September 2017

www.uop.com
 CONTENTS
September 2017 Volume 22 Number 09 ISSN 1468-9340
03 Comment
05 World news
12 The UK in focus
Nunzia Florio, UKPIA, UK, discusses the downstream oil sector in
the UK, and the challenges it is set to face following the nation’s
decision to leave the EU.
118 A digital ecosystem
Marcio Donnangelo, Emerson Automation Solutions, USA, discusses
how installing wireless transmitters can help refineries to improve
operations and reduce the number of unscheduled outages, while
being safer and more energy efficient.
125 Tracking trends
Michael Sanches, Airswift, USA, presents an objective perspective
on petrochemical hiring trends in the downstream sector.
129 The recruitment round-up
Andrew Duffy, Petroplan, USA, analyses the ongoing trends for
recruitment in the downstream oil and gas industry, particularly
following the rise of LNG projects.
131 Right here, right now
David Wright, Bilfinger, UK, discusses the art of resourcing plant
turnarounds and finding the right people, in the right place, at the
right time.
133 Training to be the best
Jennifer Gaines, Sulzer, USA, explains why it is essential that every
business has a skills training programme in place to ensure that
the next generation retains the skills and expertise of experienced
workers.
138 Defend against silicon poisoning
Peter Piotrowski, Honeywell UOP, USA, and Austin Schneider,
Crystaphase, USA, provide a case study in how refineries can
proactively protect against unexpected silicon poisoning.
143 A refreshing boost
Gene Mueller, Dr Michael Severance, and Dr Axel Düker,
Clariant Catalysts, examine how a new generation of phosporic acid
catalysts can lead to more profitable and sustainable fuel upgrading
in FCC refineries.
149 Achieve high, aim low
Andy Huang, Gary Cheng, Ann Benoit, and Bob Riley, W. R. Grace &
Co., USA, explain how refiners can meet the need for higher octane
gasoline while ensuring sulfur content remains within regulations.
155 Afterburn relief
Ron Butterfield, Tom Ventham, Paul Diddams and Martin Evans,
Johnson Matthey, explore how to prevent FCC afterburn in the
downstream industry.
161 Optimum design of fuels blend header
Dr Suresh S. Agrawal and Meena S. Agrawal, Offsite Management
Systems LLC, USA, discuss the design of a fuels blend header for an
in-line blending system.
167 Rising from the ashes
Thomas R. Kline, Structural Technologies, USA, explores how a
solution-oriented response and effective decision-making can
restore a refinery safely after a fire incident.
173 Keeping a watchful eye
Scott W. Sexton, Haldor Topsoe Inc., USA, discusses how monitoring
furnace fireboxes, burners and tube temperatures improves
operations, safety, reliability, efficiency and life cycle.
178 Take advantage
Chris Wajciechowski, Alfa Laval, USA, explains how the introduction
of welded plate heat exchangers has optimised naphtha
hydrotreater efficiency at a major refinery on the US Gulf Coast.
183 Heating up
Ilan Toledano, Wattco, USA, advises on how to pick the right
thermal fluid heating equipment and provides an overview of the
use of circulation heaters in the petrochemical industry.
187 Focus on right temperatures
Harpal Singh, Bartec Singapore, explains why heat tracing systems
are a crucial element of petrochemical production, with reference
to a recent project carried out for PTT Phenol in Thailand.
190 Tanks of steel
Quinten Eyckmans and Daria Astakhova, Madesta, Switzerland,
outline the important role that steel plays in the construction of
storage tanks.
195 Casting call
Uwe Kellner and Hans-Jürgen Steinhart, Zollern GmbH & Co. KG,
Germany, introduces high performance metals and alloys for use in
the downstream oil and gas industry.
101 New media
Gregory Hallahan and Caleb Smathers, ProSep, USA, and Jeff Myers,
Williams, USA, examine the effective removal of BTEX from rich
water to reduce the concentration of BTEX in reclaimed methanol
using a new media system.
106 Water treatment Q&A
Hydrocarbon Engineering questions a number of water treatment
experts about R&D, regulatory compliance, productivity
improvements and the overall market outlook.

THIS As silicon’s popularity in upstream processes has

MONTH'S
soared, refineries are discovering a nasty side
effect: shorter catalyst life, more unit reloads and
unplanned downtime due to silicon contamination

FRONT
in the refinery chain. Learn how refineries can
proactively protect against unexpected silicon

COVER
poisoning with this informative case study from
Crystaphase and Honeywell UOP (p. 38).

2017 Member of ABC Audit Bureau of Circulations

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COMMENT
CALLUM O'REILLY
EDITOR
W
hile many of us in the northern
hemisphere have been enjoying
our summer holidays over the
last couple of months, September
is often synonymous with a return to work,
school or university/college. It also signals the
start of graduate recruitment season – that time of year when a horde of new
graduates take their first steps into the big wide world of work.
For an industry with a well-publicised skills shortage, attracting this
new generation of workers is essential. It is particularly pertinent given the
rising emergence of digitalisation within the sector, which has elevated the
importance of IT expertise. In a recent survey of 2000 workers in the energy
sector, Petroplan found that 34% of respondents concur, citing IT skills as a
growing requirement in the industry.1
Petroplan’s report emphasises the increasingly important role that
graduates have to play as they “can provide the new ideas that will make the
future easier to navigate.” The report rightly argues that it shouldn’t be difficult
to engage younger employees in the oil and gas industry due to the wealth
of innovation within the sector. However, it warns that the next generation of
workers are “seeking roles with more collaboration and open communication
and less top-down decision making.”
This, of course, leads us onto the next big workforce challenge for the
sector. Attracting the next generation of talent is one thing, but retaining
them is quite another. While corporate culture, pay, benefits, and job security
are all important to workers, so is the opportunity to learn and develop their
talents. And just as it is critical to teach the older generation of workers the
new skills that they will need to thrive in an era of increased digitalisation,
it is essential to ensure that practices are in place to enable the younger
workforce to absorb the knowledge and skills of their more experienced
colleagues. Airswift’s Global Energy Talent Index (GETI) suggests that just 6%
of the workforce in the downstream sector is aged 18 – 24. Although this is a
higher proportion of young workers compared to other energy sectors, it is
still relatively low, highlighting the importance of adequate knowledge transfer
from one generation to the next.
In this issue of Hydrocarbon Engineering, Sulzer outlines the value of
investing in a comprehensive skills training programme and provides details
about its approach to internships (p. 33). The company argues that effective
training is essential to gather, retain and share knowledge, which is the
ultimate goal to benefit both its internal staff and its customers.
You can also read more about Airswift’s GETI and the company’s
perspective on hiring trends in the petrochemical sector, starting on p. 25 of
this issue. Continuing the theme, Petroplan has contributed a piece looking
at the recruitment market in the downstream oil and gas industry (p. 29) and
Bilfinger has offered its insights on how to tackle resourcing challenges during
a plant turnaround (p. 31).
1. ‘Talent Insight Index 2017’, Petroplan, (July 2017).
 WORLD NEWS
USA | KPE wins contract from Targa
T arga Pipeline Mid-Continent
WestTex LLC, a subsidiary of Targa
Resources Corp., has awarded KPE a
contract to provide engineering,
procurement and construction (EPC)
for a 200 million ft3/d natural gas
cryogenic processing facility located
near Midkiff, in the Permian Basin of
West Texas.
The facility will include a
condensate stabiliser, low pressure
compression, intermediate
compression, custody transfer
metering, slug catchers and a control
system for processing raw natural gas
into merchantable natural gas by
extracting NGLs and removing
Saipem wins Al Zour refinery
Kuwait |
contract
S aipem has been awarded a
contract worth approximately
US$850 million. Its activities under
the contract involve engineering,
procurement, construction and
commissioning for the ‘Feed
Pipelines for New Refinery Project’
(NRP) in relation to the
development of the new Al Zour
refinery, which is located in the
south of Kuwait.
The contract was awarded to
Saipem by the Kuwait Oil Co. (KOC),
a subsidiary of the Gulf country’s
USA | Wood Group awarded refinery maintenance contract
P hillips 66 has awarded Wood
Group a five-year contract to
provide supplemental maintenance
services and support for small
capital construction projects and
turnarounds to the Sweeny Refinery.
Wood Group confirmed that 175
of its employees will be based at the
refinery, which is located
approximately 65 miles southwest of
Houston, Texas. These employees will
provide the maintenance services.
impurities. KPE has confirmed that the
contract is valued in excess of
US$100 million.
William E. Preston, KPE’s President
and Chief Operating Officer (COO),
said: “This award, the third major
project for Targa within the past
18 months, is the result of substantial
collaboration between Targa and KPE
that ensured the project’s advanced
process design is efficient and
cost-effective [...] The cryogenic gas
plant will allow Targa to increase its
NGL extraction capacity, and we look
forward to helping them build on their
gas processing capabilities in the
Permian Basin.”
national oil company, the Kuwait
Petroleum Corp. (KPC).
The scope of work comprises the
construction of a system pipeline of
various diameter and approximately
450 km in length, for the
transportation of crude oil and gas
from various KOC South Tank Farm
manifolds to the new Al Zour refinery.
The project also includes the
realisation of a network for the
transportation of the refined
products to the storage areas present
in the refinery of Mina Al Ahmadi.
Wood Group has supported the
refinery for more than 20 years,
providing speciality heating,
ventilation and air conditioning
(HVAC) and construction services,
and upgrades to the process
controls, alarms and environmental
data management systems.
Andrew Stewart, CEO for
Wood Group’s Asset Life Cycle
Solutions business in the Western
region, said: “This contract builds
Mammoet
Russia |
extends work at
ZapSibNeftekhim
P JSC Sibur has announced that it
has extended its contract with
Mammoet Russia, which will cover
the unloading of more than 300
oversized and heavy components,
with a combined weight of 20 000 t,
from the river port in Tobolsk.
Subsequently, Mammoet will
transport and install these
components at the ZapSibNeftekhim
Petrochemical Complex construction
site in West Siberia.
ZapSibNeftekhim will become the
largest modern petrochemical facility
in Russia. The project incorporates a
steam cracker with a capacity of
1.5 million tpy of ethylene, around
500 000 tpy of propylene and
100 000 tpy of butane-butylene
fraction (BBF). Alongside the steam
cracker, units are being constructed to
produce various grades of
polyethylene and polypropylene to a
total capacity of 2 million tpy. The
facility is designed for deep
conversion of a substantial portion of
byproducts of oil and gas extraction,
including associated gas. It also aims
to provide import substitution for
polymers that are in high demand for
the Russian market. The facility will
contribute significantly to the
economic development of Tobolsk.
on our long-standing relationship
with Phillips 66 supporting the
Sweeny facility and other
downstream and chemical assets
across the US.
“We look forward to providing
cost-effective services and efficient
manpower practices to improve the
refinery’s performance across our
maintenance, small capital
construction, and shutdowns and
turnarounds programmes.”
HYDROCARBON 5 September 2017
ENGINEERING
 WORLD NEWS
IN BRIEF

Petronas Refinery and Petrochemical
Corp. Sdn. Bhd has awarded Fluor
Corp. an engineering, procurement and
construction management contract
for an isononanol plant located
in Pengerang, Johor. The project
is part of Petronas’ Refinery and
Petrochemical Integrated Development
(RAPID) project and the US$27 billion
Pengerang Integrated Complex
development.

US state agencies have recently
announced final approval of new
regulations to strengthen workplace
and environmental safety at
oil refineries across California.
The regulations take effect on
1 October 2017. The regulations
implement key recommendations of
the Governor’s Interagency Working
Group on Refinery Safety, which
was created after the 6 August 2012
Chevron refinery fire.

