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Fired heaters are one of the most critical pieces of equipment in a refinery. They are capital intensive and occupy significant plot space, so due consideration must be given to [...]

Selecting mechanical seals for hot services in an oil refinery or petrochemical plant is always a challenging task--and it is a task that needs careful attention, since the wrong seal [...]

Hydrocrackers are key refinery units that convert heavy feed components into valuable lighter products. The profitability of these units is directly related to this conversion level. Conversion reactions take place [...] more...

Ball valves (FIG. 1) are often an economical solution for controlling flows in refinery high-temperature applications, but their application can be complex, particularly in high-temperature uses. For the purposes of [...] more...

Thermal imaging technology has evolved over the years, and investment costs have decreased significantly. Early deployment of thermal imaging technology in industrial applications was primarily geared towards electrical inspections. In [...] more...

Revamping an existing column in an operating plant for higher throughput is a challenge, especially when the column is already operating at its rated capacity. This is particularly true for [...]

Additive manufacturing (AM), also known as 3D metallic printing, is identified as one of the game-changing technologies in recent years for the oil and gas industry. Although the nonmetallic AM [...] more...

After carbon steel, stainless steel remains the most commonly used material in the petrochemicals and oil and gas industries. Its long range of chemical resistance against corrosion has made it [...] more...

Oil refineries' use of specialty gases to correct product quality and meet emission regulations is discussed. Specialty gases also contribute to the optimum economy of a refinery. They are also used in gas chromatography. more...

The design guidelines are provided for distillation towers with the help of case studies from various refineries. The examples of butadiene polymer fouling are also discussed.

The methods to design and develop servicable fouling columns for fouling services in refinaries and petrochemical plants are discussed.

The design considerations of the 1million tonnes per year and larger, mega ethane crackers projects is discussed. It is argued that due to the ever-increasing world demand for polymers and other olefin-based derivatives, the capacity and throughput of steam crackers are continuously growing. more...

The article covers research about hydrotreaters.

When it comes to measuring the level of bulk solids, liquids, and everything in between, guided-wave radar technology now offers better level-detection capabilities than other systems. And with the need [...] more...

At yearend 1998, Koa Oil Co. (now part of Nippon Oil Corp.) embarked on a comprehensive advanced control implementation at its refineries in Marifu and Osaka. The advanced control implementation [...] more...

Use pass flowrates and outlet temperatures to identify inefficient performance Fired heater performance is affected by heat-flux imbalances in the individual heater passes. These imbalances impact the rate of coke [...] more...

Petroleum refiners adjust operations to remove butane and meet the required vapor pressure specifications of gasoline. A simulation study looked for methods of lowering vapor pressure with minimum changes in equipment. In one refinery, light straight run fractionation used a stabilizer that removed butane and lighter compounds from the blendstock. Also illustrated are the effects of preheating and debottlenecking., Reductions in gasoline vapor pressure specifications have created operational challenges for many refiners. Removal of butanes from gasoline blendstocks has become more critical to meeting product vapor pressure requirements. Some [...] more...

Thermatrix Inc. has developed a flameless thermal oxidation system that uses heated ceramic pieces to eliminate organic air pollutants. The ceramic's heat-retention properties allow the system to process various waste streams with minimal energy. A refinery in Northern California estimated that it could install 50 Thermatrix reactors for $1.35 million to reduce pollutants, compared to more than $2 million to install 400 sealless pumps., A California refinery is using a flameless thermal oxidation technology to destroy and remove organic air pollutants. The technology has achieved destruction and removal efficiencies (DREs) greater than 99.99%. The [...] more...

Examples demonstrate how to specify these specialized exchanger elements Finned tube bundles are widely used in heat exchangers, air coolers, waste heat boilers and fired heaters where energy transfer occurs [...] more...

Better testing methods enable manufacturers to provide products that last longer and meet emissions requirements With the release of the Clean Air Act, anyone using hazardous chemicals must perform leak [...] more...

Benefits include increased plant capacity due to improved reactor temperature control, smoother plant operations and reduced utilities consumption Constraint and multivariable predictive (MPC) controllers were implemented on an FCC preheater [...] more...

The occurrence of coking in petroleum refining fractionators can be prevented by properly designing the refining equipment. Coking occurring in crude vacuum columns is often caused by the use of improperly design packing. Potential design flaws in other petroleum refining equipment, including delayed coker main fractionators and hydrocracker vacuum columns are also discussed., Coking in petroleum refinery main fractionators causes unit shut-downs and significant production losses. High temperatures and long residence times are the causes of coking in these units--which include crude vacuum [...] more...

Thermal integration analysis can be used to revamp a fluid catalytic cracking unit (FCCU) to achieve optimum performance. Such a technique can be used when revamping an FCCU based on an old design. The revamping for less modern units could include adding features such as new risers, air distributors and feed nozzles. The analysis allows the FCCU to be configured to meet the heat requirements generated., The 25,000 b/d fluid catalytic cracking unit (FCCU) at Petroleos Mexicanos' idle Azcapotzalco refinery near Mexico City has been relocated to Pemex's 235,000 b/d Cadereyta refinery. The results of a [...] more...

Prosorb, a new sorbent catalyst, enables petroleum chemical producers and refineries to remove from the propylene stream contaminants that poison high-yield polymerization catalysts. Produced by Engelhard Corp, Prosorb was tested by Fina SA to polish its propylene feedstocks. The company built a new plant at the site of its La Porte, TX, refinery to utilize this purification system., Propylene streams from the refinery fluid catalytic cracking unit and delayed coker contain contaminants that are poisons to polymerization catalysts. A new sorbent catalyst, called Prosorb, allows petrochemical producers to [...] more...

