Revamp of Slovnaft’s hydrocracking unit
A revamp to maximise middle distillate production and increase unit reliability
and safety
OLE FREJ ALKILDE Haldor Topsøe
FILIP STANCL Slovnaft
T
he KHK hydrocracking unit at
the Slovnaft refinery in
Slovakia has been revamped
in a joint effort by Haldor Topsøe
and Slovnaft. The unit is a full-
conversion hydrocracker, which has
been in operation since 1991. The
nameplate capacity is 104 t/h,
equivalent to 17 700 b/d. The
unit is processing straight-run
VGO from a Russian export crude
blend.
Topsøe and Slovnaft initiated a
revamp project with the primary
objective of maximising middle
distillate production. Additionally,
unit safety and reliability were to
be improved. This should all be
Feed
Figure 1 Slovnaft refinery’s KHK hydrocracking unit
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done without costly modifications
to major equipment items.
The revamp project was
conducted in three stages. The first
stage was a revamp study, where
the current performance of the unit
was analysed in detail and a range
of possible improvements were
identified. In the second stage, the
most desired improvements were
selected and the revamp design
package was executed. In the third
stage, the detailed design and actual
unit modifications were performed.
Unit description
The KHK hydrocracking unit at the
Slovnaft refinery in Bratislava,
Make-up
hydrogen
Slovakia, is a single-stage full-
conversion hydrocracker (see Figure
1). It has been in operation since
1991 and is licensed by Unocal and
designed by Snamprogetti.
The high-pressure loop is config-
ured in a cold separator layout with
a cold separator pressure of 13.3
MPag. The unit was designed with
three reactors, with three beds in the
first reactor, two beds in the second
reactor and three beds in the last
reactor. Heat is supplied by both a
recycle gas heater and a recycle oil
heater. The recycle oil from the frac-
tionation section is sent to the
second reactor inlet when the unit is
operating in recycle mode.
Naphtha
Kerosene
Diesel
UCO
REVAMPS 2012 27
 The fractionation section is config-
ured with a debutaniser first then a
fired heater reboiler. The debutan-
iser bottoms are sent to a main
fractionation column with kerosene
and diesel side strippers as well as
kerosene and diesel pumparounds.
The fractionator overhead is sent to
a naphtha splitter (not shown in
Figure 1) for the separation of light
and heavy naphtha.
The original design of the unit
allowed for three modes of opera-
tion: maximum diesel production,
maximum naphtha production and
once-through low conversion for
unconverted oil production (steam
cracker feed). Since diesel is fore-
seen to be the most desired product
in the unit in the future, the over-
riding requirement for the revamp
was to increase the diesel yield. The
maximum naphtha yield could be
reduced if required.
In the time leading to the revamp,
several maintenance and mechani-
cal problems became evident in the
unit. Some of the problems were
solved within the revamp project,
while others were solved as regular
maintenance items during normal
service.
The unit has experienced one
serious temperature runaway event.
In March 2006, following a feed
pump trip and subsequent restart
assisted by a human factor, the
catalyst bed temperatures ran away
and within minutes exceeded meas-
urable range at some catalyst bed
points. Fortunately, the reactor skin
temperatures did not reach critical
values. The revamp also needs to
address this serious operational risk
to ensure adequate automatic safety
procedures are in place to prevent
such an event occurring again.
Revamp study
A simulation of the unit was estab-
lished. This served as the basis for
the following studies. A total of
nine flow sheet cases were devel-
oped during the study, which
detailed the performance of the
unit.
Several areas of concern were
identified during the study. First,
the high-pressure loop operation
was not sufficiently stable. This was
most evident in recycle mode
28 REVAMPS 2012
operation, where the recycle gas
compressor was operating close to
the surge line and the compressor
instrumentation was not sufficient
to determine exactly how close to
the limit the compressor was
operating.
Another serious concern with
hydrocracking units is liquid mald-
istribution, which can lead to
stagnant liquid pockets, reactor
hotspots and ultimately tempera-
ture runaways. The existing
distributor trays, quench zones and
reactor temperature measurements
were not performing as well as
modern internals could.
The temperature response of the
reactor system was slow, too.
Temperature excursions in the reac-
tor systems were difficult to control,
and thermal feedback through
feed/effluent and inter-reactor
exchangers worsened the risk of
temperature excursions leading to a
temperature runaway.
Also, the high-pressure cold sepa-
rator was not large enough to allow
for efficient separation of water and
hydrocarbons. This caused water
slip-through to the debutaniser
column. The debutaniser was expe-
riencing several problems. The water
slip-through from the cold separator
caused bad operation and corrosion
in the top of the column. Continuous
methanol injection was required to
control the formation of hydrates in
