Technology Implementation

Add-on and Retrofit Alternatives with the HS Reactor System™

Add-on and Retrofit Benefits:

  • Capitalize on inexpensive high acidity feedstock
  • Share and leverage existing infrastructure
  • Use some existing equipment
  • Short time to market as a result of shorter schedule in:
    • Engineering and construction
    • Environmental and other permits
    • Product distribution relationships and logistics already established
    • Knowledgeable personnel already in place

A. Retrofit Conventional Biodiesel Plants:

A retrofit with the HS Reactor System™ will provide a conventional biodiesel plant the ability to process feedstock with up to 100% FFA (recycled greases, animal fats, DDG oil, PFAD, TOFA, etc.) while at the same time producing premium glycerin. The retrofit will reduce operating costs by minimizing yield losses, waste water, and other inefficiencies.

A retrofit to upgrade inefficient first generation technology with the HS Reactor System™ will leverage infrastructure, storage, logistics and existing equipment, as a result, it is an attractive and cost effective alternative to improve plant economics, flexibility and profitability. The HS Reactor System™ can be installed either as a feed pre-treatment or a full train retrofit. All retrofits must be reviewed on a case by case basis as each plant is different.

B. Add-on to Ethanol Plants - DDG Oil:

The HS Reactor System™ enables the dry mill ethanol producer to leverage their existing infrastructure, storage and logistics to convert low value dry distiller's grain (DDG) oil into valuable biodiesel in a timely and cost effective fashion. About 7 gallons of biodiesel can be produced for every 100 gallons of ethanol capacity. Approximately 700 million gallons per year of DDG oil could be produced at current ethanol throughput. All retrofits must be reviewed on a case by case basis as each plant is different.

C. Add-on to Rendering Facilities - Fats and Recycle Greases:

The HS Reactor System™ enables rendering facilities to leverage their existing infrastructure, storage and logistics to convert low value animal fats and recycled greases into valuable biodiesel in a timely and cost effective fashion. About 1 gallon of biodiesel can be produced for every gallon of fats and recycled greases. There are approximately 4 billion gallons of animal fats available globally. All retrofits must be reviewed on a case by case basis as each plant is different.

D. Add-on to CTO Refinery - TOFA:

The HS Reactor System™ enables the crude tall oil (CTO) refiner to leverage their existing infrastructure, storage and logistics to convert co-products, such as tall oil fatty acid (TOFA) into valuable biodiesel in a timely and cost effective fashion. About 30 gallons of biodiesel can be produced for every 100 gallons of CTO capacity. There are approximately 900 million gallons of CTO Worldwide. All retrofits must be reviewed on a case by case basis as each plant is different.

E. Add-on to Palm Oil Refiner - PFAD:

The HS Reactor System™ enables the palm oil refiner to leverage their existing infrastructure, storage and logistics to convert low value co-products such as palm oil fatty acids (PFAD) into valuable biodiesel in a timely and cost effective fashion. About 5% to 10% of a palm oil refiner capacity is PFAD and other acidic products. One pound of PFAD converts into one pound of biodiesel. There are approximately 1.2 billion gallons per year PFAD available globally. All retrofits must be reviewed on a case by case basis as each plant is different.

F. Add-on to Traditional Refiner - Acidic Crude:

The HS Reactor System™ enables the conventional refiner or crude oil producer to leverage their existing infrastructure, storage and logistics to upgrade discounted "opportunity high acid crude oil" in a timely and cost effective fashion to lower corrosiveness and improve stability. A World Bank report estimates that high acid crudes represent 10% of the total global crude oil production. All retrofits must be reviewed on a case by case basis as each plant is different.

G. Add-on to Traditional Refiner - Biocrude:

The HS Reactor System™ enables the conventional refiner to leverage their existing infrastructure, storage and logistics to upgrade biocrude in a timely and cost effective fashion to lower corrosiveness and improve stability. Biocrude is generated by introducing biomass into existing refinery upgrader units. The Department of Energy Billion Ton Study estimates a billion tons per year of biomass available, this translates to approximatelly 120 billion gallons per year of alternative fuel feedstock or 60% of all transportation fuel consumed in the US. All retrofits must be reviewed on a case by case basis as each plant is different.

H. Add-on to Pyrolysis oil facility:

The HS Reactor System™ enables the pyrolysis oil facility to leverage their existing infrastructure, storage and logistics to upgrade pyrolysis oil in a timely and cost effective fashion to lower corrosiveness and improve stability. Pyrolysis oil is produced by converting biomass in a thermochemical process. The Department of Energy Billion Ton Study shows a billion tons per year of biomass available, this translates to approximatelly 120 million gallons per year of fuel feedstock or 60% of all transportation fuel consumed in the US. All retrofits must be reviewed on a case by case basis as each plant is different.

I. Other Plants (oleo-chemical plants, chemical plants, tank terminals, etc.):

Many other plants are also attractive retrofit candidates for the HS Reactor System™. Key criteria include: location relative to feedstock and market, available rail, barge and truck infrastructure, storage capacity, utilities, and general site infrastructure (labs, control room, maintenance shop, etc.). All retrofits must be reviewed on a case by case basis as each plant is different.