Ashland Petroleum Co's use of a near-infrared (NIR) gasoline analysis system has helped the company increase its return on investment. The NIR system produced by Fluid Data Inc. is an on-line process analyzer that gives the processor greater accuracy when blending. NIR system analyzers develop a comparison between a chemical or physical property and a sample's NIR spectrum instead of directly measuring a chemical or physical property as other analyzers., Careful design of a near-infrared (NIR) analysis system can optimize reformulated gasoline blending. The lessons learned by Ashland Petroleum Co., and the companies that designed its NIR systems, will help [...] more...

Design flaws in distillation equipment can be isolated and solutions evaluated with simple analysis. A case history is presented to illustrate the steps involved in analyzing such flaws. These steps include defining the objective of the process, evaluating the system's current operation, checking the equipment to locate potential problem areas and determining and implementing changes to the process and equipment., Simple analysis methods and field data are the key to pinpointing causes of and solutions to distillation equipment operating problems. The first step in troubleshooting common field problems is to [...] more...

The proper design of gas flare systems for gas processing plants and petroleum refineries is discussed. Design aspects covered include liquid knockout drums, liquid seal drums, ground flares, ignition systems and vapor recovery systems. Minimization of flare noise due to combustion, venting and steam injection is also discussed., Gas flare systems include many features that enhance safety and reduce atmospheric emissions. This concluding article in a two-part series on gas flares looks at the proper use of liquid [...] more...

Catalyst manufacturers introduced more than 120 new petroleum refining catalysts in 1992. Over half of the new products are for fluid catalytic cracking, hydrotreating/hydrogenation/saturation or steam hydrocarbon reforming. One major change in the catalysts industry was the acquisition of Katalistiks International Inc by UOP. A table detailing the characteristics and applications of the petroleum refining catalysts introduced during 1992 is also presented., Catalyst manufacturers and vendors worldwide report more than 120 new catalysts introduced r over the past year (Table). This is almost twice the some 65 catalysts added last year, and [...] more...

Basic frontline, advanced regulatory, constraint and inferential controls must work well before additional sophistication is attempted. A control technology audit of five refineries highlights mistakes made On-line process optimization is [...] more...

ARCO Products Co designed an automated compressor-packing system that will meet California's tough South Coast Air Quality Management District Rule 1173. The rule took effect Feb 1, 1991, and calls for a reduction in gas leaks from valves and machinery to 1,000 pounds per minute (ppm) from a previous allowable level of 10,000 ppm. A complete summary of how the automated compressor-packing system was designed is included., In 1991, Southern California fell under the most stringent fugitive emission regulation in the nation: South Coast Air Quality Management District (Scaqmd) Rule 1173. Under the new rule, 27 reciprocating [...] more...

The benefits of an oxygen enrichment system in the fluidic catalytic cracking process were clearly demonstrated by a Compania Espanola de Petroleos SA (Cepsa) refinery in San Roque, Spain. Cepsa tests of the equipment indicated that the oxygen enrichment increased the ability of catalytic units to adapt to changes in feedstock. The process also made it possible to increase throughputs while maintaining conversion levels., At the Gibraltar refinery in San Roque, Spain, compania Espanola de Petroleos S.A. (Cepsa) finds it easier to cope with continuously changing feedstocks by using oxygen enrichment of fluid catalytic [...] more...

Four systems required for company operation can provide better information about the plant and timely feedback for management Four systems used to optimize a company have a relationship with real-time [...] more...

Here's how one refiner justified, specified and installed a decision system to improve productivity and quality Fina's Port Arthur refinery plantwide refinery information management system (RIMS) project was initiated to [...] more...

The Journal's latest survey of worldwide refining catalysts reveals that there are more than 1,040 unique catalyst designations in commercial use in 19 processing categories-an increase @f some 140 since [...] more...

A patented packaged system is now available for safely and automatically draining water from product storage tanks. it can operate on a single storage tank or, with a manifolding system, [...]

Advanced ion chromatograph detects low MEA levels Texaco Refining & Marketing Inc. is using an advanced method of ion chromatography at its Puget Sound refinery in Anacortes, Wash., to detect [...] more...

An often-overlooked function of insulation in piping designs is to mitigate weather effects Thermal insulation is mainly used to reduce heat loss and noise level. It is also used to [...]

Byline: Deters, B. Wolkart, R. The case history discusses conditions occurring in delayed coker operations at two refineries in Louisiana, the impacts on valve performance, and a solution that offers [...] more...

The PER + Shell Refinery (Shell Pernis) counts on gasification technology to reduce emissions and properly handle process waste. The refinery recently installed an integrated gasification combined cycle (IGCC) unit, which was designed to generate steam and electricity, as well as co-produce hydrogen. The IGCC unit is an integral part of the refinery's facilities upgrade project, which has a total cost of $2 billion. An important component of the Pernis project is the gas turbine fuel gas control system which was designed to burn syngas., A project which uses gasification technology is scheduled to start-up shortly in Rotterdam. The PER+ Shell Refinery has installed an integrated gasification combined cycle unit to generate electricity and steam, [...] more...

The need for specialty fluid catalytic cracking (FCC) additives is likely to increase, given the increasing complexity of the refining environment and the arrival of reformulated gasoline prompted by the [...] more...