Neste has announced plans to begin
a two-month shutdown at its refinery
in Naantali. The major turnaround
will complete a plan that was first
introduced in 2014 to implement
closer integration of the operations
of two Finnish refineries under
uniform management. The Finnish
refinery operations of Neste consist
of four production lines at the Porvoo
refinery, and one in Naantali.

Metso has signed four non-exclusive
distribution agreements in India for
its valve products. The agreements
with Fluidline Systems, General
Energy Management Systems Ltd,
SB Enterprise and Proflo Systems were
signed during 1H17.
September 2017 6 HYDROCARBON
ENGINEERING
Shell completes sale of SADAF
Saudi Arabia |
share to SABIC
S hell has announced that it has
completed the sale of its 50%
share in SADAF to SABIC for
US$820 million.
The sale of the petrochemicals
joint venture, located in Al Jubail, was
originally announced in January 2017.
Completion follows anti-trust
filings in the relevant countries and
regulatory approval from the
Kingdom of Saudi Arabia.
Jacobs extends master services
USA |
agreement with Chevron
J acobs Engineering Group Inc. has
signed a master services
agreement (MSA) expansion
amendment with Chevron Products
Company (Chevron) to provide
elective construction management
(CM) services on an as-needed basis
at the company’s refineries in
El Segundo and Richmond, California;
Pascagoula, Mississippi; and Salt Lake
City, as well as at various terminals
across the US.
In addition to providing existing
engineering and procurement services,
the MSA amendment allows Jacobs to
provide integrated project delivery
(IPD) solutions to Chevron in the
above-mentioned locations.
China | Mogas receives valves order
M
ogas Industries Inc. has received
contracts to supply severe service
isolation valves for a new heavy oils
construction project on ChangXing
Island in Dalian City Liaoning, China.
Mogas will provide Hengli
Petrochemical (Dalian) Refinery Co.
Ltd, China, a subsidiary of Hengli
This acquisition will enable SABIC
to optimise operations at SADAF and
further invest in the facilities,
integrating them with the company’s
other affiliates.
In a statement, Shell said that the
sale will enable the company to focus
its downstream activities and make
selective investments to support the
growth of its global chemicals
business.
IPD is a project delivery approach
that integrates people, systems,
business structures and innovative
practices into a process that optimises
project results, increases value to
facility owners, reduces hours in the
field and rework and maximises
efficiencies through all phases of the
project.
Jacobs Global Field Services Senior
Vice President and General Manager,
Valerie Roberts, said: “As an
experienced IPD provider, we will
support Chevron’s facility and business
objectives while delivering engineering,
procurement and construction
management services at the company’s
US refineries and terminals.”
Group, with over 950 valves that will
be used in a variety of severe service
applications in the ebullating bed unit,
including high pressure letdown
isolation, catalyst isolation and many
high cycle, thermal shock applications.
Delivery of these valves is
scheduled for early 2018.
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 WORLD NEWS
IN BRIEF

Greenfield Global Inc. has commenced a
feasibility study to significantly expand
operations for sustainable biofuel
production at its biorefinery in Varennes,
Quebec. The potential expansion stands
to increase its annual ethanol production
capacity by 70%. The feasibility study
will also incorporate the adaptation
of emerging advanced biofuels
technologies using non-traditional
feedstocks and processes, including
cellulosic ethanol, renewable diesel and
renewable natural gas.

The Linde Group has received a contract
to engineer and supply a modular
hydrogen manufacturing unit for the
St1 Refinery in Gothenburg. Linde’s
Engineering Division will start the
engineering and construction of the
unit immediately, with the completion
estimated for the end of 2018.

Honeywell Process Solutions has
announced that its ControlEdgeTM
Programmable Logic Controller (PLC)
has received ISASecure® Embedded
Device Security Assurance (EDSA)
Level 2 certification by exida, the ISO
17065 accredited certification body who
conducted the assessment.

WAKGROUP and Guangdong Electrical
Design Institute (GEDI) have singed an
EPC agreement to engineer, design and
construct the state-of-the-art Falcon Oil
Refinery at KP Pakistan. The oil refinery is
a deep conversion and has the capacity
to produce up to 100 000 bpd. The
project is expected to be completed
30 months after work has commenced.
September 2017 8 HYDROCARBON
ENGINEERING
USA | Calumet to sell Superior refinery
C alumet Specialty Products
Partners L.P. has signed
agreements to sell the ownership
of its Superior, Wisconsin refinery
and various related assets to Husky
Superior Refining Holding Corp.
Tim Go, CEO of Calumet, said:
“This transaction provides both
financial and strategic benefits for
our unitholders, as we further
position Calumet to move forward
on our stated objectives including
strengthening our balance sheet,
lowering our leverage, and freeing
up capital resources that will allow
Jacobs wins ammonia rehabilitation
Mexico |
project contract
P
EMEX Fertilizantes has awarded
Jacobs Engineering Group Inc. a
contract to deliver project
management contract (PMC)
services for the Ammonia IV
Rehabilitation Project in the
Cosoleacaque Petrochemical
Complex in Veracruz.
The Ammonia IV plant and its
associated auxiliary facilities are
IndianOil to expand Gujarat refinery
India |
capacity
I ndianOil has approved the
expansion of its Gujarat refinery
from its existing 13.7 million tpy
crude oil processing capacity to
18 million tpy. The project will cost
approximately Rs 15 034 crore.
The project will include the
proposed upfront execution of a
new 15 million tpy atmospheric
vacuum unit (AVU) with associated
utilities to replace the four
atmospheric units and two vacuum
units that are currently installed at
various stages of the refinery’s
phase-wise capacity.
us to better invest and fund future
EBITDA enhancing growth strategies
within our core Specialties
portfolio. The transaction also
reduces our go-forward exposure
to commodity pricing and
volatility.”
Under the agreement, Husky
will pay US$435 million in cash, plus
an additional payment for net
working capital, inventories, and
reimbursement of certain capital
spending. The transaction is subject
to customary closing conditions
and regulatory approvals.
being rehabilitated in order to
restore its operating design
capacity and reduce the risks
associated with non-programmed
shutdowns and abnormal
operations.
As PMC contractor for PEMEX
Fertilizantes, Jacobs will supervise
the EPC contractor developing the
Ammonia IV Plant Rehabilitation.
The execution of the
15 million tpy AVU in 50 months
after Stage-1 approval, ahead of
other units by about 11 months, will
provide impetus to the total project
execution and will accrue significant
savings and improved energy
efficiency by way of operation of a
new, large size AVU in place of
existing small units. Commissioning
the new AVU almost a year ahead of
other units will also help in smooth
commissioning and stabilisation of
other downstream secondary
processing units.
 WORLD NEWS
DIARY DATES China | DuPont wins repeat order

27 - 28 September
D uPont Clean Technologies has
been awarded a contract to
supply the China Petroleum &
Tank Storage Asia Chemical Corp. (Sinopec) with a
Singapore second STRATCO® alkylation unit.
www.tankstorageasia.com This unit is for Sinopec Qilu
Petrochemical Corp., a large scale
2 - 4 October refiner and producer of
AFPM Operations & Process Technology Summit petrochemicals, fertilizers and
Austin, Texas, USA chemical fibre in Zibo, Shandong
www.afpm.org/conferences
Province.
7 - 10 October In order to comply with the
Middle East Petrotech
China V standard of 10 ppm sulfur
Bahrain content for fuel, Sinopec
www.mepetrotech.com commissioned DuPont for the
license, engineering and equipment
10 - 12 October of a the alkylation unit. It will
ASIA-TECH / ASIA-CAT enable Sinopec Qilu to generate
Bali, Indonesia low-sulfur, high-octane, low-Rvp
www.europetro.com alkylate with zero olefins that meets
the criteria of the China V standard.
Startup is targeted for mid-2018.
The Sinopec Tianjin Company
(TPCC) had previously awarded a
contract to DuPont for a STRATCO
alkylation unit at its oil refinery in
the Tianjin Binhai New Area district
in northern China. The Tianjin
alkylation unit startup is scheduled
for mid-2018.
Due to plot space limitations
within the refinery, DuPont has
designed the alkylation unit with
Model 74 ContactorTM reactors,
which have been developed to
reduce the number of reactors in an
alkylation unit. This reduces the
required plot space and lowers
overall capital cost, while offering
high reliability and on-stream time.

31 October - 2 November
2017 Chem Show Amec Foster Wheeler receives
France |
refinery FEED contract
New York City, USA
www.chemshow.com

6 - 9 November
Sulphur 2017
Atlanta, Georgia, USA
A mec Foster Wheeler has been
awarded a front-end engineering
design (FEED) contract by Total
currently lacks desulfurisation
capacity, and a significant proportion
of its fuels are, therefore, exported as
www.sulphurconference.com Raffinage France, a subsidiary of Total, they no longer meet fuel quality
for its Donges refinery. European Union specifications.
13 - 15 November The project, comprising a new Amec Foster Wheeler will support
ERTC Annual Meeting vacuum gas oil hydrotreater unit and the modernisation of Total Raffinage’s
Athens, Greece sour water stripping unit, as well as Donges refinery by combining its
ertc.wraconferences.com modification of existing units and new refinery FEED expertise, integrated
interconnections, is part of the engineering systems capabilities and
29 - 30 November investment planned by Total to its Asset Information Hub with the
Tank Storage Germany
upgrade its Donges refinery, improving visualisation and digital asset virtual
Hamburg, Germany
www.tankstoragegermany.com
its performance. The refinery plant technology.

4 - 7 December
BBTC MENA 2017 / ME-CAT 2017
Oman | DRPIC to award US$2 billion contract
Bahrain
www.bbtc-mena.biz / www.me-cat.biz
I n a 50/50 joint venture,
Samsung Engineering and
Petrofac have received
work includes engineering,
procurement, construction,
commissioning, training and
11 - 15 June 2018
ACHEMA 2018 notification of intent by Duqm start-up operations for all of the
Frankfurt, Germany Refinery and Petrochemical utilities and offsites at Duqm.
www.achema.de Industries LLC (DRPIC) for a Work on the 47-month project
contract worth approximately will commence soon, subject to
US$2 billion in southern Oman. financial closure and full notice
Petrofac and Samsung’s scope of to proceed from DRPIC.

September 2017 10 HYDROCARBON

ENGINEERING
At the end of the day, you
want a technology supplier
who works with you.
You’re committed to progress and success. We’re committed to you. And we demonstrate
our commitment through licensing world-class refining, gas, chemical technologies and
specialty catalysts that drive exceptional performance. You can count on our proven
technology and long-term collaboration to help you keep pace with the increasingly
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Learn more about how we can work together to grow your business.
www.catalysts-licensing.com

© 2016 Exxon Mobil Corporation. All rights reserved. ExxonMobil, the ExxonMobil logo, the interlocking “X” device and all product names herein are trademarks of Exxon Mobil Corporation.
 Nunzia Florio, UKPIA, UK,
discusses the downstream
oil sector in the UK, and
the challenges it is set to
face following the nation's
decision to leave the EU.

