(237b) Unlocking the Value of Bio-Naphtha: A Life-Cycle and Economic Assessment of Bio-Naphtha to Renewable BTX and Hydrogen

Bio-naphtha, a by-product of synthetic aviation fuel (SAF) and renewable diesel (RD) production, is projected to experience significant global growth, driven by the expanding production of SAF and RD. However, its current use as a gasoline blendstock offers limited economic value due to its low octane number [1] and dependence on the gasoline market—a market increasingly impacted by the rise of vehicle electrification in recent years [2]. Converting bio-naphtha to value-added chemicals unlock its value for diversifying chemical supply chains and lowering overall bio-refinery costs.

Our previous study assessed the viability of converting bio-naphtha to olefins and SAF via steam cracking and olefin oligomerization. The results revealed this conversion pathway only favors bio-naphtha with low naphthene and aromatic contents, such as bio-naphtha from Fischer-Tropsch and hydroprocessed esters and fatty acids, and is not suitable for bio-naphtha from catalytic fast pyrolysis (CFP) and hydrothermal liquefaction (HTL), due to selectivity and coke formation issues.

This study explores the potential of using these four bio-naphtha for renewable BTX and hydrogen production through catalytic reforming. A detailed Aspen HYSYS process model, coupled with life cycle analysis (LCA) and techno-economic analysis (TEA), evaluates the environmental and economic performance of each feedstock. Compared to steam cracking, catalytic reforming demonstrates a higher suitability for bio-naphtha from HTL and CFP, yielding the highest renewable BTX and hydrogen outputs with the lowest minimum product selling price. This study offers critical environmental and economic insights, enabling bio-refineries to identify optimal pathways for upgrading bio-naphtha and maximizing its value, thereby fostering advancements in biofuel production.

References

[1] Abhari, R., Tomlinson, H. L., & Roth, G. (2013). U.S. Patent No. 8,581,013. Washington, DC: U.S. Patent and Trademark Office.

[2] https://www.bls.gov/opub/btn/volume-12/charging-into-the-future-the-transition-to-electric-vehicles.htm