FlexUp Process for Downstream Desulfurization and Upgrading
FlexUp is a catalytic desulfurization and upgrading process used in downstream refining. It removes sulfur, nitrogen, and trace metals while increasing API gravity in heavy-sour oil feeds. The process offers an alternative to conventional hydrotreating (HDT) and operates at lower capital and operating costs.
Hydrogen Reduction and Repurposing
Unlike hydrotreating, which depends on energy-intensive hydrogen for desulfurization, FlexUp uses air to achieve similar outcomes. This allows hydrogen capacity to be redirected for hydrogenation or other refining needs, potentially reducing hydrogen-related infrastructure demands.
Lower Capital Requirements
Compared to hydrotreating systems, FlexUp requires significantly lower capital investment. Refineries planning to expand HDT capacity may avoid additional hydrogen gas infrastructure by implementing FlexUp. The process also supports the use of lower-quality crude oils without requiring expensive upgrades to protect against naphthenic acids, metals, or high sulfur levels.
Compliance with Sulfur Regulations
FlexUp removes sulfur from heavy distillates using minimal energy input. As global fuel standards continue to enforce stricter sulfur limits for road diesel, marine fuel, and other products, FlexUp has demonstrated consistent performance in reducing sulfur to compliant levels. This includes oil feeds where conventional hydrotreating struggles to meet regulatory targets.
FlexULS for Sulfur and Nitrogen Polishing
FlexULS is derived from the FlexUp process and specializes in sulfur and nitrogen removal. It is well-suited for feeds with sulfur levels as high as 2,000 parts per million (PPM), particularly where hydrogen saturation offers limited benefits. FlexULS can reduce sulfur content below 10 PPM and lower a refinery’s overall hydrogen consumption by decreasing the desulfurization workload.
Reduced Carbon Emissions
FlexUp operates at lower temperatures and pressures than hydrotreating, leading to reduced energy consumption and a smaller carbon dioxide footprint. In lifecycle analyses of bitumen processing, FlexUp has shown potential to lower CO₂ emissions by up to 10%.