Co-refining of bio-based and fossil feedstock in a continuous slurry hydrocracking pilot plant

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Description

The slurry hydrocracking pilot plant is built to treat biomass slurry and assess its conversion into fuels under conditions that closely replicate industrial operations. It can run in either continuous or batch mode and is equipped with a stirred tank reactor (CSTR) of about 2 dm³, enabling precise testing of mixtures of bio-based and fossil feedstocks. The system operates under severe conditions, with temperatures reaching up to 500°C and pressures up to 180 bar, alongside a continuous supply of hydrogen to drive catalytic hydrogenation and thermal cracking processes. The biomass slurry, typically produced from pyrolysis oil, is introduced into the reactor with catalysts and hydrogen, where it is converted into multiple products such as gas, light and heavy fractions, and water. The plant integrates all key stages, including slurry preparation, gas injection, reaction, and product separation. Designed for stable continuous operation, it delivers accurate mass balance measurements, demonstrating its suitability for industrial scale-up. Overall, the pilot plant is essential for validating co-refining processes and improving the efficient use of biomass slurry in sustainable fuel production.

Features

Operational Capabilities
Operates at high temperature (up to 500°C)
Handles high pressure (up to 180–200 bar with hydrogen)
Supports both continuous and batch processing modes
Reactor & Process Design
Equipped with a stirred tank reactor (CSTR) (~2 dm³ volume)
Uses slurry feed with dispersed homogeneous catalysts
Enables catalytic hydrogenation and thermal cracking
Integrated hydrogen injection system
Feedstock Flexibility
Processes biomass-derived oils (e.g., pyrolysis oil)
Allows co-refining with fossil feedstocks
Handles complex and heavy feedstocks
Process Integration
Includes full system:
Slurry preparation unit
Reactor section
Gas feed system
Product separation (light, heavy, water fractions)
Continuous hydrogen flow and recycling system
Performance & Monitoring
Achieves up to ~90% conversion efficiency
Enables detailed analysis:
Mass balance
Elemental balance (C, H, N, S, O)
Advanced characterization (GC-MS, distillation)
Research & Flexibility
Designed as an open research infrastructure
Allows testing of different catalysts and feedstocks
Suitable for scale-up validation and industrial studies


Benefits

* High efficiency: up to ~90% conversion of feedstock
* Sustainability: integrates biomass with fossil fuels → lower environmental impact
* Valorization of waste: turns low-value biomass into useful fuels
* Industrial relevance: compatible with existing refineries and scalable
* Flexibility: handles complex feedstocks and supports innovation/testing