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SAF blendstock hydrocarbon separation unit (distillation)

Screening model for a hydrocarbon separation section recovering SAF blendstock and co-products from a stabilised hydrocarbon mixture, with energy demand estimates and a granular equipment purchase cost split.

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alexi

I do low-carbon energy stuff for 10 years & build things I wish existed.

Inputs

Total mass flow of stabilised hydrocarbon mixture entering the separation/stabilisation section.

t/h

min 0.1 · max 500 · step 0.1 · t/h

Average annual utilisation of the unit, including planned and unplanned downtime.

min 10 · max 100 · step 1 · %

Fraction of inlet mass recovered as SAF blendstock cut. Remaining material becomes co-products, recycle, and small losses.

min 0 · max 80 · step 1 · %

Strategy affects separation severity, recycle fraction, and utilities/CAPEX multipliers.

Parallel separation trains. Used to compute per-train capacity for scaling, then aggregated back to total CAPEX.

-

min 1 · max 6 · step 1 · -

All-in electricity price for the site (screening).

EUR/MWh

min 0 · max 300 · step 1 · EUR/MWh

All-in cost of thermal energy (e.g., steam or fired heat) used for reboilers/strippers.

EUR/MWhth

min 0 · max 200 · step 1 · EUR/MWhth

Used for CAPEX annualization via the capital recovery factor (CRF). Enter as a decimal ratio (0.08 = 8%).

ratio

min 0 · max 0.25 · step 0.005 · ratio

Amortization period for annualizing equipment purchase CAPEX.

years

min 5 · max 40 · step 1 · years

Results

Total hydrocarbon inlet capacity

Nameplate inlet to separation section

…t/h

Number of parallel trains

Used for per-train scaling and total CAPEX aggregation

…

SAF blendstock production rate

Recovered kerosene-range cut (mass basis)

…t/h

Co-products production rate

Non-SAF liquid/gas products dispatched to blending or storage

…t/h

Recycle flow

Internal or upstream recycle/return stream (screening fraction)

…t/h

Annual hydrocarbon inlet requirement

Total mixture processed per year

…t/yr

Annual SAF blendstock production

Mass of SAF cut recovered per year

…t/yr

Annual co-products production

Remainder products (mass) recovered per year

…t/yr

Annual heat demand

Reboilers/stripping/stabilisation duty proxy

…MWhth/yr

Annual electricity consumption

Pumps, controls, refrigeration/auxiliaries proxy

…MWh/yr

Scaled specific equipment CAPEX

Per (t/h) of inlet, equipment purchase only

…EUR/(t/h)

Total equipment purchase CAPEX

Columns + exchangers + pumps + condensers + product recovery (excludes installation/indirect/owner costs)

…EUR

CAPEX: distillation columns

Equipment purchase allocation

…EUR

CAPEX: heat exchangers

Preheat/coolers/reboilers (purchase cost allocation)

…EUR

CAPEX: pumps

Transfer and circulation pumps (purchase cost allocation)

…EUR

CAPEX: condensers

Overhead condensation and associated equipment allocation

…EUR

CAPEX: product recovery systems

Cut recovery, product rundown, and storage interface allocation

…EUR

Scaled fixed O&M fraction

Annual fixed O&M as fraction of equipment purchase CAPEX

…ratio

Annual fixed O&M cost

Labour, routine maintenance, overheads (screening proxy)

…EUR/yr

Annual variable O&M cost

Consumables, waste handling, routine chemicals (excludes energy)

…EUR/yr

Annualized replacement cost

Periodic internals/rotating equipment refresh (screening)

…EUR/yr

Annual energy cost

Electricity + heat (based on user prices)

…EUR/yr

Annualized CAPEX (CRF)

Equipment purchase CAPEX annualized over project lifetime

…EUR/yr

Total annual cost

Annualized CAPEX + fixed/variable O&M + replacement + energy

…EUR/yr

Levelized separation cost (SAF basis)

