WORLDWIDE REFINERY PROCESSING REVIEW Monitoring Technology Development and Competition in One Single Source
First Quarter 2013 Sulfur Plant and Crude Distillation Plus
Latest Refining Technology Developments & Licensing
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WORLDWIDE REFINERY PROCESSING REVIEW Monitoring Technology Development and Competition in a Single Source
First Quarter 2013 Sulfur Plant and Crude Distillation Plus Latest Refining Technology Developments & Licensing
http://www.hydrocarbonpublishing.com
WORLDWIDE REFINERY PROCESSING REVIEW is published by Hydrocarbon Publishing Co. every quarter. Copyright 2007-2013. All rights reserved. No part of this publication may be reproduced, stored in a retrieval system or transmitted in any form or translated into any language or by any means—electronic, mechanical, photocopying, recording or otherwise—without prior written permission of Hydrocarbon Publishing Company. P.O. Box 661, Southeastern, PA 19399 (USA). Tel: (610) 408-0117, Fax: (610) 408-0118. E-mail: review@hydrocarbonpublishing.com
Abbreviations 1Q, 2Q, 3Q, 4Q... (the) first, second, third, and fourth quarters, respectively AAA.................... American Automobile Association (US) ANS .................... Alaskan North Slope crude API...................... American Petroleum Institute (US) ARA .................... Antwerp, Rotterdam, Amsterdam ASTM ................. American Society for Testing & Materials b or bbl................ barrel(s) B ......................... billion boe ...................... barrel(s) of oil equivalent CA....................... California CAA .................... Clean Air Act (US) CARB ................. California Air Resources Board cf ......................... cubic foot, cubic feet cfr........................ cost and freight cif ........................ cost, insurance, and freight Concawe ............. Conservation of Clean Air and Water Europe CIS ...................... Commonwealth of Independent States CNG.................... compressed natural gas cst........................ centistoke d .......................... day DOE .................... Department of Energy EEC .................... European Economic Community EIA .......................US Energy Information Administration EPA .................... US Environmental Protection Agency EPC(M) .............. engineering, procurement, and construction (management) EU15 ................... 15 original EU members EU25 ................... EU15 and the 10 new members admitted in May 2004 EUROPIA ........... European Petroleum Industry Association (Brussels) FCV .................... fuel cell vehicle fd ......................... free delivered FEED .................. front-end engineering design fob ....................... free on board gal ....................... gallon GTL .................... gas to liquid(s) h .......................... hour H1 or H2 ............. first or second half of the year ICE...................... Int'l Commodity Exchange (UK— formerly Int'l Petroleum Exchange) IEA ..................... Int'l Energy Agency (Paris-based)
IPAA ................... Independent Petr. Assoc. of America IPO...................... initial public offering j.v. ....................... joint venture LPG .................... liquefied petroleum gas K ......................... thousand kL........................ kiloliter lb ......................... pound(s) METI .................. Ministry of Economy, Trade and Industry (Japan) MM ..................... million MOU ................... memorandum of understanding mpg ..................... miles per gallon mt ........................ metric ton MW ..................... megawatt N.A. .................... not applicable or not available NAAQS .............. national ambient air quality standards NESCAUM ......... Northeast States for Coordinated Air Use Management NG ...................... natural gas NGL .................... natural gas liquid NPRA ................. National Petrochemical & Refiners Association (US) NWE ................... Northwest Europe NYMEX ............. New York Mercantile Exchange (US) OECD ................. Organization for Economic Cooperation & Development OPEC .................. Organization of the Petroleum Exporting Countries OSHA ................. Occupational, Safety and Health Administration (US) PC ....................... petrochemical(s) PM ...................... particulate matter RBOB ................. RFG before oxygenate blending RFG .................... reformulated gasoline RMT.....................refining, marketing, and transportation RVP .................... Reid vapor pressure SCAQMD ........... South Coast Air Quality Management District (California) VLCC ................. very large crude carrier WTI .................... West Texas Intermediate y .......................... year ¢ .......................... US cent(s) € .......................... EU euro(s) £ .......................... UK pound(s) $ .......................... US dollar(s) ¥ .......................... Japanese yen
Please note that other international currencies are abbreviated using International Standards Organization codes, which can be found at www.xe.com.