September 2017 12 HYDROCARBON

ENGINEERING
 he downstream oil sector in the UK is a significant
contributor to the country’s economy and growth, and
provides vital products that are relied upon daily. From
lubricants, petrochemicals and heating fuels, to road and
construction, paints and solvents, and carbon electrodes for the
aluminium sector, the downstream oil industry is responsible for
providing the building blocks for many products that are
fundamental to the way life is lived today and for future innovations.
Today, the sector supplies over 34% of the UK’s primary energy
needs and powers 96% of its transportation energy demand.1
Domestic UK oil refining and marketing assets also make a substantial
contribution to the UK economy, supporting the employment of
88 100 people and many more jobs in related industries that depend
on a strong, competitive refining and marketing industry. The annual

HYDROCARBON 13 September 2017

ENGINEERING

Figure 1. Licensed cars in Great Britain by fuel type (thousand).8
8 vehicle stock is to increase by a factor of
Figure 2. UK new passenger car registrations (thousand).
contribution of the six UK refineries to the
economy is some £2.3 billion,2 with each estimated
to inject approximately £60 million locally, 3 in
addition to the value of its production output. If
the activities of the UK’s North Sea oil production
sector are included, an additional £9 billion 4 can be
added to the annual contribution to the UK
economy.
Crude oil in its natural state is of no use until it
has been processed at an oil refinery and converted
into usable products. Therefore, refineries
somewhere are required to process UK production
and the two sectors cannot be entirely segregated.
The UK downstream oil industry also fosters skills,
knowledge and expertise in associated scientific,
engineering and technical disciplines in areas of
the UK economy that require the high quality jobs
the sector provides directly and through the
industries that are linked to its production.
To 2035 and beyond, is it projected that the
transportation sector in the UK will continue to
rely on petroleum products for approximately 90%5
of its energy needs, due to a combination of
factors such as their comparatively low cost and an
established infrastructure. The chemical sector will
continue to depend upon petrochemical
feedstocks for the production of plastics and
polymers that are used in everything from medical
September 2017 14 HYDROCARBON
ENGINEERING
equipment and pharmaceutical products,
cosmetics and clothing, to computers, wind
turbines and solar panels. Overall,
petroleum products are expected to
continue powering over one-third of the
UK’s total energy needs.4
With oil products expected to continue
representing an essential part of the
nation’s energy supply mix well into the
future, the critical importance of the
downstream oil sector cannot be
overstated. Globally, the outlook is not
dissimilar with vital oil derived feedstocks’
demand from refineries to the chemical
sector expected to increase by
approximately 45%5 to 2035, with rising
prosperity stimulating demand for
fertilizers, plastics and other chemical
products. Global transportation demand is
also expected to continue being largely
fuelled by petroleum products, as no other
transportation fuel provides more energy
by volume than gasoline, and diesel is more
easily stored as an energy source in lorries
and cars. Liquid petroleum-based fuels
currently account for well over 90%6 of
global transport energy demand. By 2040,
the International Energy Agency (IEA)6
estimates that the total global passenger
two, to around 2 billion vehicles, and that
demand for road freight transport is to
grow strongly, representing around one-third of net
global oil demand growth. Demand in areas such as
aviation and international shipping is also set to
increase.
Road transport fuels in the UK
In the year ending September 2016, the Department
for Transport estimates that 320 billion7 vehicle
miles were travelled on Great Britain’s roads, with
total traffic 1.8% higher than the pre-recession peak
of 2007. Rolling annual motor vehicle traffic has
continued to increase each quarter in succession
for the past 15 quarters due to a number of factors,
including population growth, personal travel
choices and a growth in demand for goods and
services. Over the last 20 years, traffic has
increased across all vehicles types, with car traffic
increasing by 12%, van traffic by 70% and lorry
traffic by 5.5%. Currently, petrol and diesel
powered vehicles account for 99% of the UK’s
passenger car fleet, with petrol cars representing
61.2% of the total and diesel vehicles 37.8%. The
balance is made up of LPG and other gas and
electric vehicles.
To 2035, it is estimated that petrol and diesel
cars will continue to account for just under 90% of
total new car registrations across Europe.9 At
present, they account for the vast majority
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 (approximately 97%) of all new cars sold in the UK,
with the balance made up of LPG and other gas
and electric vehicles. On average in the UK,
2 – 2.5 million new cars are registered every year
and, typically, a vehicle will remain in the car parc
for a period of 12 years.
Across Europe, in around two-thirds of Member
States, registrations of new passenger cars powered
by diesel engines have outnumbered new petrol
powered cars for a number of years.10 Principally
owed to a fiscally driven dieselisation of the
private car fleet and a marginal growth in
commercial diesel consumption, diesel demand in
the UK has been increasing steadily for the past
three decades and now accounts for over 63%1 of
total road fuel sales in the UK. This has created a
substantial imbalance with refining output. The UK
has only six refineries remaining and they are
unable to produce sufficient volume to cover this
demand. For this reason, significant diesel imports
(48%1 of demand) mostly from Russia are now
required to maintain the UK’s diesel supply/demand
balance while, at the same time, the UK exports
surplus petrol production. However, diesel demand
is expected to peak in 2017 before declining to
2008/09 levels by 2035,9 also owing to greater
vehicle efficiency gains. The UK is already classed
at high energy security and resilience risk for diesel
and jet fuel, importing around 60% jet fuel and, as
indicated, 48% of diesel demand, according to the
IEA’s Model of Short-Term Energy Security
(MOSES). It is estimated that further refinery
closures would result in jet and diesel imports
increasing to more than 80% of market demand,
leaving the UK even more exposed to the
international traded product market for those
products already at high risk. For this reason,
sustaining and maximising domestic production
will be key to ensuring a secure and reliable energy
future, and one that underpins the UK’s economic
strength and growth.
Powering the UK’s future
Looking ahead, it must be ensured that an
environment where the sector can continue to
thrive to the benefit of all is created, particularly
as the UK looks to build a new relationship with
the EU and a meaningful energy and industrial
strategy. In terms of what industry wants more
broadly from an industrial strategy, above all, it
must ensure confidence in the business and
regulatory environment. The downstream oil sector
competes in a global market and requires a stable,
long-term legislative framework, which promotes a
level playing field, ensuring competitiveness both
within Europe and also globally.
A sound industrial strategy for the UK should
thus be based on clear guiding principles, including
a competitive free market operating within a clear,
robust and well designed legal, fiscal and
September 2017 16 HYDROCARBON
ENGINEERING
regulatory framework. If such a framework is
lacking, it not only discourages investments but
disadvantages domestic manufacturing with
respect to other world regions with which UK
industries compete. This, in turn, has the potential
to further erode the country’s energy resilience,
industrial fabric and subsequent opportunities for
employment and growth. For this reason, getting
an industrial strategy right is a precondition for the
success of the wider economy. The government
must also value and remain cognisant of the
downstream oil sector’s value in terms of research,
development and innovation efforts, which are
important drivers of competitiveness and widely
recognised as key to improving prosperity and
growth. For example, the industry employs one of
the largest percentages of highly skilled labour
amongst manufacturing sectors, and has one of the
highest knowledge intensities. The downstream oil
sector is also important in the employment arena
for chemical and engineering graduates, those with
related vocational skills, and training and
apprenticeship opportunities. These unique
capabilities should be fully acknowledged and
enabled through the promotion of a long-term
vision in collaboration with UK industry to aide
both productivity and social mobility. Designed
correctly, an industrial and energy strategy for the
UK can provide the necessary focus and the
visibility that the sector deserves. In addition,
following the UK’s vote to leave the EU in
June 2016, it is vitally important that the
government works collaboratively with industry to
ensure that the many challenges arising can be
tackled, risks managed and opportunities seized.
Conclusion
To help shape this new reality for the UK, with the
right policy environment, the downstream oil
sector stands ready to apply maximum effort in its
contribution to jointly work towards a secure
energy future for the UK, strengthen and grow the
economy, and ensure a thriving industrial base and
supply chain for the benefit of generations to
come.
References
1. 'Digest of United Kingdom Energy Statistics (DUKES)',
BEIS, (2016).
2. 'The role and future of the UK refining sector in the
supply of petroleum products and its value to the UK
economy', IHS, (2013).
3. UKPIA data.
4. BEIS, 'Updated energy and emissions projections
(including aviation)', (2016).
5. 'BP Energy Outlook', BP, (2017).
6. 'World Energy Outlook', International Energy Agency
(IEA), (2016).
7. DfT, Provisional Road Traffic Estimates Great Britain:
October 2015 – September 2016. Cars and taxis:
249.4 billion vehicle miles. LGVs: 48.2 billion vehicle
miles. HGVs: 17.1 billion vehicle miles. Other: 5.4 billion
vehicle miles.
8. 'Vehicle Data', SMMT, (2017).
9. 'Energy View to 2035', Wood Mackenzie, (2016).
10. 'Passenger cars in the EU', Eurostat, (2016).

Tower Technical Bulletin
Troubleshooting distillation columns – Part 1: The basics
Background
Properly designed and operated distillation columns can
provide long-term, trouble-free service. However, mechanical
failure, process upsets, and other factors can occur, preventing
the distillation system from achieving the expected design
performance.
Taking a tower off-line is time consuming and expensive; before
doing so it is important to have a good idea of what is causing
the problem. A systematic study of the column should be made
(often with the assistance of the column equipment provider).
After careful study, a tower inspection should be performed
to confirm the cause of the problem and to determine and/
or provide a proper solution. In emergency cases, expected
replacement equipment may need to be on site prior to the
column opening.
Understanding mass transfer fundamentals is critical
Knowledge of the column thermodynamic and hydraulic
functions is the key starting point. Any problem that develops
that does not allow the vapor and liquid to contact each other
in the manner for which the device was designed, or keeps the
vapor and liquid from separating after contact, will adversely
affect column performance. For example, the packing shown
below will not provide good flow or vapor/liquid contacting
efficiency because some of the packing is blocked off by fouling.
Hydraulic evaluation
Symptoms of hydraulic flooding include excessive or erratic
pressure drop, reduced bottoms flow, reduced column
temperature profile, and excessive liquid carryover.
Conversely, low pressure drop is an indication of missing
trays or packing.
Europe, Middle East and India
Sulzer Chemtech Ltd.
P.O. Box 65
8404 Winterthur, Switzerland
Phone: +41 52 262 50 28
chemtech@sulzer.com
Legal Notice: The information contained in this publication is believed to be accurate and reliable, but is not to be construed as implying any warranty or guarantee
of performance. Sulzer Chemtech waives any liability and indemnity for effects resulting from its application.
Sulzer Chemtech
Where to start
Ask yourself the following questions:
• What specifications are not being met? What could
happen internally to create this issue?
• Is this a capacity problem? Has the column ever run
successfully at these rates? If not, the internals may be at
their capacity limit.
• Have there been any upset conditions that may have
damage internals?
Working toward a solution
The simple checks should be made first. Check the
instrumentation to ensure that flows, levels, temperatures,
and pressures are correct. Check to make sure that feed
compositions and analyses are correct. Conduct a single gauge
pressure survey and a temperature survey as possible. Perform
a mass balance across the column—a closure of 3-5% is
normally considered acceptable.
Once you have this information, review the information with
plant engineering and operations. Consult with your equipment
vendor to further investigate the problem. Decide on the
feasibility of a column gamma scan. If practical, schedule a
tower inspection at the first opportunity in order to personally
examine the internals.
In the meantime, the problem may be temporarily alleviated
by reducing rates, changing the reflux and reboiler duties,
changing the feed location, and increasing or decreasing the
tower pressure.
The Sulzer Applications Group
Sulzer has over 150 years of in-house operating
and design experience in process applications. We
understand your process and your economic drivers.
Sulzer has the know-how and the technology to design
internals with reliable, high performance.
Asia Pacific North and South America
Sulzer Chemtech Co., Ltd. Sulzer Chemtech USA, Inc.
10 Benoi Sector 8505 E. North Belt Drive
Singapore 629845 Humble, TX 77396, USA
Phone: +86 65 6515 5500 Phone: +1 281 604-4100
ctsg@sulzer.com ttb.ctus@sulzer.com
 Marcio Donnangelo, Emerson Automation Solutions, USA, discusses how installing
wireless transmitters can help refineries to improve operations and reduce the
number of unscheduled outages, while being safer and more energy efficient.

