Co-processing in Refineries
Enable renewable fuel production using existing refinery infrastructure
Co-processing integrates bio-based feedstocks such as used cooking oil, animal fats and other organic materials into existing petroleum refining processes. By utilizing existing hydroprocessing units, refiners can produce renewable hydrocarbon fuels compatible with current fuel infrastructure while using existing refinery assets.
What is co-processing in a refinery?
Co-processing combines renewable feedstocks with conventional fossil-based feeds and processes them together within standard refinery units. These units most commonly include hydrotreaters, hydrocrackers, and fluid catalytic cracking systems.
Within these processes:
- Bio-based feedstocks are blended with traditional refinery streams
- Established hydroprocessing conditions are applied
- Outputs include hydrocarbon fuels compatible with existing distribution systems
This integration shapes how refineries operate and enables renewable feedstocks to be processed within existing refining workflows.
Why is co-processing used in petroleum refineries?
Co-processing utilizes existing refinery infrastructure, allowing additional feedstocks to be processed without significant modification. For refineries with available capacity, this can create opportunities to increase renewable fuel production using established operations.
In this context, co-processing can support:
- More efficient use of existing refinery assets
- Alignment with sustainability and emissions reduction objectives
- Increased renewable fuel output using established processing conditions
Depending on refinery configuration and product goals, co-processing is typically implemented in hydrotreating, hydrocracking, or catalytic cracking units.
How does co-processing work within refinery units?
Co-processing is introduced at defined points within refinery flows, where bio-based materials are blended into conventional feed streams before entering processing units. This blending enables renewable and fossil feedstocks to be processed under the same operating conditions.
A typical process flow includes:
- Feedstock preparation and blending to enable consistent input despite variability in bio-based materials
- Introduction into hydroprocessing units using established refinery conditions
- Conversion during processing where feedstocks are transformed alongside conventional streams
- Separation and finishing to produce hydrocarbon fuels suitable for existing infrastructure
Co-processing insertion points in a refinery
Pall filtration and separation technologies can be applied at multiple points throughout the co-processing process. The diagram below highlights common contamination control locations, with the numbered sections beneath showing related application areas and recommended solutions.
Typical contamination control solutions used in a co-processing application
Filtration and Separation Solutions Throughout the Co-Processing Process
1. Hydrotreater feed filtration
- Application: Removal of particulates from feed streams before processing
- Recommended Solutions: Ultipleat® High Flow filters, Ultipleat® High Flow HT filters, Ultipleat® HT filters
- Role in process: Helps protect downstream equipment and catalyst systems from fouling
2. Hydrotreater feed water removal
- Application: Separation of water from feed streams
- Recommended Solutions: AquaSep® XS liquid/liquid coalescers, PhaseSep® EL coalescers
- Role in process: Supports stable operation by managing water-related contamination
3. Liquid/liquid coalescer protection
- Application: Protection of coalescing systems from particulate contamination
- Recommended Solutions: Ultipleat® High Flow filters
- Role in process: Supports consistent separation and coalescer performance
4. Sour water removal from hydrotreated product
- Application: Removal of water from treated streams
- Recommended Solutions: PhaseSep® EL
- Role in process: Reduces downstream corrosion and processing constraints
5. Water removal from stabilized product
- Application: Final removal of water prior to storage or distribution
- Recommended Solutions: AquaSep® XS liquid/liquid coalescers
- Role in process: Supports product quality and handling
6. Hydrogen recycle and compressor protection
- Application: Removal of contaminants from hydrogen streams
- Recommended Solutions: SepraSol™ Plus, Medallion™ HP gas coalescers
- Role in process: Helps protect compressors and maintain gas stream purity
7. Final product polishing
- Application: Removal of remaining particulates and impurities
- Recommended Solutions: Liquid and gas filtration technologies
- Role in process: Supports final product specifications
8. Hydrogen recycle and make-up gas compressors protection
- Application: Removal of contaminants from hydrogen recycle and make-up gas streams
- Recommended Solutions: SepraSol™ Plus, Medallion™ HP liquid/gas coalescers
- Role in process: Helps protect compressors from fouling and supports reliable gas stream handling
9. Low NOx burner protection
- Application: Removal of contaminants from gas streams feeding burners
- Recommended Solutions: SepraSol™ Plus, Medallion™ HP liquid/gas coalescers
- Role in process: Helps prevent burner fouling and supports consistent burner operation
What challenges are associated with co-processing bio-feedstocks?
As co-processing integrates bio-based materials into standard refinery operations, differences in feedstock composition introduce specific challenges. Bio-feedstocks are often variable in quality and may contain impurities even after pre-treatment.
Common challenges include:
- Variability in feedstock composition and consistency
- Presence of contaminants such as particulates and gels
- Formation of dissolved or semi-solid impurities during processing
- Increased potential for fouling within equipment and catalyst systems
How does contamination affect co-processing performance?
As processing progresses, contaminants can accumulate across multiple systems within the refinery. This accumulation can affect both equipment and overall process stability.
Potential impacts include:
- Fouling of heat exchangers and other process equipment
- Contamination of catalyst beds
- Increased maintenance requirements or unplanned downtime
- Variability in process performance
Before implementing or adjusting co-processing operations, it is important to understand where contamination can affect performance and how it can be managed within existing systems.
Need support with co-processing filtration and contamination control? Discuss your application with a Pall specialist.
Frequently Asked Questions
Why is co-processing important for renewable fuel production?
Co-processing enables refiners to produce renewable hydrocarbon fuels using existing refinery units. This allows production to scale without requiring new fuel infrastructure.
What are the main challenges of co-processing bio-feedstocks?
Challenges include variability in feedstock composition and the presence of contaminants such as particulates, gels, and dissolved impurities that affect processing stability.
How are contaminants managed in co-processing?
Contaminants are managed using filtration and separation technologies applied at different stages of the refining process.
Can co-processing be used in existing refinery units?
Yes. Co-processing is typically implemented in hydrotreaters, hydrocrackers, and catalytic cracking units already present in refineries.
Where is filtration applied in co-processing?
Filtration is applied across feed preparation, processing units, water treatment, gas handling, and final product finishing stages.
Get guidance on filtration and separation approaches for your refining process