TABLE OF CONTENTS 1Q 2013 Review Sulfur Plant and Crude Distillation 1. Introduction ..................................................................................................................................... 1 2. Sulfur Plant ..................................................................................................................................... 5 2.1
2.2
MARKET/TECHNOLOGY TRENDS & OPPORTUNITIES ............................................................................................. 5 2.1.1 Introduction .............................................................................................................................................. 5 2.1.2 Market Conditions and Outlook................................................................................................................ 6 2.1.2.1 Fuel Specifications and Unit Emissions Considerations ............................................................ 6 2.1.2.1.1 Transportation Fuels .................................................................................................. 6 2.1.2.1.2 Bunker Fuels.............................................................................................................. 8 2.1.2.1.3 Refinery Units Emitting Sulfur.................................................................................. 9 2.1.2.2 Increasing Use of Opportunity Crudes ..................................................................................... 11 2.1.2.3 Sulfur Production, Demand, and Pricing .................................................................................. 13 2.1.2.3.1 Global Sulfur Production and Demand ................................................................... 13 2.1.2.3.2 Sulfur Prices ............................................................................................................ 15 2.1.2.3.3 New Outlets for Refinery Sulfur ............................................................................. 17 2.1.2.4 Sulfur Plant Capacity and Expansion ....................................................................................... 19 2.1.3 Technology Competition, Directions, and Future Prospects .................................................................. 20 2.1.3.1 Acid Gas Removal .................................................................................................................... 21 2.1.3.2 Acid Gas Enrichment ................................................................................................................ 22 2.1.3.3 Claus ......................................................................................................................................... 23 2.1.3.4 Tailgas Treating ........................................................................................................................ 25 2.1.3.5 Alternative Sulfur Production and Handling Methods ............................................................. 27 2.1.4 Conclusion .............................................................................................................................................. 28 STATE-OF-THE-ART TECHNOLOGY ..................................................................................................................... 29 2.2.1 Introduction ............................................................................................................................................ 29 2.2.2 Commercial Process Technology............................................................................................................ 30 2.2.2.1 Acid Gas Removal .................................................................................................................... 30 2.2.2.1.1 BASF ....................................................................................................................... 31 2.2.2.1.1.1 PuraTreat R ....................................................................................... 31 2.2.2.1.1.2 aMDEA............................................................................................. 31 2.2.2.1.2 Dow Gas Treating Products and Services ............................................................... 33 2.2.2.1.3 ExxonMobil ............................................................................................................. 34 2.2.2.1.4 Fluor ........................................................................................................................ 37 2.2.2.1.5 INEOS Oxide .......................................................................................................... 38 2.2.2.1.6 Lurgi ........................................................................................................................ 39 2.2.2.1.7 Shell Global Solutions ............................................................................................. 40 2.2.2.1.7.1 ADIP ................................................................................................. 40 2.2.2.1.7.2 Sulfinol ............................................................................................. 41 2.2.2.1.7.3 ADIP-X and Sulfinol-X .................................................................... 41 2.2.2.1.8 Uhde ........................................................................................................................ 42 2.2.2.1.8.1 Morphysorb ...................................................................................... 42 2.2.2.1.8.2 Genosorb........................................................................................... 43 2.2.2.1.9 UOP ......................................................................................................................... 44
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TABLE OF CONTENTS 2.2.2.2 Acid Gas Enrichment ................................................................................................................ 45 2.2.2.2.1 BASF ....................................................................................................................... 46 2.2.2.2.2 ExxonMobil ............................................................................................................. 47 2.2.2.2.3 Fluor ......................................................................................................................... 48 2.2.2.2.4 TKK ......................................................................................................................... 50 2.2.2.3 Claus ......................................................................................................................................... 51 2.2.2.3.1 Oxygen Enriched Claus ........................................................................................... 52 2.2.2.3.1.1 Air Liquide ........................................................................................ 52 2.2.2.3.1.2 CB&I ................................................................................................. 52 2.2.2.3.1.3 Duiker Combustion Engineers .......................................................... 53 2.2.2.3.1.4 Fluor .................................................................................................. 53 2.2.2.3.1.5 Goar, Allison & Associates ............................................................... 54 2.2.2.3.1.6 Linde/BOC Gases/WorleyParsons .................................................... 56 2.2.2.3.1.6.1 Simple Enrichment ..................................................... 