the LPG line. The H2S removal in
the column was also insufficient,
resulting in too high a sulphur
content in the light naphtha.
The capacity of the wash water
pump was on the limit for protect-
ing the high-pressure piping from
corrosion due to NH2SH. The maxi-
mum rate of wash water was just
able to keep the concentration in
the sour water below 6 wt%, but
there was no excess capacity for, for
instance, treating heavier feed or
handling a higher throughput.
Likewise, the kerosene pumpa-
round piping and heat exchanger
layout was limiting the heat recov-
ery in the kerosene section. Also,
the formation of heavy polynuclear
aromatics (HPNA) in the high-
conversion recycle mode could limit
the maximum achievable overall
conversion.
Finally, the catalyst volume was
limiting the cycle length. The deac-
tivation rate of the pretreatment
catalyst was the main factor limit-
ing the cycle length of the unit and,
when the HDN activity of the
pretreatment system became too
low, the activity of the whole cata-
lyst system was too low and EOR
was reached.
The study considered two catalyst
cycle length cases: either keeping
the existing three-year cycle length
or reducing the cycle length to two
years while increasing the middle
distillate yields.
The option of co-processing some
LCO in the unit was also studied.
This would lead to higher hydrogen
consumption, higher exotherm in
the first reactor, lower diesel prod-
uct quality (density and cetane
value) and various other detrimen-
tal effects.
Recommended changes
Based on the detailed analysis
performed in the study, a compre-
hensive list of recommended
changes was made. The changes
were grouped into minimum
recommendations that were viewed
as critical, primary recommenda-
tions that were viewed as optimal,
and alternative recommendations
that were alternatives to the
proposed changes.
Minimum recommendations
The minimum recommendations for
required changes were that the two
last beds of the first reactor should
be combined. This increases the
pretreatment catalyst volume by
18%, which is the single most
important factor that limits the cycle
length of the unit. The expected
temperature rise in the new
combined bed will be acceptable if
the upstream quench system and
distributor tray is working well. All
distributor trays and quench zones
must be replaced, too. Most impor-
tantly, this increases the safety of
the unit, since maldistribution in the
hydrocracking catalyst can lead
to hotspots and temperature
runaways. Additionally, a better
distribution results in a better utili-
sation of the catalyst.
New reactor thermocouples are
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TK-931
Max. MD
TK-931
Max. MD
Figure 2 Catalyst loading scheme for two hydrocracking reactors
also required. Monitoring of the
catalytic bed temperatures is essen-
tial both for safety and good
operation of the unit. Temperature
excursions need to be captured by
the thermocouple system as quickly
as possible for a safe operation. For
operation, the reactor temperatures
are the primary control parameter
for setting the conversion in the
unit.
Debutaniser overhead modifica-
tion is a necessity, too. Water
condensation is causing both corro-
sion and control problems in the
debutaniser overhead. This water
has to be removed either by modi-
fying the overhead vessel or by
allowing for water draw-off in the
top of the debutaniser.
Meanwhile, the cold low-pressure
separator is not able to separate
water and oil phases. The separator
should be modified to allow for
adequate separation of phases.
Emergency temperature control is
required at the reactor inlet. In the
case of a temperature runaway in
the reactor system, the slow
response of the reactor charge
heater combined with the thermal
feedback of the feed effluent
exchangers makes it difficult to stop
a temperature runaway. An emer-
gency quench line must be installed
at the inlet of the pretreatment
30 REVAMPS 2012
TK-951
Flexible
TK-951
Flexible
TK-926
Isomerisation
reactor to allow for a rapid cooling
of the reactor system.
Finally, the configuration of the
kerosene pumparound should be
modified. The existing layout limits
the heat transfer and, by placing
two exchangers in parallel instead
of in series, a better heat recovery
will be possible in the unit.
Primary recommendations
The primary recommendations that
would give the best possible
performance of the unit after the
revamp were to install a hot separa-
tor in the unit. This would result in
several benefits: the HPNA build-
up in recycle mode would be
reduced, which allows the unit to
increase the total conversion and
thereby reduce UCO production.
The H2S leakage from the debutan-
iser would be minimised, which
reduces corrosion problems, and
the high-pressure loop pressure
drop would be reduced. The water
separation in the cold separators
would be improved. Installing a hot
separator in the unit is, however, a
significant change in the unit and
would require some modifications
of the high-pressure loop.
The unit is equipped with a
power recovery turbine on the cold
separator liquid stream. The turbine
was broken, but repairing this and
taking it into operation would save
power for the feed pumps.
The unit was only equipped with
