More sustainable fuels: GEA wins first customer for Pre2Fuel process

GEA is breaking new ground with its innovative Pre2Fuel technology to make the production of “Hydrotreated Vegetable Oil” (HVO) and “Sustainable Aviation Fuel” (SAF) more efficient and sustainable.

Biofuels such as HVO and SAF play a central role in the decarbonization of the global transportation sector, which is under increasing pressure to reduce its CO₂ emissions. GEA's Pre2Fuel process offers a promising solution for this challenge: through an optimized pretreatment process, biofuel plant owners can reduce their operating costs by up to 50 percent and cut CO₂ emissions by up to 12 percent compared to conventional pretreatment. A first project with a customer who will use the Pre2Fuel technology in Asia to process used cooking oil and palm oil waste products underlines the potential of this innovation.

High purity requirements for HVO and SAF

Pretreatment plays a crucial role in HVO and SAF production. By-products and waste materials such as used cooking oil (UCO), animal fats, or palm oil mill effluent (POME) are increasingly being used as raw materials. These are often characterized by low quality and high levels of contamination. At the same time, the purity requirements in HVO and SAF production are on a par with or even higher than the standards of the food industry. In order to meet these high requirements, especially when using low-quality raw materials, traditional processes require the use of bleaching earth, which entails considerable costs and ecological impacts.

Innovative pre-treatment: cost savings by eliminating the bleaching process

With the new Pre2Fuel technology, GEA has developed a solution that cleans the raw materials so effectively during degumming that bleaching is no longer necessary. This results in compelling advantages for users:

• Cost savings: Operating costs for pre-treatment are reduced by up to 50 percent, as the purchase, handling and disposal of bleaching earth is no longer necessary.
• Efficiency increase: Reduced oil losses contribute to revenue optimization.
• Environmental benefits: Savings of up to 12 percent of CO₂ emissions by avoiding environmentally harmful steps.

GEA Pre2Fuel is based on a two-stage process that focuses on PE filtration and degumming. The experts at GEA Separation have optimized the separation efficiency of the process to such an extent that the previous three process steps – PE filtration, degumming and bleaching – have been reduced to two. Tests with a wide range of raw materials show that the results of the Pre2Fuel process exceed those of conventional processes in terms of purity and efficiency.

Scientific validation and successful tests

GEA has conducted extensive tests to validate the performance of Pre2Fuel. These tests include both laboratory studies and trials with specially developed pilot plants. The results show:

• Higher purity: Significantly lower residual phosphorus and metal levels compared to conventional processes.
• Extended feedstock flexibility: Successful processing of used cooking oils, animal fats (categories 1–3), palm oil mill effluents and residues (POME), and non-edible vegetable oils such as carinata.

These advantages make the process particularly attractive for operators seeking to maximize the efficiency and sustainability of their operations while processing a wide range of raw materials of varying quality.

Growing market and sustainability pressure drive demand for HVO and SAF

The market for HVO and SAF is growing rapidly. Both fuels are based on the Hydroprocessed Esters and Fatty Acids (HEFA) technology. Regulations and stricter emission targets are steadily increasing the demand for sustainable fuels. In the EU, for example, 2 percent of aviation fuel must already be sustainable by 2025, and 70 percent by 2050. GEA's Pre2Fuel process aims to provide biofuel producers with a solution that supports cost-effective and environmentally friendly production, thus contributing to the decarbonization of the transportation sector.

Background information on HVO and SAF

Hydrotreated Vegetable Oil (HVO)
Hydrotreated Vegetable Oil (HVO) is a type of renewable diesel produced from vegetable oils, animal fats, and other renewable feedstocks through a process called hydrotreatment. A significant portion of HVO is also derived from waste products such as Used Cooking Oil (UCO). Unlike traditional biodiesel, HVO has a similar chemical structure to fossil diesel, making it a drop-in replacement that can be used in existing diesel engines without modification. HVO offers several advantages, including higher energy density, better cold flow properties, and a lower carbon footprint compared to conventional diesel.

Sustainable Aviation Fuel (SAF)
Sustainable Aviation Fuel (SAF) is an alternative to traditional jet fuel derived from renewable sources such as plant oils, waste fats, and other sustainable feedstocks. SAF is designed to reduce greenhouse gas emissions to improve sustainability of the aviation industry. It can be blended with conventional jet fuel and used in existing aircraft engines, providing a more sustainable aviation.
Production Routes for SAF: There are multiple pathways to produce SAF, each utilizing different technologies and feedstocks. The most common are:

• Fischer-Tropsch (FT) Synthesis: Converts syngas derived from biomass or municipal solid waste into liquid hydrocarbons.
• Alcohol-to-Jet (AtJ): Converts ethanol or butanol from biomass into jet fuel.
• Hydroprocessed Esters and Fatty Acids (HEFA): Utilizes fats, oils, and greases, which are hydroprocessed to produce jet fuel

GEA Pre2Fuel is the right pretreatment for anyone who decides to produce SAF via the HEFA route.