57 2.2.2.3.1.6.2 SURE Single Combustion .......................................... 57 2.2.2.3.1.6.3 SURE Double Combustion ........................................ 58 2.2.2.3.1.7 Lurgi/Black & Veatch ....................................................................... 60 2.2.2.3.2 Sub-dew Point Claus ................................................................................................ 61 2.2.2.3.2.1 BP ...................................................................................................... 61 2.2.2.3.2.2 DEG-ITS ........................................................................................... 62 2.2.2.3.2.3 Jacobs Comprimo Sulfur Solutions ................................................... 64 2.2.2.3.2.4 Linde ................................................................................................. 64 2.2.2.3.2.5 Lurgi .................................................................................................. 65 2.2.2.3.2.6 WorleyParsons .................................................................................. 66 2.2.2.3.3 Direct Oxidation....................................................................................................... 68 2.2.2.3.3.1 Jacobs Comprimo Sulfur Solutions ................................................... 69 2.2.2.3.3.1.1 SUPERCLAUS .......................................................... 69 2.2.2.3.3.1.2 EUROCLAUS ............................................................ 71 2.2.2.3.3.2 Linde ................................................................................................. 72 2.2.2.3.3.3 Lurgi .................................................................................................. 73 2.2.2.3.3.4 UOP/WorleyParsons ......................................................................... 73 2.2.2.3.4 Other Claus Processes .............................................................................................. 74 2.2.2.3.4.1 Foster Wheeler .................................................................................. 74 2.2.2.3.4.2 Siirtec Nigi ........................................................................................ 75 2.2.2.3.4.2.1 Modified Claus Process .............................................. 75 2.2.2.3.4.2.2 Advanced Ammonia Claus Technology..................... 76 2.2.2.3.4.3 WorleyParsons .................................................................................. 77 2.2.2.3.4.3.1 Modified Claus Process .............................................. 77 2.2.2.3.4.3.2 Ammonia Destruction ................................................ 78 2.2.2.4 Tailgas Treatment...................................................................................................................... 79 2.2.2.4.1 BASF ....................................................................................................................... 79 2.2.2.4.2 CANSOLV Technologies ........................................................................................ 80 2.2.2.4.3 CB&I ........................................................................................................................ 81 2.2.2.4.4 DuPont Clean Technologies .................................................................................... 82 2.2.2.4.5 Fluor ......................................................................................................................... 84 2.2.2.4.6 Linde ........................................................................................................................ 85 2.2.2.4.7 Lurgi......................................................................................................................... 86 2.2.2.4.8 MECS....................................................................................................................... 86 2.2.2.4.8.1 DynaWave......................................................................................... 86 2.2.2.4.8.2 SUPERCLAUS/DynaWave .............................................................. 88 2.2.2.4.8.3 ClausMaster ...................................................................................... 90 2.2.2.4.9 Prosernat IFP Group Technologies .......................................................................... 90 2.2.2.4.9.1 CLAUSPOL ...................................................................................... 90
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TABLE OF CONTENTS 2.2.2.4.9.2 Sultimate ........................................................................................... 92 2.2.2.4.10 Shell Global Solutions ............................................................................................. 93 2.2.2.4.11 Siirtec Nigi............................................................................................................... 94 2.2.2.4.12 SWAPSOL .............................................................................................................. 96 2.2.2.4.13 Technip .................................................................................................................... 97 2.2.2.4.13.1 Reduction Absorption Recycle ......................................................... 97 2.2.2.4.13.2 Multipurpose Reduction Absorption Recycle................................... 98 2.2.2.4.14 TKK ......................................................................................................................... 99 2.2.2.4.15 UOP/WorleyParsons.............................................................................................. 100 2.2.2.4.15.1 Beavon Sulfur Removal .................................................................. 100 2.2.2.4.15.2 Catalytic Thermal Incineration ....................................................... 103 2.2.2.4.15.3 Ammonia Combustion .................................................................... 104 2.2.2.5 Alternative Sulfur Removal Processes ................................................................................... 105 2.2.2.5.1 Adding a Redox Process for Increased Sulfur Recovery ...................................... 105 2.2.2.5.1.1 Gas Technology Products (GTP) .................................................... 106 2.2.2.5.1.1.1 LO-CAT .................................................................... 106 2.2.2.5.1.1.2 LO-CAT II ................................................................ 107 2.2.2.5.1.1.3 MINI-CAT ................................................................ 109 2.2.2.5.1.2 Prosernat IFP Group Technologies/Le Gaz Integral....................... 109 2.2.2.5.1.3 Shell Global Solutions .................................................................... 109 2.2.2.5.2 Produce Sulfuric Acid ........................................................................................... 110 2.2.2.5.2.1 DuPont STRATCO ......................................................................... 110 2.2.2.5.2.2 Haldor Topsøe ................................................................................ 111 2.2.2.5.2.2.1 Wet Gas Sulfuric Acid (WSA) ................................. 111 2.2.2.5.2.2.2 SNOX ....................................................................... 114 2.2.2.5.3 Other Processes ..................................................................................................... 115 2.2.2.5.3.1 Black & Veatch .............................................................................. 