Total annual cost divided by annual SAF production

…EUR/t

Levelized separation cost (energy basis)

Converted using SAF LHV

…EUR/MWh-fuel

Indicative green H2 demand (integrated e-fuels context)

Stoichiometric signal for FT-like SAF production from CO2 + H2

…tH2/yr

Indicative CO2 demand (integrated e-fuels context)

CO2 feed signal for FT-like SAF production

…tCO2/yr

About

Calculator context

Introduction

This calculator provides a pre-feasibility (screening-stage) estimate of mass flows, utility consumption and equipment purchase CAPEX / OPEX for a hydrocarbon separation unit recovering SAF blendstock (e-kerosene cut) plus co-products from a stabilised hydrocarbon mixture, consistent with an e-fuels / Fischer–Tropsch liquids pathway. It is intended for early project definition in a generic (non-region-specific) context, using standard chemical engineering scaling and literature-typical intensities.

Methodology

The model is structured as a simple mass/energy balance with scale-up costing:

  • Operating time

    • annual_operating_hours = hours_per_year * (capacity_factor_pct * 0.01)
    • annual_inlet_t = hydrocarbon_inlet_tph * annual_operating_hours

  • Mass balance (cuts, recycle, losses)

    • saf_flow_tph = hydrocarbon_inlet_tph * (saf_yield_pct * 0.01)
    • recycle_flow_tph = hydrocarbon_inlet_tph * recycle_fraction (strategy-adjusted)
    • losses_flow_tph = hydrocarbon_inlet_tph * losses_fraction
    • coproduct_flow_tph = max(inlet − SAF − recycle − losses, 0)

  • Utilities (screening intensities per tonne of inlet, adjusted by cut strategy)

    • annual_heat_mwhth = inlet_tph * specific_heat_mwhth_per_t_feed * strategy_heat_mult * annual_operating_hours
    • annual_electricity_mwh = inlet_tph * specific_electricity_mwh_per_t_feed * strategy_elec_mult * annual_operating_hours

  • CAPEX (equipment purchase only) with scaling (common in IEA/IRENA/NREL-style techno-economic screening and classic process design texts)

    • capacity_ratio = (capacity_per_unit_tph / ref_capacity_tph)
    • specific_capex_scaled = clamp(capex_ref_eur_per_tph * capacity_ratio^capex_scale_exponent * strategy_capex_mult, min, max)
    • capex_total = specific_capex_scaled * total_capacity_tph
    • CAPEX split by fractions into columns, exchangers, pumps, condensers, product recovery.

  • OPEX, replacement, and levelized cost

    • CRF = (r*(1+r)^n)/((1+r)^n−1)
    • annualized_capex = capex_total * CRF
    • fixed O&M = capex_total * om_fraction_scaled (scaled and clamped)
    • variable O&M = annual_inlet_t * variable_om_eur_per_t_feed
    • replacement_annual based on a periodic internals/rotating equipment refresh interval
    • levelized_cost_eur_per_t_saf = total_annual_cost / annual_saf_t

  • E-fuels physics signals (indicative)

    • SAF LHV used to compute EUR/MWh-fuel; indicative CO2 and H2 demands are estimated from literature-typical stoichiometry for FT-like hydrocarbons (IEA/IRENA/Concawe/Fraunhofer).

Applications

  • Business developer / project origination: compare cut strategies (SAF-max vs balanced vs diesel-max) on SAF output, utility loads, and levelized separation cost.
  • Process concept screening: rapid “what-if” sizing of number of trains and capacity to understand CAPEX scaling and cost breakdown drivers.
  • Early techno-economics: combine with upstream synthesis models to translate SAF output into EUR/MWh-fuel and indicative CO2/H2 feed needs for integrated e-fuels studies.

Model

106 variables — inputs, calculations and outputs, with their dependencies.

