SIM 4910 Sustainable Aviation Fuel Biorefinery (SAF)

 Model Description

Fischer-Tropsch (FT) Synthesis: 

The syngas feed is converted into hydrocarbons of varying types and lengths in a Fischer-Tropsch reactor. 

• Heavier Liquid Products (FT Wax): Exits the reactor, undergoes catalyst separation, and is sent to the hydrocracking section. 
• Lighter Gaseous Products: Are cooled, and the condensate is processed in the gas separation unit. 

Gas Separation Unit: 

The FT condensate is processed in a three-phase separator to split into: 

• Water stream 
• Oil stream 
• Tail gas stream 

Hydrocracking Section: 

This two-stage process converts long hydrocarbons into shorter, kerosene-range hydrocarbons: 

1. Cracking Stage: Breaks down long hydrocarbons into smaller, more useful chains. 
2. Saturation Stage: Converts alkenes to alkanes using hydrogen. 

The product is flashed to recover and recycle hydrogen back into the reactor. 

Fractionating Column: 

The distillation process separates hydrocarbons by chain length into streams such as kerosene, naphtha, and diesel. Heavy hydrocarbons recycle into the hydrocracker, while light gases are fed into the tail gas stream. 

Learning Outcomes

• Explore the Context of SAF Production: Learn why SAF is a sustainable fuel alternative, understand its various production pathways, and gain knowledge about fuel standards and blending limits. 
• Master the Anderson-Flory-Schultz (ASF) Distribution: Understand how the ASF model predicts product distribution in a Fischer-Tropsch reactor and learn to adjust operating conditions to optimise outputs. 
• Operate the FT Reactor Effectively: Gain the skills to fine-tune the reactor to maximise the production of kerosene-range hydrocarbons. 
• Control Key Unit Operations: Develop proficiency in operating the essential units of a Fischer-Tropsch plant, including reactors, separators, and control systems. 
• Analyse Plant Economics: Understand the economic drivers of SAF production and learn to operate the plant efficiently, balancing safety and profitability.