115 2.2.2.5.3.2 CrystaTech ...................................................................................... 116 2.2.2.5.3.3 Paques BV/Shell Global Solutions ................................................. 118 2.2.2.5.3.4 Paques BV/Shell Global Solutions/UOP ........................................ 119 2.2.2.6 Sulfur Degasification .............................................................................................................. 121 2.2.2.6.1 Black & Veatch ..................................................................................................... 121 2.2.2.6.2 ExxonMobil ........................................................................................................... 122 2.2.2.6.3 Goar, Allison & Associates ................................................................................... 122 2.2.2.6.4 Lurgi ...................................................................................................................... 124 2.2.2.6.5 Shell Global Solutions ........................................................................................... 125 2.2.2.6.6 Siirtec Nigi............................................................................................................. 125 2.2.2.6.7 WorleyParsons....................................................................................................... 125 2.2.2.7 Sulfur Finishing Processes...................................................................................................... 126 2.2.2.7.1 Enersul ................................................................................................................... 126 2.2.2.7.1.1 GX .................................................................................................. 127 2.2.2.7.1.2 WetPrill........................................................................................... 128 2.2.2.7.2 Sandvik .................................................................................................................. 129 2.2.3 Commercial Catalysts ........................................................................................................................... 131 2.2.3.1 Axens ...................................................................................................................................... 131 2.2.3.1.1 Claus Catalysts ...................................................................................................... 131 2.2.3.1.2 Tailgas Treating Catalysts ..................................................................................... 132 2.2.3.2 BASF Catalysts....................................................................................................................... 134 2.2.3.3 Criterion Catalysts & Technologies ........................................................................................ 136 2.2.3.4 UOP ........................................................................................................................................ 137 2.2.4 Advanced Process Control and Simulation .......................................................................................... 137 2.2.4.1 Aspen Tech ............................................................................................................................. 137 2.2.4.2 Bryan Research and Engineering............................................................................................ 137
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2.4
2.2.4.3 Jacobs Comprimo Sulfur Solutions ......................................................................................... 138 2.2.4.4 Optimized Gas Treating .......................................................................................................... 138 2.2.4.5 Siirtec Nigi .............................................................................................................................. 139 2.2.4.6 Shell Global Solutions ............................................................................................................ 139 2.2.5 Summary of Commercially Available Sulfur Plant Technologies ......................................................... 140 2.2.6 Comparison of Commercial Sulfur Plant Catalysts .............................................................................. 150 PLANT OPERATIONS AND PRACTICES................................................................................................................. 151 2.3.1 Acid Gas Removal ................................................................................................................................. 151 2.3.1.1 Amine Solvent Replacement ................................................................................................... 151 2.3.1.2 Optimizing an Amine Unit ...................................................................................................... 153 2.3.1.3 Amine System Operating Issues ............................................................................................. 154 2.3.1.3.1 Wet Acid Gas Corrosion ........................................................................................ 154 2.3.1.3.2 Amine Solution Corrosion ..................................................................................... 154 2.3.1.3.3 Foaming ................................................................................................................. 157 2.3.1.3.4 Amine Losses ......................................................................................................... 158 2.3.1.3.5 Carbon Filters in Amine Systems .......................................................................... 159 2.3.1.3.6 Instability in Amine Regenerator ........................................................................... 159 2.3.1.4 Proper Heat Exchanger Design for Acid Gas Removal Units................................................. 161 2.3.1.5 Safe Acid Gas Handling .......................................................................................................... 162 2.3.1.6 Fuel Gas Sweetening in a Hydrocracker Fractionation Section .............................................. 163 2.3.2 Claus Process ........................................................................................................................................ 164 2.3.2.1 Increasing Sulfur Recovery Capacity...................................................................................... 164 2.3.2.2 The Effects of Extreme Turndowns ........................................................................................ 166 2.3.2.3 Benefits and Drawbacks of Oxygen Enrichment .................................................................... 167 2.3.2.4 Claus Unit Shutdowns ............................................................................................................. 168 2.3.2.5 Claus Catalyst Life and Reuse ................................................................................................ 169 2.3.2.6 Advanced Control Systems for Claus Plants........................................................................... 170 2.3.2.7 Analyzing Sulfur Content in Claus Tailgas............................................................................. 171 2.3.3 Tailgas Treating .................................................................................................................................... 