wash water addition points for the
main process pipe. To allow for
flushing of individual air cooler
bays, additional wash water points
for intermittent use should be
installed at each bay to mitigate
potential salt formation.
Alternative recommendations
The primary recommendations
represent a significant investment
cost for Slovnaft. In case this invest-
ment could not be justified, some
alternative recommendations were
given as well. These were to install
two new wash water pumps to
increase the wash water rate and
washing efficiency. This would
reduce the corrosion problems in
the cold separator. The upper trays
and wall of the debutaniser tower
should also be inspected and, if
significant corrosion is evident, the
material should be upgraded to
appropriate stainless steel.
The numerous recommendations
presented in the revamp study were
evaluated by Slovnaft after discus-
sions with Topsøe. The result of
this evaluation is presented in the
revamp engineering section below.
Catalyst considerations
The optimal catalyst loading was
designed, based on the operational
targets of the unit. Catalyst selec-
tion is a critical parameter for the
success of a hydrocracking unit,
and the product properties and
yield structure can be optimised
based on the selected loading. The
following types of catalysts were
selected.
At the top of the first reactor, a
comprehensive catalyst grading
system was installed. The grading
catalysts are shape optimised and
have a filtering effect to capture
material brought in with the feed to
prevent pressure drop build-up.
The order of the catalysts provides
a gradual increase in activity, so
very reactive components in the
feed are gradually hydrogenated
and reaction products such as gum
or crusts are distributed down
through the guard bed, again to
prevent pressure drop build-up.
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80
65
Yields, wt% 60
40
40 40
27
20
0
Before After
revamp revamp
Naphthas
Figure 3 Product profiles before and after revamp
The grading system is also active
for removing any metals that are
present in the feed in order to
protect the downstream catalysts
from metal poisoning.
Below the grading system, a pret-
eatment catalyst with high HDN
activity was installed to convert the
organic nitrogen present in the feed
to NH3. The latest and most active
pretreatment catalyst was installed
in the unit to maximise the nitrogen
conversion, which provides the best
possible environment for the down-
stream cracking catalyst.
The two hydrocracking reactors
were loaded with a catalyst system
that optimised yields, product prop-
erties and unit flexibility (see Figure
2). It is possible to adjust the temper-
ature of the two hydrocracking
reactors in the unit independently,
so the relative activity of the cata-
lysts in the two reactors can be
adjusted by controlling the tempera-
ture difference between the reactors.
The first hydrocracking reactor
was loaded with TK-931, a highly
selective catalyst for middle distil-
lates. This catalyst provides the best
possible yields of jet and diesel at
the targeted activity.
The second hydrocracking reactor
was loaded with TK-951, which is a
flexible type of catalyst for the
balanced production of middle
distillates and lighter. By adjusting
the relative temperatures of the first
and second hydrocracking reactors,
the yield structure of the unit can
be adjusted to meet the desired
product slate.
32 REVAMPS 2012
60
50
45
40
30
25
5 5
Before After Before After
revamp revamp revamp revamp
Middle distillates Unconverted oil
Below TK-951, a layer of the
amorphous-type catalyst TK-926
was installed. This catalyst has a
high isomerisation activity and
gives excellent cold flow properties
of the diesel product.
Finally, a small layer of post-
treating hydrogenation catalyst was
installed to convert any mercaptans
that are formed by the hydrocrack-
ing catalysts. Mercaptans end up in
the naphtha fractions and result in
too high a sulphur content if they
are not controlled in the reactor
section.
Revamp basic engineering
Based on the revamp study and
detailed discussions between
Topsøe and Slovnaft, it was decided
to adopt the minimum recommen-
dations and the alternative
recommendations described above.
In addition, numerous minor
changes were implemented.
The revamp project had three
goals: to increase the middle distil-
late yield, to increase safety and to
increase the reliability of the unit.
The following changes were
included in the design to increase
the middle distillate yield:
• The volume available for the cata-
lyst was increased in the unit by
merging two beds in the first reac-
tor. This allowed more pretreatment
catalyst to be installed in the unit
• All reactor internals (inlet distrib-
utors, quench systems and
redistributors) were replaced to
ensure optimal utilisation of the
catalyst
• The debutaniser column was
modified by installing more trays
and by adding a water draw-off
tray to reduce the problem of water
carry-over from the high- and low-
pressure separators
• The high- and low-pressure sepa-
rators were modified to ensure a
better separation of water and oil.
Both vessels were equipped with
new internals
• The diesel and kerosene reflux
pumps were replaced with higher
capacity units. Two heat exchangers
