ZYME FLOW
Hardworking Chemistry: Addressing Excessive Coke in the Bottom of a Main Coker Fractionator to Reduce Mechanical Cleaning Time
Presenter: Steve Matza, Chief Scientist
Abstract:
CASE STUDY: A supermajor oil refiner located near Houston, TX contacted ZymeFlow Decon Technology to address excessive coke in the bottom of their Main Coker Fractionator.
The key objective was to decrease the amount of time to mechanically remove the coke from the bottom of their unit. The refinery was under great pressure to reduce the outage timeline so ZymeFlow Decon Technology engineered an innovative
solution to penetrate the coke and breakdown the asphaltene binders.
As the binders were removed the coke fluidized which lowered the amount of coke in the tower; reducing mechanical cleaning time by 5 ½ days.
This presentation examines an application of chemistry during the thinning flush to break down the asphalt binders in the Main Coker Fractionator. The procedures utilized by ZymeFlow Decon will be explained in detail as well as operational
risks and challenges faced when trialing the thinning flush application of chemistry.
The poster presentation will conclude by sharing the compelling mechanical cleaning timeline reduction.
The US refiner has implemented the ZymeFlow solution into their shutdown procedures and will be replicating it during their upcoming fall 2019 turnaround.
ALFA LAVAL
Unleash your Process Engineering Expertise
New tools for maximizing plant performance while minimizing CAPEX
Presenter: Eva Anderson, Refinery Industry Manager
Abstract:
Many refineries plan to make investments to modernize, optimize and maximize the efficiency of their refineries. However, when looking at the process designs provided for such investments, it is often seen that they leave a lot of room for
further improvement. Being based on traditional shell-and-tube exchanger technology, with its inherent limitations, lots of opportunities to reduce CAPEX and OPEX costs are being missed out on.
With high-efficient and compact plate heat exchangers, it is possible to optimize the process design further, thereby:
- Maximizing energy efficiency, reducing energy consumption in fired heaters and utility consumption in final coolers and maximizing steam generation from hot fractions
- Increasing high-value product yield through better separation in distillation columns or by increasing unit conversion rate
- Reducing investment cost in other process equipment such as distillation columns, fired heaters, reboilers, final coolers, pumps, compressors, vacuum systems and chillers
- Reducing cost for utility systems, such as steam, tempered water, cooling water, thermal oil
- Recovering waste energy into not only process heat or BFW preheating but for district heating, electricity generation, fresh water production and waste water evaporation
All of these solutions are technically proven with many references in the refineries world-wide.
In this poster session, the audience will be guided to let go of the old “rules of thumbs” in process design of what can be or can not be done, and instead unleash their process engineering expertise to “think outside the box” and come up
with ideas of what is actually achievable if conventional shell-and-tube exchangers would be exchanged for high-efficient compact plate heat exchangers. It is a very interactive session where we encourage the delegates to bring up examples from
their own experience and help each other to come up with good solutions to actual cases, based on the tools provided during the session.
DAILY THERMETRICS
“How do you know?” Proving reactor internals investment is paying off - Evaluating reactor performance based on temperature measurement improvements
Presenter: Austin Ward, Regional Technology Manager
Abstract:
These reactor internals will reduce maldistribution”, “We expect an increased run life with this catalyst”, “We want improved safety and less risk of hot spot conditions”. These are bold statements and require reliable data to prove. How do
you know that an investment in reactor internals and catalyst technology is worth the money? The only way: Reactor Thermocouples. Accurate, precise and dependable temperature measurement of catalytic hydroprocessing reactors is the main key to
understanding, validating, and proving reactor internals and catalyst performance. Current Licensor standards (or lack thereof) that consider partial temperature measurement only, are limiting the validity and/or disproving Licensor claims of
improved distribution and performance. Less-than-peak reactor performance (perceived or otherwise) is the result of deficient, incomplete, and unreliable temperature information.
Recent international Case Studies show the need for high performance temperature measurement inside and outside of the reactors, resulting in a complete understanding of the performance and safety of the reactor, in ways that are new to the
industry, yet long expected, by operators and managers. Daily Thermetrics’ Total Temperature Measurement approach provides operators and managers of hydro processing reactors vital information for process to understand internals and catalyst
performance. Flexible radial temperature technologies aim to protect investment and to enhance performance by notifying operators of undesirable process phenomena (such as hot-spots, maldistribution, and channeling) inside the catalyst bed, and
strategically placed temperature sensors on the outside of the reactor will assist in detecting overheating problems. However, these critical temperature sensors are usually overlooked and left to a third-party selection (EPC, Reactor
Fabricator, etc.) As stated, the only way to prove a reactor technology is working is to monitor the temperature distribution. Without strategic, specific, and well thought temperature measurement specifications, “How do you prove that
Licensors’ claims are real?”
This paper will provide technical guidelines and real-world considerations, as well as present an international Case Study.