172 2.3.3.1 Experience with Designing a TGTU ....................................................................................... 172 2.3.3.2 Proper TGT Catalyst Selection ............................................................................................... 175 2.3.3.3 Cold Bed Adsorption Units for Tailgas Treating .................................................................... 175 2.3.4 Improving Energy Efficiency of Sulfur Plants ....................................................................................... 177 2.3.5 Liquid Scavengers for H2S Removal...................................................................................................... 178 2.3.6 Sulfur Storage and Handling................................................................................................................. 179 2.3.6.1 Liquid Loading and Transport ................................................................................................ 179 2.3.6.2 Blocking .................................................................................................................................. 181 REFINING R&D ALERT! ..................................................................................................................................... 182 2.4.1 Introduction ........................................................................................................................................... 182 2.4.2 Acid Gas Removal ................................................................................................................................. 184 2.4.2.1 Multiple Absorbers and Absorption Zones ............................................................................. 184 2.4.2.2 Simultaneous Removal of CO2 and H2S ................................................................................. 185 2.4.2.3 Absorbent Materials ................................................................................................................ 185 2.4.2.3.1 Patents .................................................................................................................... 185 2.4.2.3.2 Research ................................................................................................................. 187 2.4.2.4 Amine Regeneration................................................................................................................ 187 2.4.2.5 Miscellaneous.......................................................................................................................... 188 2.4.3 Claus Technology .................................................................................................................................. 188 2.4.3.1 Process .................................................................................................................................... 188 2.4.3.1.1 Multiple Claus Reactors ......................................................................................... 188 2.4.3.1.2 Oxygen Enrichment ............................................................................................... 189 2.4.3.1.3 Miscellaneous Claus Process Improvements ......................................................... 189 2.4.3.1.3.1 Patents ............................................................................................. 189
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2.7
2.4.3.1.3.2 Research.......................................................................................... 190 2.4.3.2 Catalyst ................................................................................................................................... 191 2.4.3.3 Hardware ................................................................................................................................ 192 2.4.4 Tailgas Treating .................................................................................................................................... 193 2.4.4.1 Process .................................................................................................................................... 193 2.4.4.1.1 Increase in Sulfur Recovery Rate .......................................................................... 193 2.4.4.1.2 Energy Efficiency Improvements .......................................................................... 195 2.4.4.2 Catalyst ................................................................................................................................... 195 2.4.4.2.1 Titanium-based ...................................................................................................... 195 2.4.4.2.2 Metal Oxides ......................................................................................................... 196 WORLDWIDE INSTALLED CAPACITY.................................................................................................................. 196 CONSTRUCTION ................................................................................................................................................. 199 2.6.1 Recent Construction Activity ................................................................................................................. 199 2.6.2 Completed Construction Projects ......................................................................................................... 203 REFERENCES ..................................................................................................................................................... 235
3. CRUDE DISTILLATION ................................................................................................................... 249 3.1
3.2
3.3
MARKET/TECHNOLOGY TRENDS & OPPORTUNITIES ......................................................................................... 249 3.1.1 Introduction .......................................................................................................................................... 249 3.1.2 Market Conditions and Outlook............................................................................................................ 249 3.1.2.1 Crude Oil ................................................................................................................................ 249 3.1.2.2 Supply and Demand: Diesel vs. Gasoline ............................................................................... 250 3.1.2.1 Shifting Crude Slate................................................................................................................ 251 3.1.2.1.1 Opportunity Crudes ............................................................................................... 251 3.1.2.1.2 Shale Oil ................................................................................................................ 254 3.1.2.2 Crude Distillation Capacity and Throughput .......................................................................... 255 3.1.2.3 Refinery Expansion ................................................................................................................ 255 3.1.3 Technology Competition, Directions, and Future Prospects ................................................................ 256 3.1.3.1 Feed Flexibility ....................................................................................................................... 256 3.1.3.2 Product Selective Operations .................................................................................................. 