106 variables shown of 106
VariableValueUnitDepends on
50t/h—
90%—
35%—
2——
1-—
80EUR/MWh—
25EUR/MWhth—
0.08ratio—
20years—
VariableFormulaUnitDepends on
if(((<=)+(<)+(>)+(<)+(>)+(<)+(>)+(<)+(<)+(<)+(<)+(>)+(<=))>,,)bool
*—
*h/yr
*—
if(==,,if(==,,))—
if(==,,if(==,,))—
if(==,,if(==,,))—
*if(==,,if(==,,))—
*t/h
/max(,)t/h
/max(,)—
*(^(-1))*EUR/(t/h)
*(^)ratio
*EUR/yr
*EUR/yr
(*(1+)^)/max(((1+)^-1),)—
**/max(,)MWh-fuel/yr
*/max(,)*L/yr
/max(,)MWh/yr
+MWh/yr
VariableFormulaUnitDepends on
—
t/h
*t/yr
*t/h
*t/h
max((---),)t/h
*t/yr
*t/yr
***MWhth/yr
***MWh/yr
clamp(,,)EUR/(t/h)
*EUR
*EUR
*EUR
*EUR
*EUR
*EUR
clamp(,,)ratio
*EUR/yr
*EUR/yr
*/max(,)EUR/yr
+EUR/yr
*EUR/yr
++++EUR/yr
/max(,)EUR/t
/max(,)EUR/MWh-fuel
*tH2/yr
*tCO2/yr

Assumptions

49 assumptions used in the calculations

  • Prevents division-by-zero and unstable ratios in screening calculations.

    0.000001
    Modeling guard

  • Used to avoid inline numeric literals in the DSL.

    Market range 0

    0
    Math constant

  • Used to avoid inline numeric literals in the DSL (unitless identity and boolean true).

    Market range 1

    1
    Math constant

  • Used to avoid inline numeric literals in the DSL (selector option id).

    Market range 2

    2
    Math constant

  • Used to avoid inline numeric literals in the DSL (selector upper bound).

    Market range 3

    3
    Math constant

  • Used for percent bounds and conversions without inline numeric literals.

    Market range 100

    100
    Math constant

  • Converts percent inputs (0-100) to fractions (0-1).

    Market range 0.01

    0.01fraction/%
    Unit conversion

  • Used to convert capacity factor into annual operating hours.

    8760h/yr
    Calendar constant

  • Reference capacity for scaling the specific equipment purchase CAPEX and O&M fraction.

    50t/h
    Screening reference point

  • Represents an order-of-magnitude equipment purchase cost intensity for multi-column hydrocarbon fractionation and associated systems.

    120000EUR/(t/h)
    Screening CAPEX anchor

  • Represents economies of scale for equipment purchase costs in process plants (six-tenths rule family).

    0.6
    Cost scaling law

  • Lower bound to prevent unrealistically low scaled specific CAPEX at large capacity.

    60000EUR/(t/h)
    Screening clamp

  • Upper bound to prevent unrealistically high scaled specific CAPEX at small capacity.

    220000EUR/(t/h)
    Screening clamp

  • Fixed O&M as a fraction of equipment purchase cost, representing staffing, maintenance contracts and overheads at screening level.

    0.04ratio
    O&M heuristic

  • Allows modestly lower O&M fraction for larger facilities due to shared labor/overheads.

    -0.1
    Scaling heuristic

  • Prevents unrealistically low fixed O&M fraction at very large capacities.

    0.02ratio
    Screening clamp

  • Prevents unrealistically high fixed O&M fraction at very small capacities.

    0.08ratio
    Screening clamp

  • Represents non-energy variable costs (chemicals, filters, waste, routine consumables) proportional to throughput.

    0.5EUR/t
    Screening consumables proxy

  • Represents periodic replacement/overhaul of internals (trays/packing), seals, and selected rotating equipment components.

    8years
    Maintenance heuristic

  • Fraction of equipment purchase CAPEX representing the cost of periodic replacement items during a major refresh.

