Hydrotreated Vegetable Oil (HVO/HEFA) SAF PreFEED

Objective

To deliver a PreFEED study for an integrated, industrial-scale Hydrotreated Vegetable Oil (HVO) Sustainable Aviation Fuel (SAF) facility in Romania, converting Camelina seed into SAF via the Hydroprocessed Esters and Fatty Acids – Synthetic Paraffinic Kerosene (HEFA-SPK) pathway. The study aimed to:

• Establish the technical requirements for a greenfield, co-located development.
• Define project boundaries and work packages.
• Develop process simulation and design deliverables.
• Produce a Class IV CAPEX estimate.
• Assess carbon intensity in line with RED III requirements.
• Support an application for €93 million funding from the EU Modernisation Fund.

The development is intended to contribute to the decarbonisation of the European aviation sector.

Project Scope

The PreFEED covered an integrated development at a greenfield site in Romania.

Integrated Facilities

The project comprises:

1. Camelina Seed Pre-Treatment and Pressing Facility
   • Pre-cleaning, flattening, moisture and heat treatment.
   • Mechanical oil extraction.
2. Solvent Extraction Plant
   • Additional oil extraction from pressed cake.
   • Production of meal as a by-product.
3. Camelina Oil Refinery
   • Degumming, neutralisation and bleaching.
   • Production of refined Camelina oil suitable for SAF conversion.
4. SAF Production Facility (HEFA-SPK Route)
   • Hydrogen generation via electrolysis.
   • Hydrotreating.
   • Isomerisation / hydrocracking.
   • Hydrogen recovery.
   • Distillation to produce SAF, HVO diesel and naphtha.
5. Utilities and Infrastructure
   • Electrical substation and grid connection.
   • Water supply from the Danube.
   • Effluent and wastewater treatment.
   • Storage and export systems.
   • Flare, firewater and supporting utilities.

Design Basis & Capacity

The updated basis targeted:

• ~3,600 tpd Camelina seed.
• ~50 t/h refined Camelina oil feed to SAF production.
• SAF production of ~22.6 t/h (~180 ktpa).
• HVO diesel production of ~19.5 t/h (~156 ktpa).
• Overall plant power demand of ~153 MW (End of Life basis).

The facility is designed to operate in base case mixed product mode or in maximum SAF or maximum HVO modes.

Findings & Recommendations

Findings

Integrated Technical Concept Defined

Complete PreFEED technical package, including:

• In-house HYSYS simulation of the SAF Production Facility.
• 84% overall conversion of Camelina oil to SAF and HVO diesel.
• Flexible product slate capability (SAF/HVO ratio adjustable).
• Identified energy penalty when operating in maximum SAF mode due to additional hydrocracking.

Carbon Intensity Compliance Achieved

Using RED III Annex V methodology:

• Calculated CI: 23.85 gCO₂e/MJ
• RED III target: ≤ 32.9 gCO₂e/MJ
• Calculated reduction vs fossil comparator: 74.6%

The project meets the RED III requirement of at least 65% emissions reduction.

Seed yield was identified as the dominant driver of lifecycle emissions (eec component).

Capital Cost Structure Established

Two concepts were evaluated:

1. Core facility.
2. Facility plus port and train storage infrastructure.

The estimate was prepared in accordance with AACEi Class 4 methodology (±40% accuracy). The hydrogen plant, SAF production facility and utilities represent the largest cost blocks.

Value Improvement Opportunities Identified

A structured review identified potential cost reduction measures, including:

• Reduction of refined oil, product and feedwater storage capacity.
• Cost optimisation by using alternative hydrogen generation technologies and impact on Carbon Intensity
• Firewater demand reduction via tank segregation.
• Conveyor system length optimisation.
• Removal of potable water system (if tie-in feasible).

Collectively, these measures could reduce expected project cost by approximately 6.4% (Concept 2 basis).

Logistics and Infrastructure are Critical Risk Areas

The feasibility of the project is strongly dependent on:

• Availability of sufficient agricultural land.
• Seed storage and transport capability (road, rail and barge).
• Port and train station storage capacity.
• Power supply constraints and green PPA availability.
• Raw water extraction permitting from the Danube.
• Final SAF licensor selection and vendor engagement.

Economic Sensitivity to Market Variables

The economics model identified exposure to:

• Meal monetisation risk.
• Diesel sales price volatility.
• Camelina seed feedstock price.
• Grid power pricing.
• Capital cost escalation.

Upside cases show improved performance under stronger pricing or reduced capital cost conditions.

Recommendations

Confirm Optimal Production Strategy

• Reassess optimal throughput and product slate based on refined logistics data and economics.
• Confirm whether base case mixed production or maximum SAF mode provides strongest long-term position.

Advance Seed Supply and Logistics Definition

• Confirm land availability and realistic seed yield assumptions.
• Validate storage and transport capacity at farm, port and rail nodes.
• Perform detailed logistics study in next phase.

Progress Licensor Engagement

• Continue engagement with Honeywell-UOP.
• Engage additional licensors (e.g. Axens).
• Perform paid technical studies to firm up scope and guarantees.
• Select licensor prior to FEED.

Refine Carbon Intensity Model

• Update CI model at next engineering stage.
• Incorporate confirmed farm locations and transport routes.
• Refine seed yield assumptions and logistics emissions.

Confirm Utilities and Infrastructure

• Confirm grid capacity and green PPA feasibility.
• Confirm raw water permitting and pump house suitability.
• Develop detailed port and rail infrastructure definition.
• Confirm export routing strategy.

Optimise Plot Plan and Storage Strategy

• Perform detailed plot plan optimisation to reduce footprint.
• Evaluate storage reduction scenarios against operational flexibility.
• Validate firewater demand reduction strategy.