HEATMATRIX
Corrosive flue gas is no longer a show-stopper for heat recovery
Presenter: Frank Tielens, CEO
- The issue of corrosive flue gas
- A solution for more heat recovery whilst increasing the reliability of the furnace operation
- Condensing sulphuric acid and lowering the acid dew point
- Case study on a CDU
NESTE ENGINEERING SOLUTIONS
Improved Fuels via Expanding the Production Formula
Presenter: Matti Koskinen Senior Technologist, Licensing
- Key requirements for new and future fuels
- Swing production concept
- Flexible renewable motor gasoline and jet production in one unit
Abstract:
After removing sulfur from common fossil-based fuels to 10 ppm level and tightening general specifications for other pollutants, e.g. benzene and polyaromatics and emissions in general, the following breakthrough in fuels automotive world
has been that of advanced renewable fuels, which are now gradually finding their ways to airline industry also. As the current trend clearly requires minimized pollutants via advanced properties of the fuels themselves and better fuel economy,
any new compound has to be improved compared to original in the key properties required.
Additionally, the market and hence the requirements set for production are changing, which means that production flexibility to serve the different market conditions and also new product areas comes ever more important Gasoline production
for effective formulation of optimal blending requires high-octane, non aromatic components which fit into any foreseeable emission requirements. A jet fuel component has to meet the prolific need for blending stocks, which do not require too
laborious testing program to be certified for aviation fuel use. Add to this the requirement of flexibility and the advantages of swing-mode processing of various gasoline and jet components in one unit makes a lot of sense. This can be
achieved via new improved NEXOCTANE/NEXETHERS process concept which has lately been further developed to include further oligomerization mode for jet markets. With isobutene coming from bio-origin source, all products are fully renewable.
Using experience gained in conjunction with the on-going multinational co-operation project "ReWoFuel" the renewable jet production from one of the most common building blocks in petrochemical industry, the isobutene molecule, can now be
used for various markets and fuel requirements. Case examples are included.
PALL
Speaker – Giovanni Baronne, Sales Manager
Assess Renewable Feedstock Contamination Challenges
Abstract:
The use of bio-feedstocks is having a growing interest for energy production, with conventional crude oil refineries considering to incorporate them into their process. The nature of the feedstock and its preparation pose legitimate questioning about processing challenges. One of them relates to particulate contamination, to anticipate potential equipment fouling issues. The assessment of the nature and the size of the particulates is important for the filtration strategy. Laboratory test means exist for refiners, for equipment selection and sizing, to maximize plant reliability while managing filtration lifecycle costs.
IGS
Increasing Capacity of CRUs, SMRs and Hydrogen Reformers - Case Study
Presenter: Cyril Narjoz, Director Business Development
- Cetek Ceramic Coatings for process tubes and refractory in fired heaters can help operator to save fuel on increase capacity of the unit
- CO2 and NOx emission cut
Abstract:
Refinery fired heater tubes are subject to oxidation and continuing scale growth. The scale can grow to significant thicknesses with time. Frequently it is enough to insulate the outer tube surfaces and inhibit conductive heat transfer to
the process fluid. Increasing the firing rate to overcome the insulating effect of the scale soon leads to limitations in flue gas temperature (bridgewall temperature).
The only recourse in this case is to reduce charge rate. Cetek services of the application of Ceramic Coatings for Process Tubes effectively stop oxidation and prevent scale growth. After the coating, there is no loss in radiant efficiency
and the heaters will operate as new for the life of the coating. Additionally, our services of the application of High Emissivity Ceramic Coatings for Refractory Surfaces provide an improvement in radiant heat transfer over design.
Our customers report fast Return on Investment and huge IRR. Reduction of NOx and CO2 emission is an additional benefit of Cetek ceramic coatings. We will provide a real life case study of Cetek coating application with benefit analysis.
NICKELHUETTE
Spent Catalyst and Residue Recycling
Presenter: Clemens Kuhnert, Head of Purchasing Department
Abstract:
Nickelhütte Aue GmbH is specialized in the recycling of waste materials containing non-ferrous metals. We treat Nickel, Copper, Cobalt, Vanadium, Molybdenum and precious metal containing materials like spent catalysts, ashes, dusts, grindings, liquids, slurries and sludge's as long as they contain one or a combination of the above mentioned metals. In our pyrometallurgical works we produce non-ferrous metal concentrates suitable for further treatment in our hydrometallurgical plant where we refine Ni-, Cu-, Co- and V-chemicals. Our production is based on synergy effects due to the combination of pyro- and hydrometallurgy. As an example we can mention our heat recovery system and internal recycling of by-products. Furthermore, the use of alternative fuels instead of fossil fuels contributes to the economic and environmentally friendly treatment system.
SARTEC
Catalytic management optimization and HDT Pilot Plant Testing
Presenter: Michela MEDDE, Pilot Plants, Oil Processes And Oil Laboratory Manager
- Research, development and technical service programs for catalysts application and processes optimization
- Hydrotreatment Pilot Plant Tests that meet customer needs
- Detailed feeds and products analytical characterization
Abstract:
Sartec has developed a consolidated experience in the management and performance of the catalytic units of the Saras Refinery and can offer research, development and technical service programs for catalysts application and processes
optimization. The activity is supported by a specific know-how in the Hydrotreatment Pilot Plant Tests especially for hydrodesulfurization of gasoil and hydrocracking of heavy vacuum gasoil. Tests are based on customer’s specific needs as the
evaluation of catalyst performance and feedstock quality impact and/or as the process optimization with the possibility to simulate a wide range of operating conditions, enhanced by a detailed feeds and products analytical characterization.