were set in parallel instead of in
series to improve the heat recovery
• The wash water pumps were
replaced with new and higher
capacity units.
The following changes were
included in the design to increase
the overall safety:
• A new quench connection was
made to the inlet of the first
pretreatment reactor. This quench
is closed in normal operation, but
in the case of a temperature runa-
way it is possible to direct a large
amount of quench to the inlet of the
first reactor. This results in rapid
cooling of the whole reactor system,
which allows the unit to stop an
occurring temperature runaway.
The emergency quench is required
since the inherent temperature
response of the unit is slow
• New thermocouples were
installed in all the reactors to allow
for accurate and detailed monitor-
ing of the catalytic bed
temperatures. This gives more
precise control and better monitor-
ing of hotspot formation
• The improved distribution of gas
and liquid due to the new reactor
internals will also help prevent
hotspot formation
• All four fired heaters were
equipped with new burners with
flame detectors, a new fuel gas line
testing system and an automatic
block-and-bleed shut-off system for
the fuel gas lines.
The following changes were
included in the design to increase
reliability:
• A new common air preheat
exchanger for all four fired heaters
was installed
• A large number of control valves
(52 in total) were replaced
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 Product properties after revamp light naphtha yield. After two-and-
a-half years of operation, the sour
gas yield is less than 2 wt%. The
Product Property Typical range LPG yield was mostly just below 5
Light naphtha Total sulphur content, wtppm 0 1.5
Reid vapour pressure, kPa 74 79 wt%. The light naphtha yield was,
RON 77.5 80.2 for most of the cycle, in the range
Heavy naphtha Total sulphur content, wtppm 0.1 0.5 of 7-8 wt%. The lowest yields of
Aromatics content, wt% 5.6 7.6 these products were — due to the
Naphthenes, wt% 53.3 56
Kerosene Total sulphur content, wtppm 0.1 0.3 less severe conditions — lowest in
Freeze point, °C -65 the recycle mode. With heavy naph-
Smoke point, mm 23.5 25 tha, the range obtained was
Aromatics content, vol% 8 14 broader: from 22 wt% to more than
Diesel Total sulphur content, wtppm 0.1 0.5
Cetane index 68 74 30 wt%. The range, of course, was
Cloud point, °C -5 influenced by the naphtha cut point,
Unconverted oil Total sulphur content, wtppm 1 6 which varied from 160 to 180°C
(ASTM D86). Similarly, the kero-
Table 1 sene yield is very flexible, allowing
for both jet fuel and diesel fuel
• The make-up compressor lubrica- operation. Altogether, 140 000 man- production. The corresponding
tion system was updated hours were spent. The project cost yield varied from 23 wt% to 35
• The debutaniser overhead less than $20 million, while two wt%. With partial catalyst deactiva-
condenser motors were replaced years’ return on investment was tion (in once-through mode), the
• Numerous minor maintenance expected. kerosene yield increased further,
and mechanical problems were still with good quality. The gas oil
solved. Unit performance after revamp yield’s flexibility was lower: 23 wt%
The revamp’s target was to shift to 27 wt% in once-through and up
Revamp detailed engineering and product flexibility towards more to 29 wt% with the recycle mode.
implementation diesel. While in the past up to a 65 The latter is explained by less
The project time line covered (from wt% naphtha yield was desired, severe reaction conditions in the
basic engineering to unit commis- after the revamp Slovnaft expected recycle mode.
sioning) two years, starting in June to obtain a maximum 40 wt% to The unit kept a reasonable
2007 and ending in June 2009. keep certain flexibility, while the conversion flexibility. Up to 25 wt%
Based on Slovnaft’s experience, no diesel yield was to take the major of unconverted oil could be
language barrier and close location, part of production. There was still produced in once-through mode. A
CB&I (located in Brno, Czech the intent to have the possibility to higher yield was not possible as
Republic) was chosen as project produce some unconverted oil, there would be too little gases
contractor. used as lube oil base and/or FCC formed and the debutaniser opera-
In total, the unit was shut down feed. tion would suffer.
for 47 days (oil-out). Night shifts For the revamped unit, low gas The product properties achieved
were used partially. Some prepara- formation is typical. Few gases are are shown in Table 1. All items
tion works were done during formed and the same applies to the show values typical for hydrocrack-
ing products. Especially good were
the kerosene freeze point (typically
40 below -65°C) and the kerosene
Once-through smoke point (slightly descending
UCO recycle from values above 25 mm at the
30 28.7
start up to 23 mm after more than
27.5 30 months of operation). The gas oil
26.4
fraction cloud point desired value
20 of -5°C (winter quality) could be
achieved with distillation cuts of up
to 362°C. The latter represents a 5°C
10 improvement in distillation cut and
6.5 6.4
is attributable to increased isomeri-
2.8
1.7 sation on the specialised catalyst
0
bed (TK-926).
es