A
DIGITAL
GIT
ECOSYSTEM
IMPROVING
REFINERY
MARGINS
KEYNOTE
SERIES

September 2017 18 HYDROCARBON

ENGINEERING
O
il refineries operate under a wide range of economic
pressures, government regulations, and changing
conditions, making it more difficult to maximise refining
margins. Refineries are faced with problems such as the
loss of senior personnel to retirement, different crude feedstock,
ageing equipment, and a lack of information from various areas of
the plant.
For example, many refiners maximise their use of discounted
opportunity crude oils, but using this type of feedstock often
presents significant processing challenges. Refineries built in the
1960s and 1970s were originally designed to handle a certain type of
oil, such as sweet crude. The changing nature of oil being supplied
for refining magnifies problems in new and ageing facilities. For
example, unit preheat exchangers can foul unpredictably when fed
with certain types of crude.
Installing WirelessHART® pressure and temperature transmitters
on heat exchanger banks and feeding their measurements to process
data analytics software makes it possible to identify problems with
heat exchanger fouling. Similar problems can also be identified on
many other types of refinery equipment with the transmitters.
Table 1 shows the potential savings in a 250 000 bpd refinery
when the transmitters are installed on various equipment and
processes, with data analytic software processing the
measurements.

The wireless solution

Wireless measurement devices using WirelessHART technology are
key enablers to implementing a Pervasive SensingTM strategy to
monitor anything, anywhere, in the refinery. WirelessHART is an
international industrial standard (IEC 62591) self-organising, wireless,
mesh network leveraging the well-known and widely used HART
protocol. Adding low cost installation of wireless monitoring points
throughout the plant provides analysis and alerts personnel to
problems. This helps optimise production processes by monitoring
the health of pumps, motors, steam straps, pressure relief valves
(PRVs), heat exchangers, valves, piping systems, and other equipment.

HYDROCARBON 19 September 2017

ENGINEERING
 Table 1. Potential savings in a 250 000 bpd refinery when non-intrusive to the process and can be installed
transmitters are installed without any downtime.
Application Monitoring Savings Implementation ROI The initial installation requires a gateway, which
and analytics (US$ million) cost (months) interfaces wireless transmitters to an analytics
(US$ million) software application, to a historian and/or to the
Heat Fouling rate 2.7 – 3.6 0.62 3 control and monitoring system – leveraging multiple
exchanger and limits communication protocols to make these connections.
monitoring Once the first system is installed, it becomes easier to
Cooling Efficiency 0.3 – 0.5 0.16 4 add new wireless transmitters.
tower and health Adding new transmitters also makes the network
monitoring stronger because in a mesh network, every transmitter
Steam trap Failure 2.5 – 3.3 1.48 5 also works as a repeater, routing the signal along
monitoring multiple paths as needed to extend the perimeter of
Relief valve Releases and 2.4 – 3.2 1.59 6 coverage and provide alternative paths in case of
monitoring leaks obstruction. The more wireless transmitters installed
Pump Cavitation, 0.5 – 0.6 0.55 11 in an area, the stronger and more widely spread the
monitoring pump health network signals (Figure 1).
Air-cooled Fan health 0.9 – 1.1 1.2 13 For example, a major US refinery installed six
heat and fouling Rosemount 708 acoustic transmitters on its Butane
exchanger Bullet relief valves. These devices notify operators if a
monitoring
relief valve is beginning to relieve or leak.
Mobile Turnaround 1.6 – 2.1 0.4 3 In 2014, the refinery added three Rosemount 848
workforce diagnostics
high-density temperature transmitters on its diesel
Safety Trigger Per incident 0.39 Safety hydrotreater and combined feed exchangers.
shower and indication
In 2015, the refinery installed a Permasense
eye wash
monitoring corrosion monitor and 20 sensors in the refinery’s
coker and crude unit. An adapter, which converts a
Total 10.9 – 14.4 6.4 5
wired transmitter’s 4 – 20 mA output signal to
WirelessHART, was added to a meter on a crude feed
tank to monitor flow, temperature and API gravity. A
wireless vibration monitor was added to the coker jet
pumps.
In 2016, the refinery added a high capacity Elite
Coriolis Meter with the adapter to its oil movement
area for custody transfer of asphalt.

Refinery improvements
The first step toward refinery improvement is to
define new sensing point locations, determine how
the new information will be used, and associate the
economic values with each pervasive sensing
application. Unscheduled outages and production
slowdowns classified as mechanical unavailability
occur from common problems such as rotating
equipment failure, heat exchanger fouling, piping
Figure 1. If an obstruction is introduced into the network, data
will continue to flow because the device already has other corrosion, and fired equipment constraints.
established communication paths. Energy losses occur from heat exchanger fouling,
failed steam traps, and process unit inefficiencies
– each of which may go undiscovered from a lack of
The technology is compatible with new and legacy complete energy measurements. Refineries understand their
refinery control systems. A Pervasive Sensing solution can be macro energy performance through their energy intensity
installed, running and improving operations in any refinery in index, but determining exactly where energy is lost is a
short order. common challenge when driving an energy improvement
Previously, additional sensor inputs would have been programme.
wired from the sensing point – such as a pump – to a
control and monitoring system. Adding this wiring to an Cooling towers
existing facility is usually an expensive undertaking, and Cooling tower instrumentation in many refineries is often old,
often requires significant downtime. But wireless transmitters with many measuring devices out of service. Measurements
allow points of measurement to be added at a fraction of are difficult because the process environment is corrosive to
the cost and time of their wired equivalents. Some are wiring, mainly due to chemical vapours. As a result, these areas

September 2017 20 HYDROCARBON

ENGINEERING
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Figure 2. An enclosure protects WirelessHART
transmitters from the corrosive environment near
cooling towers.
Figure 3. Rosemont 708 wireless acoustic transmitter
detects steam trap problems.
can be poorly instrumented and controlled. Consequently,
monitoring is poor, operations are inefficient, and the towers
require a great deal of maintenance and manual operator
interaction.
Online measurements are required to provide the data
needed to tightly control cooling towers, maintain the assets,
and prevent over-maintenance. Automated monitoring also
prevents failures, thus limiting downtime in each cooling
tower section.
WirelessHART monitoring (Figure 2) offers better control
to improve tower efficiency and minimise water consumption.
Having the right data enables proper dosing of the cooling
tower water to prevent excess chemical use, and to provide
the right water chemistry to avoid fouling and damage to the
pipes. Proper dosing also improves cooling tower efficiency.
Monitoring cooling towers provides early alerts of bearing,
lubrication, or alignment problems in cooling tower fans and
pumps. Data analytics software can provide timely alerts for
September 2017 22 HYDROCARBON
ENGINEERING
reverse fan operation in periods of cold weather, and for
suggested fan sequencing for optimal power consumption.
Data analytics can also provide recommended blowdown and
make-up flows to help minimise chemical and water costs.
Steam traps
When a steam trap fails to shut, it no longer passes steam and
will no longer remove water, air or other gases from the steam
system. When a steam trap fails in the open or blow-through
condition, it constantly passes steam, meaning despite the
internal orifice limiting the amount of steam loss, the amount
lost can still be significant.
Steam trap monitoring (Figure 3) reduces water hammer
incidents, detects traps that have failed open or failed closed,
and eliminates the need for manual rounds and foot traffic in
high risk areas. Monitoring also reduces equipment damage
caused by water hammer, impingement and corrosion.
Relief valves
Monitoring relief valves, rupture discs, and other pressure relief
devices provides immediate notification of a release. New US
Environmental Protection Agency (EPA) and other regulations
now require monitoring of relief valves and rupture discs.
Time-stamped alerts allow a refinery to conduct root cause
analyses to avoid future releases. As with steam traps, wireless
monitoring safely collects data without manual rounds, keeping
employees out of hazardous areas or remote locations.
In addition to potential environmental and safety
concerns, process upsets causing overpressures can affect
production and uptime, negatively impacting profitability. A
relief valve is sometimes the only indicator of process upsets,
so the sooner an event can be detected, the quicker operators
can respond to the root cause.
Historically, relief valves have been difficult to monitor
because of their hard-to-access locations Monitoring methods
typically include the manual inspection of tell-tale signs. For
example, wind socks are often used to monitor releases to the
atmosphere.
A reliable, effective and economic way to monitor relief
valves and rupture discs is to use non-intrusive acoustic
transmitters. Process fluid flowing through valves and orifices
generates acoustic waves in a wide and complex range of
frequencies and magnitudes. Acoustic transmitters detect
ultrasound acoustic waves in the pipe wall as well as its
temperature. These devices are wireless, small, lightweight, and
non-intrusive. They can be easily clamped on the exhaust pipe
with no required process penetrations or downtime (Figure 4).
Pumps
The online monitoring of pumps through the addition of
wireless measurement of vibration, pressure, and seal fluid
levels allows for the early detection of excessive vibration,
cavitation, and seal failure problems. Maintenance can be
notified of pending problems, leading to improved production
through fewer unscheduled outages.
For example, 10 – 15 LPG pumps in a refinery are typically
checked manually once a month for vibration, and bad actors
are checked once a week. With ever-changing process
conditions, infrequent spot inspections are insufficient to
detect pump problems and seal failures. Hydrocarbon leaks
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1-724-327-6100 I 800-545-5001

Figure 4. A wireless relief valve monitor simply
clamps on to the pipe downstream of the valve.
Figure 5. An example of a digital ecosystem.
Your Specialist for
PRESSURE RELIEF
SOLUTIONS
Inc.
3809 Beam Road Suite K | Charlotte, NC 28217, USA
F +1 704 716 7025 | info@rembe.us | www.rembe.us
are possible due to seal failures, which can lead to production
losses, fires and safety incidents. If a pump fails and seals break
in an LPG area, this presents a high risk of explosion. A refinery
can see a US$100 000 insurance premium risk reduction by
adding automated monitoring to process pumps.
The digital ecosystem for IIoT
A refinery employing wired and wireless transmitters, gateways
and analysis software creates an Industrial Internet of Things
(IIoT) ‘digital ecosystem’ within the entire complex. For
example, Emerson’s Plantweb Digital Ecosystem (Figure 5) using
a Pervasive Sensing portfolio of wired and WirelessHART
transmitters is a digital ecosystem. These devices send reliable
real-time data through secure communication to appropriate
experts, application software, or to remote connected services
– turning the data into actionable information, which can be
sent to anyone, anywhere.
Conclusion
A typical 250 000 bpd refinery has hundreds, if not thousands,
of unmonitored processes, devices and systems susceptible to
unplanned failures or degraded operations. These conditions
can waste energy, increase the probability of safety issues, and
escalate repair costs – potentially shutting down processes or
an entire refinery.
A ‘digital ecosystem’ strategy using wireless sensors to
monitor equipment, detect problems, and alert operations
personnel can save a refinery millions of dollars every year in
maintenance and energy costs. These solutions can also
improve safety, prevent releases that could result in fines and
penalties, and extend the life of expensive process
equipment.
T +1 704 716 7022
T +49 2961 7405-0
Consulting. Engineering. Products. Service.
Gallbergweg 21 | 59929 Brilon, Germany
F +49 2961 50714 | www.rembe.de © REMBE | All rights reserved
Michael Sanches, Airswift, USA, presents an
objective perspective on petrochemical hiring

TRACKING
trends in the downstream sector.