257 3.1.3.3 Fouling and Corrosion ............................................................................................................ 258 3.1.3.4 Energy Efficiency ................................................................................................................... 258 3.1.3.5 Internals and Hardware ........................................................................................................... 259 3.1.3.6 Research and Development .................................................................................................... 260 3.1.4 Conclusion ............................................................................................................................................ 263 STATE-OF-THE-ART TECHNOLOGY ................................................................................................................... 263 3.2.1 Introduction .......................................................................................................................................... 263 3.2.2 Commercial Processes .......................................................................................................................... 264 3.2.2.1 Foster Wheeler ........................................................................................................................ 265 3.2.2.2 KBR ........................................................................................................................................ 266 3.2.2.3 Shell Global Solutions ............................................................................................................ 268 3.2.2.4 Total/Technip.......................................................................................................................... 271 3.2.2.5 Uhde ....................................................................................................................................... 272 3.2.3 Summary of Commercial Crude Distillation Processes........................................................................ 273 3.2.4 Comparison of Commercially Available Advanced Control and Optimization Systems ...................... 274 3.2.5 Process Models, Simulators, Analyzers, and Other Technologies........................................................ 277 PLANT OPERATIONS AND PRACTICES ................................................................................................................ 282 3.3.1 Feed Considerations ............................................................................................................................. 282 3.3.1.1 Shale Oil ................................................................................................................................. 284 3.3.1.2 Canadian and Opportunity Crudes.......................................................................................... 284 3.3.1.3 High Naphthenic Acid Crudes ................................................................................................ 287
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3.3.2 Crude Tower .......................................................................................................................................... 289 3.3.2.1 Design Optimization ............................................................................................................... 289 3.3.2.2 Optimization Through Monitoring .......................................................................................... 290 3.3.2.3 Trays ....................................................................................................................................... 291 3.3.2.4 Overpressure Mitigation ......................................................................................................... 293 3.3.3 Vacuum Tower....................................................................................................................................... 294 3.3.3.1 Design ..................................................................................................................................... 295 3.3.3.2 Operation................................................................................................................................. 295 3.3.3.3 Internals................................................................................................................................... 296 3.3.3.4 Troubleshooting the Vacuum Tower and Related Systems .................................................... 297 3.3.3.4.1 Vacuum Overhead Ejector System ........................................................................ 297 3.3.3.4.2 Emissions from the Overhead ................................................................................ 300 3.3.3.4.3 Equipment Damage ................................................................................................ 300 3.3.3.4.4 Flash Zone Quenching ........................................................................................... 301 3.3.3.4.5 Flash Zone Coking ................................................................................................. 301 3.3.3.4.6 Vacuum Tower Wash Zone ................................................................................... 301 3.3.3.4.7 Inaccurate Tower Pressure Measurement .............................................................. 304 3.3.3.4.8 Methods of Determining Vacuum Bottoms Cut Point ........................................... 304 3.3.4 Heat Exchanger Network ...................................................................................................................... 305 3.3.4.1 Improving Energy Efficiency .................................................................................................. 305 3.3.4.1.1 Optimizing Heat Integration .................................................................................. 305 3.3.4.1.2 Increase in Pumparound Ratios.............................................................................. 307 3.3.4.1.3 Hydraulic Problems in the Preheat Train ............................................................... 308 3.3.4.2 Methods to Prevent or Reduce Fouling and Corrosion ........................................................... 308 3.3.4.2.1 Process Design and Revamp .................................................................................. 310 3.3.4.2.2 Operational Adjustments ....................................................................................... 311 3.3.4.2.3 New Technologies ................................................................................................. 311 3.3.4.2.3.1 Tube Inserts ..................................................................................... 311 3.3.4.2.3.2 Chemical Additives ......................................................................... 313 3.3.4.2.3.3 Novel Exchangers ........................................................................... 313 3.3.4.2.3.4 Monitoring and Treatment .............................................................. 314 3.3.5 Maximizing Yield of Specific Product Cuts ........................................................................................... 315 3.3.5.1 Catalytic Reformer Feed ......................................................................................................... 