Integrating pyrolysis oil into FCC units. SINTEF’s advanced modelling strategy

On the occasion of the 34th European Biomass Conference & Exhibition (EUBCE 2026) held in The Hague, colleagues from SINTEF presented the latest developments achieved within the framework of the European REFOLUTION project. The presentation, delivered by Bernd Wittgens, highlighted how integrating pyrolysis oil into existing refineries represents a concrete solution for the production of sustainable fuels.

A bridge between biomass and large-scale refining facilities

Fast pyrolysis confirms itself as a mature technology for transforming lignocellulosic biomass into biocrude. However, to be used in high-impact transport sectors, such as aviation and maritime transport, bio-oil requires stabilization and conversion phases to remove oxygen and acidity, making it compatible with traditional fuel standards.

One of the key contributions presented by SINTEF concerns the development of an advanced predictive model (lumped modelling approach). This simulation tool allows for a detailed analysis of what occurs when stabilized pyrolysis oil is co-fed alongside traditional fossil feedstocks into Fluid Catalytic Cracking (FCC) units.

Thanks to this approach, it is possible to:

  • Evaluate the impact of the bio-share on kerosene, gasoline, and diesel yields.
  • Track the quality and chemical composition of the resulting products and by-products.
  • Monitor the “green carbon” content within the distilled fractions.

This work is the result of a close synergy involving several of the project’s industrial and research partners, including Moeve (which provided experimental data from pilot plants), DLR (for advanced chemical analyses), BTG and BTG Bioliquids.

The project’s next milestones involve validating the model on a larger pilot scale at the VTT laboratories in Finland and using it to assess the technical and economic sustainability of the process on an industrial scale. The final results will help accelerate the transition toward increasingly decarbonized mobility, optimizing renewable energy resources across Europe.