TRENDS
T
he last few years have been fairly turbulent
for the oil and gas industry. Although not as
badly hit as its upstream counterparts, the
petrochemicals sector has not emerged
unscathed from the downturn.
Certain business fundamentals remain the same
future, which locations will be the next energy
hotspots, which energy sectors will provide the
most jobs, and what the talent pool will look like
when hiring starts again in earnest.
In order to get the insight the industry needs
right now, Airswift surveyed more than 16 000
despite the state of the global economy, ensuring professionals in 156 countries to gather their
that essential skill sets are in the right place at the thoughts about hiring, skills, knowledge-sharing and
right time – and for the right price. Decision makers talent in the petrochemicals industry. Combined
want to know how salaries will change in the near with an analysis of key data from more than 64 000

HYDROCARBON 25 September 2017

ENGINEERING
 job postings and contract and permanent hire data,
the result is the Global Energy Talent Index (GETI).
The numbers
According to GETI, the downstream sector has a
greater proportion of 18 – 24 year olds working in it
compared to other energy sectors – although this is
still only 6% of the total workforce. Additionally, it
is also known that 62% of the global workforce is
under 45 years old. That is a positive place to be,
provided the sector can harness the knowledge of
its veterans and put the practices in place to
transfer skills and knowledge through the ranks.
Today, there are also more women working in
petrochemicals than in renewables, which in turn
has a larger female workforce than oil and gas.
However, there is still some disparity between the
number of men and women who hold management
positions. Only 31% of women are working at a
senior level in petrochemicals, compared to 38% in
oil and gas, and 53% in renewables.
Finally, hiring remains at relatively low levels,
despite continued investment in new projects. Only
one in five hiring managers expect recruitment to
really pick-up in the near future, and only 11% plan
to hire more than 51 employees in the next
18 months.
The disconnect
However, one of the most striking findings from the
GETI are the differing expectations of those looking
for jobs and those providing them, especially in the
downstream sector. Over two-thirds of hiring
managers believe there is a skills shortage in the
sector, despite attracting a significant number of
graduates. Nearly two-thirds (63%) said that a “lack
of planning for knowledge transfer and skills
retention” was responsible for the skills shortages,
while 38% felt that a “loss of manpower due to an
ageing workforce” was also accountable.
When it comes to overcoming the skills
shortage, hiring managers emphasised making
changes to retention and recruitment policies (69%),
as well as increasing training and development
(63%). There was also a notable interest in working
with educational bodies to develop the skills
needed, as half said that partnering with colleges
would help, and 44% cited graduates and
apprentices as another potential solution.
Three-quarters of respondents felt that hiring
outside of the industry could prove to be beneficial;
75% said it would widen the talent pool, while 69%
felt it would offer the industry a new perspective.
Interestingly, more felt that bringing back retirees
was the answer to the skills gap rather than
targeting new audiences, particularly women.
Furthermore, only 13% of hiring managers said
that salary was an important factor in attracting
new employees, while 50% said corporate culture
was the most compelling draw. This is where the
September 2017 26 HYDROCARBON
ENGINEERING
disconnect between employees and their potential
employers really starts to show as one-third of all
professionals (33%) said that salary was the main
attraction, and only 11% said it was corporate
culture.
Although most employees were focused on
salaries and benefits, they did not always have
realistic expectations. The GETI shows that 53% of
professionals would not move to another sector
without a pay rise. Topping the reasons for moving
to a new field was a better salary and benefits
package.
The second most startling disconnect appears
when future salary expectations are discussed. A
majority (64%) of employees in the petrochemicals
sector believe salaries will increase over the next
12 months, but only one in five hiring managers feel
the same way. Employee confidence was less marked
in Europe, where only 41% believe salaries will
increase. However, 83% in Asia, 85% in Latin America
and 74% of employees in the Middle East were
confident of a near-term boost to salaries.
Connecting the dots
When expectation and reality are this far apart, it
sets the scene for disappointment in the future –
and could even prolong the skills shortage. So how
can hiring managers close this troubling gap
between what is expected to be on offer and what
employees expect to receive?
One solution is to ensure that everything is
being carried out internally to fill skills gaps. Plans
need to be made to ensure adequate knowledge
transfer to the younger workforce. Re-hiring older
employees may be one answer, but more
adventurous thinking might deliver greater benefit.
For example, careful deployment of modern
communications and mobile technology may be a
more cost-effective approach for making extensive
expertise available on even the most remote front
lines – without the experts leaving home.
Innovation is going to be key.
Employers can also recognise where there is
common ground with employees – 25% of
employees and 23% of hiring managers felt a
company’s ethical reputation would attract more
employees. Since this data suggests employees want
to work for a company with strong ethics, honesty
and transparency should become a prominent part
of any brand identity.
However, there is no getting away from the fact
that employers need to be mindful of the
importance of salary and benefits. In regions where
benefits are not widely offered, targeted benefits
could make the difference. For example, 39% of
Europeans get a health plan, but 55% of
professionals view healthcare as the most valuable
benefit.
Employees also need to be aware of where it
pays to work. The average annual salary for a
petrochemical health, safety and environment (HSE)
manager in Europe is US$49 162; in North America it
is US$70 473 and US$50 298 in the Middle East.
Those wishing to work in Europe, therefore, may
have to revise their salary expectations or seize
training opportunities when they are available –
both of which are likely to enhance employment
prospects in today’s hiring market.
However, most importantly, employers need to
view the skills gap and hiring challenge as part of a
more holistic operation, in which strategic long-term
planning replaces short-term, on-demand hiring
tactics. Many companies across the process,
infrastructure, and energy sectors experience
challenges when closing skills gaps and preparing for
cyclical hiring trends. When hiring talent for capital
projects or static operations, employees will be
promoted into new roles or retire from their posts;
therefore, the immediate challenges are reducing
attrition and training up junior level employees for
the vacant roles. The larger challenge for these
companies is addressing the competencies that new
hires will need to perform well in their roles. It takes
many months, sometimes years, for junior level
employees to attain the necessary competency level
for the more senior positions they have been trained
to backfill. In some instances, employees are
deployed to execute work in new manufacturing
areas or on capital projects, thus steepening the
learning curve.
A skills gap eradication programme should be
developed to lessen the competency challenges and
manage change for growth. This could include
building talent pipelines, understanding where skills
are currently located (both internally and externally
in a given company), mapping out future needs,
working with experts who are prepared to go beyond
social media to connect with the right personnel,
and implementing support mechanisms so
employees can reach full competency in the shortest
possible time. Working with specialist providers who
have the experience to develop the benefits
packages and ensure a smooth on-boarding process
is also essential.
Conclusion
The GETI shows us that there are plenty of reasons
to be optimistic about the future of the
petrochemicals industry. The sector does appear to
have learned more from the last downturn as now it
is more diversified, it has spread risk more widely,
and its demographics are some of the most positive
in the industry. Furthermore, even though the market
remains challenging, it is still making significant
gains. So, if the industry continues down this path, it
should remain an attractive employment sector.
Andrew Duffy, Petroplan, USA, analyses the ongoing
trends for recruitment in the downstream oil and gas
industry, particularly following the rise of LNG projects.

THE
RECRUITMENT
ROUND-UP
W
hile the oil price has been in the doldrums, the downstream oil and gas sector has
benefitted from reduced material costs, which has meant that recruitment has,
generally, been more buoyant than in the upstream sector. Yet the downstream
industry is not a homogenous one, which can now be seen manifested in the
varying recruitment activity across the different subsectors.

The past year

Just a year ago, the recruitment situation appeared positive for the refining and petrochemicals
sectors. Refineries were running at high utilisation rates, which meant there was an increased
need for skilled personnel to undertake planned maintenance and plant turnarounds. For the
petrochemicals sector, in-demand speciality products were commanding high margins.
Fast forward a year, and while the business context has changed little on the surface,
recruitment activity is considerably flatter in both areas, due in no small part to the integrated
structure of many of the world’s larger international oil and gas companies.
Refinery utilisation rates remain high (touching 90% in the US)1, and there is still strong demand
for speciality petrochemicals, which maintain their high margins. Petrochemical and polymer prices
are under pressure, however, and the continued low oil price – combined with an overall global
economic slowdown – has meant those downstream players with an upstream business are
reluctant to invest heavily in the expansion of refineries or petrochemical facilities. This effect has

HYDROCARBON 29 September 2017

ENGINEERING
 been felt throughout the world, but particularly in Asian
markets given the slowing of China’s economy.
Meanwhile, as natural gas increases in popularity as a
cleaner fuel source – and LNG provides a means of
transporting gas to parts of the world that are sometimes
lacking in major pipeline infrastructure – the LNG industry is
going from strength to strength. In the US, the ramp up of
shale gas production has also contributed to this surge.
Furthermore, the profile of companies involved in LNG is
often different to refining and petrochemicals, with smaller
start-up companies also involved in projects. These companies
come without an upstream business and, as a result, are free of
the financial constraints that come with it.
LNG
Given the context outlined above, many are competing to get
LNG projects, such as Tellurian’s Driftwood LNG and
NextDecade’s Rio Grande LNG, into construction and on-line,
both internationally and in the US. With the average cost of an
LNG project at approximately US$11 billion, according to the
latest estimates, a number of the smaller start-up companies
involved are either approaching banks or floating publicly in
order to raise funds. While the upfront costs may seem
substantial, so are the potential returns. For example, at the
Sabine Pass LNG facility in the US, there is currently only one
liquefaction train (out of an eventual six) in operation. Yet, the
facility’s operator, Cheniere Energy, has reported its latest
quarterly profit to be approximately US$54 million, and one
can imagine it is these figures that are catching the attention
of investors.
From conceptual design through to production, a new
LNG project can require up to 8000 personnel, and a growing
investment means personnel will be needed both to get
projects off the ground and – in the medium term – for
operational duties. At present, there is a strong demand for
mechanical and process engineers, two specialisms where
there seems to be a perennial shortage.
The challenges
One of the many challenges recruiters in the downstream
sector now face is finding personnel with the right kind of
experience, either in terms of project type or specific
technology. Although there is a demand for personnel in the
downstream sector (and a relative surplus in upstream), this is
the barrier that those trying to re-train and make the transition
from the upstream sector are coming up against – that just
having general experience in the oil and gas industry is not
enough.
Generally speaking, the global oil and gas workforce has
always been a relatively mobile one, with personnel usually
willing to travel for the best positions. This adaptability
widens the recruitment resource pool throughout the world,
and as some of the major LNG projects in Western Australia
wind down (e.g. Wheatstone and Gorgon), a flow of personnel
with recent LNG project experience have returned from
Australia to work on LNG projects currently under
construction in the US. After the current boom in the US
begins to settle down, many of these project experts can be
expected to move on to other projects in Canada and East
and West Africa.
September 2017 30 HYDROCARBON
ENGINEERING
Immigration requirements
Immigration and entry requirements can also act as a barrier to
global mobility, and it is one that employers do not always
factor in. In locations where employees need to be sponsored
to come into the country (e.g. in the US, Australia, or in some
Middle Eastern markets), smaller companies may not always
have the means to carry this out. As LNG and other major
downstream projects ramp up, immigration rules may become
a hindrance to those sourcing the personnel required to get
projects off the ground and operational, something that both
the industry and international governments will need to bear
in mind.
Salary competitiveness
With regards to salary, talented individuals come at a
premium, and the competition to attract them is fierce.
However, remuneration in the downstream sector has been
affected, especially for those working in integrated companies
where issues in a company’s upstream business have trickled
down. More recently, however, both candidate expectations
and employer offers have been edging up, reflecting the
increased competition for talent. As one example, engineers
working in the US downstream sector can expect an annual
salary between US$150 000 and upwards of US$300 000,
depending on the individual’s seniority and experience.
Lack of new interest
The oil and gas industry has faced recruitment challenges for a
long time, as engineers with extensive and specific experience
retire and the number of graduates reading disciplines required
by the sector is lower than needed. The turbulent times the
industry has faced over the past couple of years may also act
as a deterrent for budding engineers, who feel apprehensive
about entering the industry during a period of instability.
Maintaining a continuous succession in human resources is,
therefore, as important as ever and recruitment is a priority
area.
The solutions
Access to a global network of industry specialists and a
detailed understanding of the needs of all oil and gas sectors
are vital elements in being able to fill recruitment gaps where
needed and respond quickly to changing human resource
demands.
In addition to this, recruiters need to look at their social
media presence on mediums such as LinkedIn and Facebook,
which can be leveraged by their in-house marketing
department to build awareness of the company brand and
drive candidate registrations.
Conclusion
Over the past year, some in the industry have observed a
relative rebound and stabilisation in crude prices. So, while
many recruiters are investing in downstream as a growth area,
it would also be wise to maintain long-standing relationships
and client bases in upstream and midstream as well.
Reference
1. 'Refinery Utilization and Capacity', US Energy Information
Administration (EIA), (2017), available: https://www.eia.gov/dnav/pet/
pet_pnp_unc_dcu_nus_m.htm, (accessed 17 July 2017).
RIGHT HERE,
RIGHT NOW David Wright, Bilfinger, UK, discusses the art
of resourcing plant turnarounds and finding the
right people, in the right place, at the right time.