315 3.3.5.2 Diesel ...................................................................................................................................... 316 3.3.5.3 VGO ........................................................................................................................................ 322 3.3.6 General Crude Unit Operational Problems .......................................................................................... 323 3.3.6.1 Preflash Drum Foaming .......................................................................................................... 323 3.3.6.2 Corrosion................................................................................................................................. 325 3.3.6.3 Detecting Improper Operations in Distillation Towers ........................................................... 329 3.3.6.4 Packing Fires in Distillation Columns .................................................................................... 329 3.3.6.5 Tray Failure Brought on by Harmonic Vibrations .................................................................. 331 3.3.7 Alternative Approach to Crude Distillation .......................................................................................... 332 REFINING R&D ALERT! ..................................................................................................................................... 333 3.4.1 Introduction ........................................................................................................................................... 333 3.4.2 Energy Savings ...................................................................................................................................... 336 3.4.2.1 Patents ..................................................................................................................................... 336 3.4.2.2 Research .................................................................................................................................. 339 3.4.3 Safety & Environment ........................................................................................................................... 340 3.4.4 Increasing Yield..................................................................................................................................... 341 3.4.5 Treatment .............................................................................................................................................. 344 3.4.5.1 Patents ..................................................................................................................................... 344 3.4.5.2 Research .................................................................................................................................. 347
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3.7
4.
3.4.6 APC & Measurement Devices............................................................................................................... 347 3.4.7 Operational Performance ..................................................................................................................... 349 3.4.8 Other ..................................................................................................................................................... 351 3.4.9 CO2 Emissions ...................................................................................................................................... 352 3.4.10 Simulation ............................................................................................................................................. 353 3.4.10.1 Energy..................................................................................................................................... 353 3.4.10.2 Economics .............................................................................................................................. 354 3.4.10.3 Optimization ........................................................................................................................... 354 3.4.10.4 Quality Control ....................................................................................................................... 355 WORLDWIDE INSTALLED CAPACITY.................................................................................................................. 356 CONSTRUCTION ................................................................................................................................................. 357 3.6.1 Recent Construction Activity ................................................................................................................. 357 3.6.2 Completed Construction Projects ......................................................................................................... 363 REFERENCES ..................................................................................................................................................... 374
LATEST REFINING TECHNOLOGY DEVELOPMENTS & LICENSING ............................................ 383 4.1 4.2 4.3 4.4 4.5 4.6 4.7 4.8 4.9 4.10 4.11 4.12 4.13 4.14 4.15
FLUID CATALYTIC CRACKING ........................................................................................................................... 383 HYDROTREATING (INCLUDING HDS) ................................................................................................................ 383 HYDROCRACKING ............................................................................................................................................. 384 ISOMERIZATION ................................................................................................................................................. 384 COKING ............................................................................................................................................................. 384 HEAVY OIL, EXTRA-HEAVY OIL, AND BITUMEN UPGRADING ........................................................................... 384 COGENERATION AND INTEGRATED GASIFICATION COMBINED CYCLE .............................................................. 385 LUBE PRODUCTION ........................................................................................................................................... 386 AROMATICS AND LIGHT OLEFINS PRODUCTION ................................................................................................ 386 PROCESS CONTROLS AND SIMULATION ............................................................................................................. 387 XTL .................................................................................................................................................................. 388 BIOFUELS AND ALTERNATIVE FUELS PRODUCTION ........................................................................................... 389 CO2 EMISSIONS (CARBON CAPTURE AND SEQUESTRATION) ............................................................................. 392 SITE EMISSIONS ................................................................................................................................................. 395 REFERENCES ..................................................................................................................................................... 396
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