    0.08ratio
    Maintenance heuristic

  • Represents purge, flaring, sampling, and handling losses across the separation section at screening level.

    0.005ratio
    Screening mass-loss allowance

  • Represents a screening recycle/return stream fraction associated with heavy ends return, off-spec recovery, or cut optimization.

    0.08ratio
    Process heuristic

  • SAF-max mode typically increases recycle/off-spec recovery due to tighter cut specs.

    1.2
    Strategy multiplier

  • Balanced mode uses the base recycle fraction.

    1
    Strategy multiplier

  • Diesel/heavier-product emphasis typically relaxes kerosene cut tightness, reducing recycle/reprocessing.

    0.8
    Strategy multiplier

  • Sharper separations generally increase reflux/reboiler duty.

    1.2
    Strategy multiplier

  • Balanced strategy uses base heat intensity.

    1
    Strategy multiplier

  • Relaxed kerosene cut sharpness can reduce reboiler duty.

    0.9
    Strategy multiplier

  • Tighter cuts may increase pumping, refrigeration/condensing duty and controls, raising auxiliary electricity.

    1.1
    Strategy multiplier

  • Balanced strategy uses base electricity intensity.

    1
    Strategy multiplier

  • Relaxed kerosene cut sharpness can slightly reduce auxiliary electricity demand.

    0.95
    Strategy multiplier

  • Sharper separations can require more stages/height, tighter materials, larger exchangers, or additional columns.

    1.15
    Strategy multiplier

  • Balanced strategy uses base CAPEX intensity.

    1
    Strategy multiplier

  • Less stringent kerosene cut can reduce required fractionation severity and equipment size/complexity.

    0.95
    Strategy multiplier

  • Represents typical reboiler and stabilisation heat duty per tonne of hydrocarbon feed for a moderate-severity separation section.

    0.35MWhth/t
    Utility intensity (screening)

  • Represents pumps, controls, and auxiliary loads per tonne of hydrocarbon feed.

    0.03MWh/t
    Utility intensity (screening)

  • Columns are typically a dominant share of purchase cost in fractionation sections.

    0.4ratio
    CAPEX allocation

  • Exchanger networks (including reboilers/coolers) are a major part of purchase cost.

    0.2ratio
    CAPEX allocation

  • Pumps are usually a smaller share of purchase cost compared with columns/exchangers.

    0.07ratio
    CAPEX allocation

  • Condensing systems may include condensers, receivers, and related equipment; separated here for requested granularity.

    0.13ratio
    CAPEX allocation

  • Represents product rundown, recovery/skids, and dispatch interface within equipment purchase scope.

    0.2ratio
    CAPEX allocation

  • Converts tonnes to kilograms for LHV and stoichiometry conversions.

    Market range 1000

    1000kg/t
    Unit conversion

  • Converts MJ to MWh (1 MWh = 3.6 GJ = 3600 MJ).

    Market range 3600

    3600MJ/MWh
    Unit conversion

  • Represents a typical lower heating value for kerosene/jet-range fuels used to report EUR/MWh-fuel.

    43MJ/kg
    Fuel property

  • Used to optionally convert SAF mass to volumetric production (litres).

    800kg/m3
    Fuel property (screening)

  • Converts cubic meters to litres for volumetric reporting.

    Market range 1000

    1000L/m3
    Unit conversion

  • Indicative hydrogen requirement for producing FT-like hydrocarbons from CO2-derived syngas; used only as an integrated e-fuels context signal (not separation unit consumption).

    0.43kg/kg
    Stoichiometric signal (indicative)

  • Indicative CO2 feed requirement for carbon in FT-like hydrocarbons; used only as an integrated e-fuels context signal.

    3.15kg/kg
    Stoichiometric signal (indicative)

  • Overall electricity-to-fuel (LHV) efficiency typical range for power-to-liquids; used to compute indicative upstream electricity requirement for integrated context.

    0.5ratio
    E-fuels signal