W
ith refinery operators looking to carry out
their turnarounds in only a few short months
of the year and the talent pool of people
qualified to carry them out shrinking, finding
resources for the projects can be a major logistical
challenge.
Plant turnarounds are one of the most technically
critical and expensive periods of a refinery’s lifespan. The
cost of suspending operations at a large facility can run
into millions of pounds per day, so executing planned
shutdowns during a specific window of time, which is as
short and predictable as possible, is paramount.
However, turnarounds are no small task. Overhauling a
large refinery might involve 30 000 hrs of work in a wide
variety of different disciplines, from manual labour to
highly specialised maintenance engineering. Identifying
this resource and getting the right people on site at the
right time is crucial to ensuring the success of any
turnaround, while combatting any of the significant
challenges involved.
Maximising the talent pool
For the vast majority of refineries, plant shutdown season is
during spring or autumn. This restricted window places
further demands on the resources that are available at the
time and in the immediate vicinity of the facility in
question. In the UK, resourcing strategies have become
increasingly nationwide, and even international to some
extent, as site leaders look beyond UK shores for the skills
required.
For a plant turnaround in the UK, a typical breakdown
of the project team might see 55% of personnel sourced

HYDROCARBON 31 September 2017

ENGINEERING

Figure 1. Identifying key resources and getting the
right people on site at the right time is crucial for
ensuring turnaround success.
from the local area, a further 25% from elsewhere in the UK
and the remaining 20% from overseas.
Right place, right time
Teams that have been built to tackle a specific project are
also subject to a certain drop-out rate. As plant
turnarounds are operations that must run to a strict
schedule, postponing them will only have significant
financial and logistical repercussions. Therefore, delaying a
project can only happen in the most extreme of
circumstances. For this reason, it is important to
over-resource (and over-hire) for such time sensitive
projects.
Since scheduling is critical, it is important to
understand that when building a timeframe for a plant
turnaround (with a set finish date and time), minor hold-ups
and delays are a reality that are practically impossible to
avoid. These setbacks must be built into the programme if
it is to run on time.
Front-loading the delivery of works is one way to
mitigate against the impact of any delays. By recruiting
more resources on site, up-front, and carrying out the most
critical parts of the overhaul as early in the programme as
possible, the project team can allow itself some flexibility
to revise the plan and still meet the schedule.
Safeguarding quality through smart
resourcing
From a contractor’s perspective, the key to taking on these
projects is to build teams of people around key facilities
who have a proven track record. Bilfinger employs a
recruitment strategy that groups people depending on
their experience with a particular site and the business,
which enables the maximisation of the proportion of the
personnel on the project team that have experience of
working with the company, or on a particular project, in the
past.
Operating in this way has had a considerable effect on
the cohesiveness of the team. More people on the ground
are familiar both with the way a company and its clients
like to work and, in many cases, with the other individuals
around them and the way that they work.
September 2017 32 HYDROCARBON
ENGINEERING
It also makes it much easier to manage health and
safety on site. With hundreds of people coming into a
new environment to work for a brief period, minimising
unexpected behaviours and ensuring every task is carried
out by a team with the right qualifications, training and
experience is vital. This is, arguably, much easier when
the proportion of new workers is kept to a controlled
level.
Getting on the same page
As with any outsourced contract, a proven strategy for
improving the likelihood of successful delivery is to
ensure that the whole project team is properly
incentivised. This means sharing both the pain and the
gains of the project with all partners taking part in its
delivery. In other words, the cost of any delays should
be shared out, but so should the benefits made as a
result of completing the job efficiently or ahead of
schedule.
This approach ensures that there is a true common
goal across the whole project delivery team, and can help
remove some of the issues that outsourcing relationships
can be subject to, such as inefficient communication
between client and contractor.
Case study: refinery turnaround in the
South of England
Bilfinger was called in by a leading global energy company
to deliver a major plant turnaround at one of the largest
refinery complexes in Europe, which involved the removal
and replacement of several vessels.
Once the inspection process had taken place, all of
the instrumentation and pipework was dismantled and
the teams oversaw the lifting and removal of the vessels
by crane. The heat exchangers were also stripped down to
their components, in preparation for them to be cleaned
and inspected before being rebuilt.
The project was completed in 20 000 working hours
with no reportable incidents and injuries, and involved a
team of 115 employees working on a split-shift system. A
robust resourcing strategy, which could deliver a talent
pool with the skills required for the work, was also
considered key to the success of the shutdown.
To achieve this, Bilfinger hosted a trade recruitment
event in Poland that would supplement its core UK-based
team with another 20 skilled contractors to work on the
project. Each new recruit was rigorously tested on their
skill levels, industry knowledge and safety awareness, and
received inductions in both Polish and English alongside
their colleagues to ensure effective integration and
understanding.
Conclusion
Plant turnarounds are a critical part of the safe and
efficient operation of any refinery, and how they are
carried out can have a direct impact on the bottom line
of an operation. Tackling the resourcing challenges and
building a team that has the specific experience and the
right dynamics to execute turnaround projects efficiently
can bring a significant boost in profitability.
Jennifer Gaines, Sulzer, USA, explains
why it is essential that every business has a
skills training programme in place to ensure
that the next generation retains the skills
and expertise of experienced workers.

TRAINING
TRAINING
TO
TO BE
THE BEST
THE BEST
I
nvesting in a comprehensive training programme is takes undergraduates that are learning basics in
very important to maintaining a high standard of theoretical engineering and places them in roles that
personnel competence that will benefit both will test and enhance their skills in project
customers and individual members of staff. management, engineering analysis and leadership. The
Starting with internal training, all employees should selection process for prospective interns starts with
be encouraged to expand their knowledge, and those careers fairs at accredited universities where students
that show a keen interest will make the most of the have applied for the programme.
investment being made in them. Of the hopeful candidates, a handful are selected
For young, potential new employees, many for the initial interview and, in the case of Sulzer, a
companies will offer an internship programme, which chosen few are then invited for a tour of the service

HYDROCARBON 33 September 2017

ENGINEERING
 centre, followed by interviews with shop managers,
superintendents and engineering staff. The final
selection is made based on their performance
during the interviews and their score from a
performance matrix.
Those aspiring engineers who are accepted into
the internship programme will be able to learn
about the capabilities of different departments and
the responsibilities of being a production engineer.
During this time, through working on different
projects, interns will also learn about the many and
varied industrial sectors that require precision
engineering solutions.
All interns should be supported throughout the
departments they are working in, as well as being
assigned a mentor, who will guide them through the
intensive learning process. As they gain an
understanding of the various roles within a
company, it will become more apparent which area
of engineering is most appealing as a future career.
Improving professional standards
It is important that throughout their employment,
new engineers are offered both internal and
external training in specialised engineering topics
that can help both the employee and the company
improve the breadth of their expertise. Along with
Figure 1. Practical training sessions are an important part of
reinforcing theoretical studies.
September 2017 34 HYDROCARBON
ENGINEERING
additional support, this will go some way to helping
employees complete professional licenses and
qualifications specific to their chosen industry, such
as oil and gas.
Of course, there is no substitute for ‘hands-on’
training and this should be applied in as many
different disciplines as possible. Within a large
service centre, there will be a wide selection of
specialist activities, depending on the main business
of the company.
From the more basic machining principles to
applying thermal barrier coatings to gas turbine
blades, the potential to learn can be enormous.
While some may choose to specialise in a particular
area, others may wish to maintain a broader outlook
and gain a more general understanding of several
areas of engineering.
However, when starting to work as an intern, it is
often the first time the candidate has been in
full-time employment. As such, there are many
other skills that will need to be learnt at the same
time. Health and safety is one of the most
important, but other skills such as communication,
ethics and quality management should also be
addressed with both interns and other new
employees.
Scaling the corporate ladder
Gaining a full appreciation of a company’s
capabilities and how they are delivered to
customers is an important part of working
within an organisation. By moving between
various departments within a company, an
employee learns not only about the variety of
services offered, but also which department is
most appealing from a professional point of
view.
As an employee’s experience increases,
their demands on the training resources will
change to keep pace with their career
development. Some prefer to specialise in a
specific section of engineering or industrial
sector, while others aspire to move into
management. In either case, continuous
training will remain an essential element of
the profession.
Capturing expertise
An employee’s value to the company
increases as they gain more experience, not
only for the expertise they can deliver to
customers, but also the knowledge they
possess can be shared with less experienced
employees. Capturing knowledge and
experience within an organisation is essential
to delivering a high quality and effective
service, even when the most qualified
personnel succumb to retirement.
Recording details of procedures and
engineering analysis in a database ensures

