Whether you are already producing renewable fuels or are just choosing a technology for it, Flexiforming can give you additional options for managing your feeds and products.
TECHNOLOGY SOLUTIONS
Flexiforming: a single-stage all gas-phase reaction across established zeolite catalyst at modest pressure and temperature (10 atm, 400 C). Yields proven with 500+ pilot plant tests on 50 different feedstocks.
Convert fuel-grade ethanol, methanol or another alcohol into SAF, BTX, or gasoline
Upgrade renewable naphtha or LPG into SAF, BTX, or gasoline
Co-process fossil naphtha (FRN, HVN, LVN, raffinate, others) with a renewable alcohol to lower CI of the products
Convert light olefins from FCC dry gas into gasoline, BTX or jet fuel (SAF, if using renewable feed for FCC).
The chemistry of Flexiforming process can be regulated by the operator to produce drop-in SAF, gasoline, or BTX from various feeds.
Key chemical reactions that comprise the Flexiforming process are shown below; the list is not exhaustive. Exothermic (heat-producing) reactions are shown in orange, and endothermic (heat-consuming) — in blue. The reactions don’t necessarily occur in the same order as they are shown. The specific molecule shown to enter a reaction (e.g. ethanol, n-hexane, etc.) is illustrative of the class of molecules (alcohols, n-paraffins, etc.).
Dehydration of alcohol can be an endo- (e.g. with ethanol, shown here) or an exothermic (e.g. with methanol) reaction. Light olefins that are formed in its course are intermediate products, they are used up or transformed in subsequent reactions. The water that is generated during this reaction turns to steam which prolongs the catalyst cycle by lifting the coke deposits from the catalyst as soon as they are formed.
Aromatization of olefins, an endothermic reaction, produces the components of the future gasoline that have the highest octane rating. It also releases hydrogen that may be used to hydrogenate sulfur in the feed into H2S, shifting sulfur from gasoline to LPG and fuel gas. This allows a Methaformer to process feeds with sulfur content up to 1000 ppm without prior hydrotreatment.
Alkylation of aromatics, an exothermic reaction, can take place when alcohol is dehydrated and an extremely active radical (methyl radical in this example) is formed. The radical then quickly joins an aromatic molecule (benzene in this case), forming alkylaromatics. Our proprietary catalyst promotes alkylation of undesirable benzene into valuable toluene and xylene and blocks formation of heavier molecules, e.g. fused-ring aromatics.
Aromatization of paraffins, an endothermic reaction, is another chemical pathway leading from low octane n-paraffins to valuable high octane aromatics and hydrogen. This reaction allows Methaforming to process the feeds that can not be upgraded by catalytic reforming, e.g. raffinate from the extraction of aromatics and GTL naphthas.
Isomerization of paraffins, an exothermic reaction, creates higher-octane isoparaffins from normal paraffins.
DOWNLOAD OUR BROCHURE
Flexiforming technology for producing Sustainable Aviation Fuel from Ethanol.
Get in touch.
We respond within 24 hours.
Equipped with the information about your feeds, target products and existing facilities, we can find an optimal application for Flexiforming for you.