The SEAFARER project focused on maturing and qualifying the L-BFO production process for market entry. Core work included TRL6 reactor optimisation—structural adaptation for final throughput, improved pumping, and heating/insulation to 400 °C—and separation optimisation for solids retention, solvent recovery/recycling, and by-product removal. Process assembly and automation integrated the upscaled reactor with feeder and separation units, achieving full automated operation via a control unit, valves, sensors, and automatic feedstock intake enabling continuous solvent recycle.
Pilot-scale commissioning followed, with joint safety validation (pressure/leak tests) and full HAZOP and ATEX assessments with Crossbridge Energy. Steady-state operation then verified the TRL7 system using wood feedstock; a ~250-hour continuous run monitored key parameters (temperature, pressure, residence time) to optimise yield, quality, and operational stability.
Fuel testing covered L-BFO properties (viscosity, heating value) and preliminary emissions (CO2, NOx, SOx), all compliant with regulations; full engine tests at DTI are scheduled for Q1 2026. The methanol-extracted fraction was also validated for methanol-powered vessels, confirming ignition quality, combustion stability, and emissions compliance without hydrotreatment or FCC.
In parallel, non-technical activities supported commercialization: monitoring standards and regulations for permitting, conducting environmental and economic assessments (LCA using Aspen Plus and economic viability analysis), and updating the commercial-scale design and CAPEX formulas to establish a reliable cost basis and revised profit projections.