Figure 2. Interns have the opportunity to learn basic
engineering techniques as well as increase their
practical understanding of turbomachinery.
accurate customer records as well as retaining
essential information that can be used to improve
company procedures. In addition, procedures and
manuals for performing various engineering tasks
will also be used to train upcoming employees.
However, the most valuable projects (in terms of
new information) are those that pose a unique
challenge or require an innovative solution.
Gathering this data and creating a forum in which it
can be passed on to others working in a similar field
is very important in improving the efficiency of
future projects.
Encouraging achievements
Many professional qualifications, such as offshore
safety and emergency training, require records of
personal development through seminars, practical
experience and recognised training courses. As
employees add to their knowledge through various
training activities (both formal and informal),
maintaining an accurate record of these
achievements is a vital part of career development.
Employees are encouraged to attend technical
conferences and committee meetings, where new
topics can be explored, to widen their overall
knowledge and increase their value to the company.
Those with more experience can also take on the
role of an in-house trainer, passing on their
knowledge to others in a similar position.
Not all training has to remove an employee from
the day-to-day job, so productivity can remain
unaffected. When time away is required, training is
rarely wasted and is almost certainly of
simultaneous benefit to both the company and the
employee. Ultimately, this will all pay off with the
customer seeing a more efficient and effective
service.
Improving customer knowledge
While internal training is important to retaining and
expanding professional expertise, many companies
September 2017 36 HYDROCARBON
ENGINEERING
can also help their customers to improve the skills
of their own personnel. This training can be tailored
to suit the needs of individual customers, allowing
them to make cost-effective investments in their
staff.
Sulzer offers a range of training courses that are
aimed at customers who are involved in the daily
operation and maintenance of turbomachinery
equipment produced by any manufacturer. The aim
of these courses is to enhance the competencies of
the trainees, enabling them to improve productivity
and reduce downtime.
Depending on the roles of the trainees, courses
can look at theoretical principles along with the
design and operational characteristics of
turbomachinery equipment. This can lead to a
better understanding of how to specify a machine
correctly, which will, in turn, ensure the equipment
is operating efficiently and reliably.
Some customers may benefit from improved
knowledge in safe operation or effective
maintenance procedures. Training on the most
suitable predictive maintenance techniques can
provide simple techniques for reducing downtime
and maximising productivity. In every case, those
participating in the course should be able to
improve their understanding and add value to their
company’s operations.
When providing training to customers, it is
essential that they receive the most appropriate
courses for their needs. In doing so, they can
expand the knowledge of their staff and create a
better relationship with the training provider.
Sharing the wealth
The ability to gather knowledge is just the first step
in a company’s journey. Retaining that knowledge
and making sure that it does not migrate with the
natural wastage of employees is the next step.
Having the ability to share the expertise for the
benefit of both internal staff and customers is the
ultimate goal.
While this appears easy in principle, the ability
to learn and conserve new information and skills is
rarely matched with the ability to disseminate
expertise in such a way that makes it easy to take
on board. Therefore, in many cases, it will be
necessary to give those with the knowledge the
necessary tools to collate their skills and pass them
on to a trainer who can formulate the most
effective way to communicate it to both employees
and customers, as necessary.
Ultimately, training any individual requires a
willingness on both sides. An eager employee who
is given opportunities to learn will make the most
of any investment. At the same time, a company
that believes in supporting its staff in improving
their knowledge will benefit from a more skilled
workforce and a more productive working
environment.
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September 2017 38 HYDROCARBON
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 Peter
Peter P
Piotr
iotrowski, Honeywell UOP, USA, and Austin Schneider,
Crystapha
hase,
se, U
USA,
SA, provi
provide a case study in how refineries can
proactively prote
rotect
ct agains
against uunexp
nexpected silicon poisoning.
O
ver the past several years, silicon has become
much more prevalent in the oil and gas industry.
Before, refineries relied on silicon compounds in
the delayed coking unit to prevent foaming in
coker drums. Now, upstream companies are starting to
favour silicon for its lubricating ability, which allows
companies to move oil quickly through pipelines, as well as
load and unload ships faster.
While pipeline lubricant applications benefit upstream
companies by improving short-term profits and efficiencies,
the use of silicon compounds also comes with inherent
performance risks for refineries downstream.
Silicon is a contaminant that, when found in crude oil,
can work its way into previously unexpected places in the
refinery, adversely affecting the units it enters. The result
is shorter catalyst cycle lengths, which lead to more
frequent reloads and more overall downtime for the unit
– all of which lead to increased expenses and decreased
profits.
Silicon: origin and destination in the
refinery
Silicon-containing compounds, like polydimethylsiloxane
(PDMS), are great anti-foam agents in the coking unit’s coker
drums, and refineries have known how to effectively plan
for its impact on downstream processing. With increased
upstream usage, however, silicon is now entering refineries
in the crude oil, affecting many more units and types of
hydrotreaters, refinery-wide. The presence of silicon in
crude oil negatively impacts the whole refinery.
Figure 1 highlights the historical source of silicon in the
refinery (the coker), as well as the negative impact of
refinery-wide silicon presence. Unless the units (particularly
hydrotreaters and hydrocracking units) can be properly
defended, catalysts will lose their activity and see a
decreased life span.
The chemistry of silicon
Silicon compounds interact with the alumina base of
hydrotreating catalyst. The reaction creates a strong
chemical bond, which is difficult to break. This is why
silicon is considered a permanent poison.
Instead of interacting with the active metal sites on the
hydrotreating catalyst directly, over time the buildup of
silicon impedes and prevents access to these active sites.
This is what causes a permanent loss in the catalyst’s ability
to remove sulfur and nitrogen.
Figure 2 illustrates the interaction between silicon
compounds and hydrotreating catalyst.
The impact that silicon has on hydrotreating catalyst
performance is quite severe. For every increase of 5%
weight of silicon (increase of 10% weight of silica) on a
hydrotreating catalyst, 10% of hydrodesulfurisation (HDS)
activity is lost and 50% of hydrodenitrification (HDN)
HYDROCARBON 39 September 2017
ENGINEERING

Figure 1. Silicon origins and destinations in the refinery.
Figure 2. Silicon poisoning reaction of a
hydrotreating catalyst.
Figure 3. Increase in silicon pickup vs catalyst surface
area (assuming same metals loading and density).
activity is lost. (As a reference point, a typical
hydrotreating catalyst has a maximum silicon pickup
capacity of 8 – 10% weight.)
This scenario is where the use of a silicon
protection solution can prevent the deactivation of
high activity hydrotreating catalyst, as well as expensive
downstream catalysts, such as reforming catalyst and
hydrocracking catalyst.
Prevent deactivation and solve the
silicon problem
Previously, silicon protection catalyst existed to control
the limited silicon migration from the coker unit. Now,
September 2017 40 HYDROCARBON
ENGINEERING
silicon is beginning to affect
the entire refinery chain.
To combat this reality, new
silicon protection catalysts
that are robust enough to
handle a wide range of feeds
while maintaining maximum
silicon uptake must be created.
Honeywell UOP’s research
team developed the
HYT-9000 series of catalysts
to minimise silicon’s harmful
impact on the refinery’s
valuable units. This family of
catalysts was designed around
advancements in the
company’s alumina technology
spanning the range of high
silicon capacity to high hydrotreating activity.
The technology behind the catalysts relies on the
concept that increasing the surface area per unit
volume in turn increases the amount of silicon uptake.
Honeywell UOP’s proprietary support composition
further improves silicon pickup, preventing deactivation.
Figure 3 illustrates the company’s findings that the
weight percentage of silicon pickup increases as the
catalyst surface area increases.
Frontline protection
Honeywell UOP developed HYT-9110, HYT-9119 and
HYT-9129 as a frontline in silicon protection across the
refinery. HYT-9119 provides maximum silicon pickup,
while also having HDS and HDN activity from the
presence of active metal sites.
HYT-9110 also provides maximum silicon pickup but
contains no active metals sites. This makes it ideal in
situations like gasoline hydrotreating, where silicon
pickup is needed, while not saturating important feed
components like olefins.
HYT-9129 combines the best aspects of the
company’s silicon pickup technology and high activity
hydrotreating technology. The result is a catalyst that
can be both a high activity silicon trap catalyst, as well
as a silicon tolerant, high activity naphtha hydrotreater
(NHT) catalyst. This is especially useful for units with
limited reactor volume. These units can now benefit
from increased silicon resilience without a loss of
overall activity. The end result is longer cycle life,
maximising profits from each loading of catalyst.
Case study
Crystaphase provides particulate trap and pressure drop
mitigation solutions for reactors in refining,
petrochemical and chemical plants worldwide.
Honeywell UOP’s research and experience has shown
that Crystaphase’s CatTrap® is an excellent filtration
solution for hydroprocessing (hydrotreating and
hydrocracking) to protect against particulates and
pressure drop buildup, both of which limit unit cycle
lengths.
 Hydroprocessing

From technical experts working together with you to Unity™

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© 2017 Honeywell International. All rights reserved.

 while preventing delta pressure
buildup.
The next case study (below)
compares the same conventional
hydrotreater offering to a system
using the latest silicon
protection solutions.
CatTrap 10 and 30 are
replaced with ActiPhase Si Trap
10 and 30. HYT-9119 is again
added, but now Honeywell
UOP’s high activity NHT catalyst,
HYT-1119, is replaced with
HYT-9129, the new silicon
tolerant, high activity NHT
catalyst.
Figure 4. Case study one: conventional hydrotreater vs Honeywell UOP offering. All layers of the hydrotreater
loading now contain silicon
protective solutions. The
combination of ActiPhase,
HYT-9119 and HYT-9129 can
increase the reactor’s overall
silicon capacity by up to 50%.
Now, a unit that is normally
reloaded once a year due to
silicon poisoning can remove
two reloads from a six year
period. The net result is two
fewer times to purchase catalyst,
two fewer times to hire catalyst
loading contractors, two fewer
times where refinery employees
need to suit up for turnaround
work, and two fewer times the
unit is down and not producing
Figure 5. Case study two: conventional vs Honeywell UOP Max Si Protect.
product.

Figures 4 and 5 illustrate a case study of a NHT unit Conclusion

comparing a conventional offering for a hydrotreater
containing silicon in feed with Honeywell UOP’s offering.
Beginning with Crystaphase’s CatTrap for filtration,
Honeywell reduces the filtration volume that is required
while improving the resistance to pressure drop. The
HYT-9119 replaces the conventional silicon trap catalyst layer
and provides up to 25% more silicon capacity within the
same reactor volume.
If the unit typically shuts down for reload once every
year due to silicon poisoning, using HYT-9119 can remove an
entire reload from a five year period. This translates to one
less time to purchase catalyst, one less time to hire catalyst
loading contractors, one less time where refinery employees
need to suit up for turnaround work, and one less time the
unit is down and not producing product.
In addition, Crystaphase’s ActiPhase® technology
enhances CatTrap to perform active functions in a complete
reactor catalyst solution.
In cases where silicon protection is vital, ActiPhase Si
Trap is helpful when designing a catalyst loading. The
activated CatTrap discs provide the unit with additional
silicon uptake capacity, further extending unit cycle length
Silicon compounds are finding their way into areas of the
refinery chain that have not historically dealt with such
contaminants. Hydrotreaters with feeds ranging from
naphtha to distillates are now at greater risk from a
permanent poison that reduces catalyst activity and
decreases unit cycle lengths.
Awareness of this expanding issue is the first step refiners
can take to deal with this modern refinery problem. With
increased knowledge about silicon contamination, the need
to be proactive in protecting high activity, expensive
catalysts is vital.
Silicon removal solutions, such as the technology
detailed in this article, are designed to protect against
silicon poisoning. The combination of these materials
provide a highly efficient use of reactor volume. For refiners
who have variable feeds and/or unknown contaminant
levels, silicon removal solutions provide insurance against
cycle life degradation and profit loss.
Maximising silicon uptake capacity with new generation
catalyst and active filtration allow refiners to get the most
out of their units, extending cycle lengths and maximising
profits.

September 2017 42 HYDROCARBON

ENGINEERING
A REFRESHING
BOOST Gene Mueller, Dr Michael Severance,
and Dr Axel Düker, Clariant Catalysts,
examine how a new generation of phosporic
acid catalysts can lead to more profitable and
sustainable fuel upgrading in FCC refineries.

R
efineries have numerous possibilities for utilising the short chain olefins that are
produced by fluid catalytic cracking (FCC) units. In case FCC is not only intended for
gasoline production, olefins are separated, purified and upgraded. The most common
application for propene is polypropylene, the demand for which is still growing.
Butenes are used in countless applications, such as methyl tertiary-butyl ether (MTBE), alkylation
and metathesis. Besides these typical applications, there are around 45 refineries worldwide that
apply a different flow scheme for FCC olefins, with good reason. The basic difference is the target
product, which is either polygasoline, nonene or tetramer. Depending on the final product, there
are different requirements on the unit regarding reactor design, temperature range and choice of
catalyst. All of these factors demand attention.
Regardless of the application and reactor design, operators require optimal catalyst
activity, selectivity and lifetime. Detailed reports already exist about the performance of
current generation catalysts.1 These are installed in polygasoline plants as well as in
higher olefins units for the production of nonene and tetramer. The catalysts are
suitable for all types of unit design, such as tubular and chamber reactors, with
or without light polymer recycle, and with or without quench.
One may ask why so much effort is spent on further
improving catalysts for such old technologies. Even
though the technology is long established,
the application and the use of