ne

O
ha

se
a
LP

C
th
as

se
ht

ie

U
ph
ap

D
g

ro
na

Recycle vs once-through mode

ur

Ke
tn
So

vy
gh

Just like the original design, the

ea
Li

revamp design considered the recy-

Figure 4 Product profiles in once-through and recycle modes cle mode of operation as that saves

34 REVAMPS 2012 www.eptq.com

the catalyst activity while minimis-
ing gas formation, plus maximum
middle distillates can be produced.
In August 2009, the FCC
pretreater unit was shut down due
to operational problems and some
FCC feedstock was needed urgently.
For this purpose, the once-through
low-conversion mode was used for
a period of two weeks (see Figure
4). Although this mode of operation
was not considered in the revamp
design, it worked fine. The unit was
able to produce up to 30 wt% of
unconverted oil and the actual unit
capacity was up to 145 m3/h of
fresh liquid feed.
Afterwards, the unit was oper-
ated in recycle mode for several
months. Later though, as the
economic recession hit Europe and
there was a need to reduce refining
costs, Slovnaft considered switching
to once-through operation at 95%
conversion.
Slovnaft recorded significant
savings on debutaniser reboiler and
recycle pump duty (the latter being
out of operation). Also, the once-
ON-LINE half page kette.indd 1
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through operation proved to be
efficient not just for the naphtha
mode (preferred during the reces-
sion; up to 42 wt% naphtha could
be produced), but also for the
middle distillate yields (the diesel
mode was used mainly since the
spring of 2010) were considerable:
up to 60 wt%. The catalyst deacti-
vation rate was still acceptable for a
three-year cycle.
Based on the above experience,
Slovnaft decided to use the once-
through mode for the rest of the
catalytic cycle.
Conclusions
The revamp project for the Slovnaft
KHK hydrocracking unit was initi-
ated with a study phase, where
numerous areas of concern were
identified and several recommenda-
tions were given to remedy the
issues. Based on the recommenda-
tions, the unit was revamped and
the revamp goals of increasing
middle distillate yields, improving
unit safety and increasing unit reli-
ability were all fulfilled.
The revamped unit was loaded
with an advanced catalyst system,
where a selection of different
hydrocracking catalyst types allows
the unit flexible operation with
excellent product properties.
The diesel fuel yield has been
increased by more than 10 wt%
(feed based) while its cold flow
properties improved. The kerosene
smoke point shows good values,
which is due to a low aromatics
content. The revamped unit has
reasonable middle distillate-
naphtha flexibility and advantageous
kerosene-gas oil flexibility. Within
the project, several safety items were
installed with the effect yet to show.
Identified old or faulty equipment
was replaced.
The unit was down for 47 days
for the revamp. The total cost of the
project was about $20 million.
Ole Frej Alkilde is Principal Process Engineer
with Haldor Topsøe, Lyngby, Denmark.
Filip Stancl is Hydrocracking Complex Deputy
Manager with Slovnaft, Bratislava, Slovakia.
05.06.2012 14:52:27
REVAMPS 2012 35