DORF KETAL
Reactive Adjunct Chemistry– A Chemical Breakthrough
Presenter: Puneet Sood, Sr. Manager - Business Development, Process Chemicals, Europe
- Improvement in desalter performance with improved salt and filterable solids removal
- Works in conjunction with demulsifier for better desalting and improvement in rag layer control
- The product is not acidic in nature and easier to handle
Abstract:
Desalting units are the key impurity removal systems within any refinery. Efficient removal of salts, solids, water, and metals helps to improve downstream operations, reduce inorganic fouling & overhead corrosion. Recently, due to
opportunity crude processing and increasing operation severity, the efficiency of many desalters using conventional chemical treatment has reduced. For such cases, Dorf Ketal has launched Reactive Adjunct technology that has demonstrated an
improvement in desalter performance in a number of refineries; more particularly improved salt and filterable solids removal can be demonstrated. This Reactive Adjunct works in conjunction with the emulsion breaker to allow for better
desalting, improvement in rag layer control and improve solids flow from the crude into the water.
It can also work to remove amines in the crude which often contribute to crude unit overhead under-deposit corrosion. A third key benefit is the product is not acidic in nature & hence easier to handle. Overall, with the use of the Reactive
Adjunct Chemistry, refiners can process opportunity crudes, run at higher throughputs and observe reductions in downstream fouling, corrosion & ETP issues.
CREALYST
Maximizing Process Unit Reactivity by Catalyst Loading Method
- How to increase reactor yields and run durations limiting hot spots and channelings?
- What real impact does catalyst packing have on unit performances?
- What is a good catalyst loading?
Abstract:
Fixed-bed reactors are the heart of units like hydrotreaters, hydrocrackers or reforming. Let’s consider three interactive drivers, which directly impact the unit yields : (1) catalyst - to ensure the function "catalysis", (2) internal
design - to ensure a good charge distribution at the interbeds and (3) catalyst packing – to keep the charge distribution through the catalyst bed. The investment in licensed processes (each specification as internal design, catalyst…) is
important and is a key point to achieve productivity goals, product specification, energy saving, i.e. revenues and benefits. The third aspect, the arrangement of catalyst particles, stays out of the main discussions and decisions, nevetheless
it can bring strong impact on the performance, up to 25%, either in positive or negative sense.
The main indicators and procedures for reaching a good catalyst loading will be explained. Because all the technologies for catalyst/adsorbents packing/loading are not equal ! Crealyst expertise is in any small particle dissemination in
vessels whose diameter is up to 25 m (oil and gaz or agriculture domains). Advanced skills, technologies and procedures were developed to preserve catalyst integrity during loading, to reduce turnarounds duration and to guarantee that the
catalyst bulk activity will be optimized.
SARTEC
Predictive Maintenance on Rotating Machines with Aspentech MTell
Presenter: Giovanni PATRINI, Predictive Maintenance on Rotating Machines with Aspentech Mtell
- Advanced digital technologies can help refiners better predict and diagnose anomalous equipment behaviour and failures
- Predictive maintenance on critical rotating machines allows refiners to minimize maintenance costs and downtimes as well as optimize resource utilization
- Early prediction of failures is achieved through Machine learning algorithms able to capture data patterns from process and equipment sensors
Abstract:
In order to address the increasing competitive pressures, process industries including Oil&Gas, are embracing digitalization to change and improve process plant, utilities and pipeline operations. Asset management is among the priority
action areas in which the new digital tools, which allow to profit from historic data and capture data patterns, promise to change the way in which the equipment is operated, assist operators in making more informed and effective decisions and
ultimately be of benefit in terms of cost reduction and operation performance.
A growing subset of such applications in refining involves advanced Predictive Maintenance (PM), whose main objectives are to: i) implement fault prediction algorithms based on sensor data collected from industrial equipment; ii) use
probability of fault predictions to define an optimal maintenance plan, which allows to minimize maintenance costs and downtimes as well as optimize resource utilization. Compared to traditional maintenance approaches, PM promises to be
extremely beneficial in improving asset reliability and availability reducing downtimes, decline of process performance and in product quality, which have a relevant negative impact on the Oil&Gas sector and on all the manufacturing industry
alike. Whereas many pilot on PM are currently been carried out, few have already been deployed and even fewer applied to a large scale.
In the present contribution we illustrate the case of the Sarroch Saras Refinery focusing on the journey from the proof of concept to deployment of a fully functional and integrated industrial solution using Aspentech Mtell on critical
rotating equipment. The case is especially relevant as rotating machines such as compressors, pumps and turbines are used throughout all verticals of the hydrocarbons industry: upstream, midstream, and downstream and are generally vital
components of plant operations whose unavailability, in some cases, may arrive to determine a plant shutdown and considerable production losses.
