful plant optimization:
1. Status evaluation
3. Offer preparation
4. Authorization procedure
5. Engineering and delivery
8. After-sales services
Additional RetroFit services
– Training of plant operators
– Production support
– Analytical support
– Safety evaluation