HVO – Gas Sample sp. z o.o.

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Biofuel production (HVO) at a refinery in Central Europe.

MARCIN MASEK – GAS SAMPLE SP. Z O.O.

INTRODUCTION

This case study describes a newly constructed HVO (Hydrotreated Vegetable Oil) unit, with a specific focus on the process analytics solutions used for monitoring and optimizing production. The plant, built by a leading Central European petrochemical company, produces 300,000 tons of biodiesel or sustainable aviation fuel (SAF) per year. The total investment cost is estimated at around 140 million Euros.

PROCESS

Hydrotreated Vegetable Oil (HVO) is a high-quality, second-generation biofuel that is increasingly used due to its sustainability and performance advantages over conventional biodiesel. HVO can be used directly in diesel engines without any modifications, offering an effective solution for reducing CO2 emissions. The production process involves the following steps:

Pre-treatment

Vegetable oils and animal fats are pre-treated to remove impurities such as phosphorus, metals, and solids.

Hydrotreating

The oils are subjected to high pressure and temperature in the presence of hydrogen. Hydrogen saturates the double bonds in fatty acids and removes oxygen in the form of water, resulting in a paraffin-like biofuel that closely resembles conventional diesel fuel.

Isomerization

The paraffinic hydrocarbons are then isomerized to improve the fuel's cold flow properties, making it suitable for use in colder climates.

Distillation and Purification

The final HVO product is distilled and purified to meet the required specifications for transport fuels.

KEY ANALYTICAL TECHNOLOGIES

To ensure the quality and safety of the HVO production process, four advanced analyzers were implemented: two Maxum II gas chromatographs, one BioTector TOC analyzer, and one SOLA iQ sulfur analyzer. These devices play a key role in monitoring process parameters, detecting impurities, and optimizing production conditions.

Gas Chromatograph 1 (Maxum II)

Measures hydrogen (H2), carbon monoxide (CO), carbon dioxide (CO2), hydrogen sulfide (H2S), and hydrocarbons in the process gas. Located in the central process unit, it ensures an efficient and safe hydrotreating reaction.

Gas Chromatograph 2 (Maxum II)

Analyzes the gas used in the amine regeneration process. It measures hydrocarbons (C1−C6) and traces of hydrogen sulfide (H2S). The gas sample is transported to the analyzer using a 67-meter heat-traced line coated with SilcoNert®. This ensures precise analysis while meeting stringent temperature and pressure requirements.

BIOTECTOR

Monitors the total organic carbon (TOC) content in condensate samples from heat exchangers. By using ozone oxidation technology, the BioTector provides accurate and reliable data on the level of organic impurities, thus protecting condensate pipes from hydrocarbon leaks. This information is essential for maintaining production process efficiency and ensuring environmental safety.

SOLA iQ

Uses pulsed UV fluorescence (PUVF) detection to accurately measure the sulfur level in HVO. The sulfur content in the final HVO product is a key quality parameter, as sulfur impurities can decrease fuel efficiency and increase emissions. This analyzer is the final quality control stage for the produced fuel.

CHALLENGES IN HVO PRODUCTION

HVO production involves several challenges that require continuous monitoring. Some process gases are hazardous, necessitating the implementation of strict safety measures.

OPERATIONAL ENVIRONMENT

The Maxum II gas chromatographs operate in hazardous areas and are housed in explosion-proof, purged Exp enclosures. They are equipped with automatic shutdown mechanisms to ensure safety in case of a malfunction. All equipment used has appropriate explosion protection.

SAMPLE QUALITY

It is crucial to ensure that the correct sample parameters—such as temperature, pressure, and flow—are maintained. This is guaranteed by appropriately designed sample conditioning systems, which are dedicated to specific measurements and analyzers. Furthermore, filters, pressure regulators, and temperature regulators ensure that the samples analyzed by the analyzers are free of particulates, oil droplets, and other impurities that could affect measurement accuracy. The innovative use of mini-modular components significantly reduced the size of the systems.

IMPURITIES

The hydrogen used in the process must not contain any impurities. Due to the fact that measuring the sulfur and hydrogen sulfide content in hydrogen is particularly difficult, the gas-wetted surfaces of the sample preparation system were coated with a special SilcoNert® layer to reduce the adhesion, absorption, or adsorption of sulfur compounds.

Finally, it's important to remember that the complex nature of the hydrotreating process requires continuous monitoring of production parameters. Therefore, the analytical systems were equipped with smart measurement sensors, which were connected to the unique Bricks’n’Cloud (B’n’C) plant monitoring system. Data transmitted from the sensors and data sent by the analyzers to the B’n’C application are recorded and categorized as:

alarms that require immediate action

warnings that require action to prevent future failures.

The database of events occurring in the plant enables the safe and uninterrupted operation of the production process.

The HVO project is a great engineering success, achieved through the proper selection of analyzers and sample conditioning equipment, and the implementation of the unique B'n'C monitoring and prediction system.

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Biofuel production (HVO) at a refinery in Central Europe.

Biofuel production (HVO) at a refinery in Central Europe.

INTRODUCTION

PROCESS

KEY ANALYTICAL TECHNOLOGIES

CHALLENGES IN HVO PRODUCTION

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