VALORIZATION OF WASTE COOKING OIL INTO SUSTAINABLE AVIATION FUEL AND RENEWABLE DIESEL

Abstract

The proposed hydroprocessing plant is designed to convert waste cooking oil (WCO) into Renewable Diesel (RD) and Sustainable Aviation Fuel (SAF) using hydroprocessing technology. This initiative supports global decarbonization efforts by providing sustainable fuel alternatives to reduce greenhouse gas emissions in the transportation and aviation sectors. Malaysia generates approximately 540,000 tonnes of WCO annually, presenting a valuable feedstock for renewable fuel production. Through a Multiple Criteria Decision Analysis, hydroprocessing was selected as the optimal route due to its technical maturity, ASTM certification, and superior economic and environmental performance. The plant, located in Pulau Indah, Selangor, processes 34,090.91 kg/h of WCO and 1,384 kg/h of hydrogen to produce 13,356.22 kg/h of SAF and 9,296.33 kg/h of RD that meet ASTM D7566 and ASTM D975 standards, respectively. Aspen HYSYS simulations confirmed product compliance and process efficiency, supported by a heat integration network recovering 12,661.37 kW of energy and reducing cold utility demand by 37.21%. Safety and environmental management are ensured through HAZOP studies, the application of Risk-Based Process Safety (RBPS) principles, and comprehensive waste treatment systems, including CO₂ capture with 94.85% removal efficiency. Economic evaluation indicates strong feasibility, with an estimated CAPEX of RM 2.66 billion, OPEX of RM 1.75 billion, and annual revenue of RM 2.11 billion. The project achieves a 15.01% ROI, 16.07% DCFROR, and a payback period of seven years, confirming its technical robustness, economic viability, and contribution toward Malaysia’s sustainable energy transition.