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A European steam cracker has identified pyrolysis oil as an alternative feedstock and a critical component of its strategy for decarbonization and sustainability. Recognizing the global demand for decarbonization, they are committed to transform their business model to become a leader in the transition to sustainable feedstocks. They plan to incorporate a defined proportion of plastic pyrolysis oil into their processes—blended with conventional feedstocks like naphtha—and aim to gradually increase this share over the coming years.
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Challenge
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Solution
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Results
Contaminant Variability in Pyrolysis Oil
The pyrolysis oil has a variable contamination profile composed of solids, semi-solids, gums and other contamination like metals with important evolution with time, coming from various partnering pyrolysis oil producers.
These contaminants can cause issues in the downstream refining process resulting in fouling and coke formation in the furnace that causes loss of performance, shorter run-length and increased maintenance costs. Therefore, specifying the cleanliness requirements of pyrolysis oil is crucial if it is to be used in steam crackers and HDT (hydrotreatment) units.
Depth Filtration for Contaminant Control
To address these challenges, Pall implemented a cellulosic depth filtration solution tailored to the contamination levels and types present in the pyrolysis oil. The approach included:
- Lab-scale analysis to characterize contaminants
- Full-scale on-site testing to validate performance
- Customized filter selection based on retention ratings
The filters effectively removed particulates, metals, semi-solids, and gels, ensuring the oil met cleanliness requirements for steam cracking.
Filtration at the storage tank and before blending onto the feed
Improved Furnace Performance and Reliability
During co-processing trials (1–3% pyrolysis oil blended with naphtha), the filtration system demonstrated:
- 90% removal of solids
- ~50% reduction in gums
- Mitigation of fouling in the convection section and instrumentation
- Reduced radiant coking and TLE fouling
Contamination levels ranged from 20–500 ppm TSM (Total Suspended Matter), yet the filtration system maintained consistent performance.
Pall mobile rental filter housing
Conclusion: Scalable, Sustainable Success
The customer’s decision to expand the implementation of these filtration solutions across additional production sites underscores the success and scalability of the approach. Pall’s involvement—from initial lab-scale testing to full-scale deployment—demonstrates the critical value of close technical collaboration.
By leveraging the expertise of Pall’s lab and service teams, the customer was able to confidently integrate sustainable pyrolysis oil feedstocks while meeting stringent performance specifications and advancing their strategic sustainability goals. This partnership exemplifies how tailored technical support can drive innovation and enable meaningful progress toward decarbonization.
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