HYDROCARBON 43 September 2017

ENGINEERING
 lower olefins is of great importance to refineries. As such,
the development of more advanced catalysts is a perfect
example of bringing a positive change to traditional
applications.
The PolyMax® series of catalysts belong to the group of
phosphoric acid catalysts. In these catalysts, a special
silicon-phosphate carrier immobilises the catalytically
active phosphoric acid. The right water partial pressure is
needed to form the right quantity and strength of
phosphoric acid during operation. The reaction of water,
silicon-phosphate, phosphoric acid and olefins is complex
and crucial for optimum catalyst performance.
Figure 1. Laboratory test: catalyst porosity and
activity.
Figure 2. Laboratory test: catalyst activity.
Figure 3. A 2000 bpd polygasoline unit – reactor inlet
temperature.
September 2017 44 HYDROCARBON
ENGINEERING
Before introducing new catalysts to the industry,
intensive testing was performed at the Clariant Innovation
Center in Louisville, Kentucky, US. These results can now be
compared with actual performance in commercial units.
This article will describe the laboratory test results and
compare them with the data measured in a 2000 bpd
polygasoline facility. The refinery operates a typical
polygasoline unit with frequently changing feed flow rates
and compositions in order to buffer the fluctuations of the
FCC unit. Therefore, all operating parameters of the
polygasoline unit are fluctuating over a wide range. This
makes the comparison of different catalysts quite
challenging.
Catalyst activity
The activity of a fresh catalyst is influenced by the
operating conditions and the catalyst properties. One of
the most important parameters is the hydration state of
the catalyst, which is calculated as acid strength of the
catalytic active phosphoric acid H3PO4. Water partial
pressure dictated by the operating parameter defines the
catalyst hydration. Even at optimum catalyst hydration, the
operators cannot observe optimum catalyst activity, as the
acid is not accessible to the olefin to react.
Figure 1 shows the results of laboratory tests, proving
that catalyst porosity drastically influences the catalyst
activity. The test simulates extreme conditions to achieve
an accelerated catalyst ageing within 200 hrs at 420˚F
(216˚C). The feed is a 55/45 wt./wt. mixture of propene and
propane.
Under the same test conditions, catalysts with different
pore volumes show different stability of the initial activity.
Figure 2 shows that the catalysts with the higher pore
volume start at a higher initial activity and maintain the
activity at higher levels throughout the test run.
In polygasoline units, higher catalyst activity can be
easily utilised by simply lowering the inlet temperature to
the reactor. Figure 3 shows the reactor inlet temperature in
a 2000 bpd polygasoline unit.
Operators can now use the higher activity to run the
unit at up to 40˚F (22˚C) lower reactor inlet temperature,
thereby significantly reducing operating costs. The value of
this saving is difficult to calculate, since it depends on the
set-up of each individual unit. It is, however, very easy to
calculate the benefit of higher polygasoline yield. Figure 4
shows yield improvements when operating with the more
active catalyst.
With the more active catalyst, polygasoline yields
increased from approximately 32% to approximately 40%.
This means higher profits day by day. The value of one
research octane number (RON) barrel varies depending on
the region; it could easily be US$1/RON bbl.
The benefit of the higher catalyst activity is, of course,
the higher olefin conversion rate, resulting in lower olefin
concentrations of the low-boiling byproducts propane and
butane. Some refineries do not separate propane and
butane but sell the low boilers as LPG. As the sale price of
LPG depends on the olefin content in many regions, the
higher active catalyst contributes to higher profitability
even with the byproducts.
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 Catalyst lifetime
Pressure drop over the reactor typically dictates the run
length of the installed catalyst. Limiting the speed of
pressure drop evolution guarantees longer service life.
It is an accepted theory that pressure drop evolution
can be slowed by allowing the catalyst more space to swell
or expand. As has been demonstrated in many reference
units, the pore structure of PolyMax catalysts provides
sufficient room to swell. In combination with the nature of
the silicon-phosphate phase, this allows the catalyst to stay
on-stream for a longer period.
Figure 4. A 2000 bpd polygasoline unit –
polygasoline yield.
Figure 5. Laboratory tests: pressure drop evolution.
Figure 6. A 2000 bpd polygasoline unit – pressure
drop (simplified).
September 2017 46 HYDROCARBON
ENGINEERING
Figure 5 shows the results of laboratory tests that
compare different catalyst generations. The graph plots
catalyst activity against pressure drop after the test.
Although data measured in such tests cannot be directly
transferred to pressure drop figures in commercial units,
they allow one to understand trends and extrapolate
results into performance predictions. Figure 5 suggests that
the pressure drop evolution of the latest catalyst
generations should be much slower than that of standard
catalysts.
Figure 6 summarises the pressure drop curves of a
commercial polygasoline unit. It shows the last 10 runs with
standard catalyst, and compares it with the first run of the
new catalyst. The peaks of all curves were smoothened,
and the plots show the borderlines of all runs. As the unit
is subject to many upstream changes, it is obvious that the
catalyst life is also influenced by many factors unrelated to
the catalyst itself.
Catalyst selectivity
Selectivity is not of much interest to polygasoline units, as
the typical objective is to treat surplus FCC olefins or to
swing production capacities with the alkylation unit. It is,
however, beneficial to produce gasoline with higher octane
numbers.
Producers of the higher olefins, nonene and dodecene
(tetramer), focus on the product slate. Being able to produce
just a few percentage points more nonene changes the
economics of operation. During periods when the refinery
targets tetramer, a higher nonene concentration in the
reactor effluent (hence, in the light polymer recycle stream)
guarantees higher tetramer production.
When starting from propene, the selectivity to nonene
depends on many parameters, such as catalyst hydration,
temperature and pressure. It is an accepted theory with
phosphoric acid catalysts that a weak acid at low operating
temperatures favours the formation of shorter chains. A
strong acid at a higher temperature favours the formation
of long chains. Consequently, when the target is the
production of nonene, the operating temperature should
be as low as possible and the acid strength should not be
too high.
Under given operating conditions, however, the catalyst
can influence the selectivity to nonene or tetramer. Figure 7
shows how significant the different pore structure
combined with the higher pore volume is in favouring the
formation of nonene.
The selectivity results of the laboratory tests can be
directly transferred to commercial units. Figure 8 shows the
difference in nonene yield when switching from a standard
catalyst to a catalyst with a special pore structure. The
nonene concentration in the liquid product increases from
near 47 wt.% to approximately 55 wt.%. The higher catalyst
selectivity also leads to a lower final boiling point (FBP) of
the liquid fraction (in this example, the FBP dropped from
215˚C to 205˚C).
Sustainability and spent catalyst
Sustainable production and use of the catalyst are
important considerations when developing new catalysts.
Hydrocarbon Engineering App

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Figure 7. Laboratory test: catalyst porosity and
selectivity.
Figure 8. Commercial nonene unit – selectivity.
NEW STRADDLE CARRIER DESIGN WHICH WILL GREATLY IMPROVE YOUR BUNDLE HANDLING
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The new phosphoric acid catalysts are designed to perform
without any promoter, and are produced from naturally
occurring silica sources and phosphoric acid. After its
useful life, the catalysts can be recycled to fertilizer or
other phosphorus-containing compounds, such as
phosphoric acid.
Data relating to the current generation of phosphoric
acid catalysts confirms customer interest in recycling, with
more than 65% of spent catalysts recycled to fertilizers.
Clariant is working to improve this ratio and is also
investigating other innovative processes starting at the
phosphate rock mine or including secondary phosphorus
sources, such as sewage sludge ash.
Conclusion
The first commercial applications of the latest catalyst
generation confirm the promising results of the laboratory
tests. With the advantages of the new generation of
phosphoric acid catalysts, refineries can now generate
considerable profits from units that were previously
neglected. It is difficult to estimate the total financial
benefit as this depends on each refinery’s set-up and
location.
Note
PolyMax® is a trademark of Clariant, registered in many countries.
Reference
1. GEBERT, S., OVIOL, L. and DÜKER, A., 'Maximising potential',
Hydrocarbon Engineering, (November 2015), pp. 57 – 60.
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ACHIEVE
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Andy Huang, Gary Cheng, Ann Benoit, and Bob Riley,

W. R. Grace & Co., USA, explain how refiners can
meet the need for higher octane gasoline while
ensuring sulfur content remains within regulations.

O
ver the last two decades, the refining
industry has weathered volatile market
conditions and increasingly stringent fuels
regulations. In North America, refiners are
tasked with meeting challenging ultra-low sulfur
gasoline regulations (Tier 3). Also, as more
turbocharged vehicles enter the market, the demand
for premium, higher octane gasoline will also increase
as automakers begin recommending or requiring the
use of higher octane gasoline.
Tier 3 regulations will create challenges as refiners
turn to higher gasoline post-treatment severity for
increased desulfurisation, which will negatively impact
octane. Under new regulations, refiners are required to
produce gasoline with an annual average sulfur
content of ≤10 ppm, with a maximum gasoline sulfur
cap at the refinery gate of ≤80 ppm. Fluid catalytic
cracking (FCC) naphtha is the main ‘problem stream’, as
it comprises 40 – 50 vol% of finished gasoline volume
and contributes 80 – 90% of the total sulfur in the
refinery gasoline pool.
Meeting sulfur limits will require operating
adjustments, catalyst formulation changes, and/or
capital investment. Operating strategies that reduce
sulfur may limit gasoline octane, reducing the
flexibility of the refinery’s gasoline blending system.

HYDROCARBON 49 September 2017

ENGINEERING

Figure 1. Gasoline RON and gasoline yield as a function of
zeolite unit cell size.
Incremental production from the reformer or alkylation
complex can alleviate some of this pressure, depending
on the refinery configuration and capabilities.
Capital solutions around the FCC include feed
and/or product hydrotreating, or other sulfur removal
units. Most refiners have some form of feed and/or
product hydrotreating in place, and these systems are
effective at reducing the sulfur content of gasoline
streams. However, there are some tradeoffs; increased
hydrotreating severity can reduce gasoline octane, and
octane preservation is a key feature in the design of
these systems. Also, increasing hydrotreating severity
increases the refinery H2 consumption and reduces the
hydrotreater run length. For some, pre-treating FCC
feed sufficiently for sulfur minimisation results in a
heat balance challenge for the FCC unit. Some of these
challenges can be exacerbated at refineries using
shale-derived crudes, which are naturally light and
produce low sulfur, but also low octane gasoline.
FCC operating strategies include undercutting
gasoline for sulfur control, and control of FCC unit heat
balance parameters to ensure that the FCC produces
enough feedstock to keep the alkylation unit full.
Often, refiners can face FCC unit limitations (e.g. wet
gas compressor capacity) when pursuing these changes,
but they are quick and often easy to implement.
Catalytic solutions offered by W. R. Grace & Co. for
gasoline sulfur reduction convert sulfur molecules to
H2S in the FCC, reducing the amount of sulfur that ends
up in FCC naphtha. These solutions can be
implemented in concert with feed/product treating to
improve octane preservation. Additionally, Grace’s
catalytic solutions to maximise alkylate production can
improve the overall refinery octane balance.
Most refiners can benefit by employing a
combination of strategies to maximise refinery octane.
In case studies presented at the American Fuel &
Petrochemical Manufacturers (AFPM) Annual Meeting in
March 2017, Grace examined several scenarios regarding
the challenges and choices available to refiners
including:
„ Feed and operational changes to maximise LPG
olefins to the alkylation unit and improve octane,
September 2017 50 HYDROCARBON
ENGINEERING
undercutting FCC naphtha to reduce post-treat
requirements and improve octane.
„ A catalytic solution to maximise LPG olefins
to the alkylation unit and improve octane
additives to boost LPG olefins to the
alkylation unit and improve octane.
„ Gasoline Sulfur Reduction (GSR®) technology
to reduce post-treat requirements and
preserve octane.
„ Combining multiple approaches.
Case one: catalytic solutions
Modifications can be made to the FCC catalyst
itself to drive octane; however, each of these
changes will have other impacts on the FCC yield
profile and overall unit profitability.
Within traditional FCC technologies, refiners
can pursue zeolite modifications to drive octane.
Most commonly, a reduced zeolite unit cell size
will favour olefin production, which will lead to
higher gasoline octanes, as well as higher olefin
production for the alkylation unit. However,
reduced zeolite unit cell size is typically achieved
by reducing zeolite rare earth stabilisation, which
reduces the acid site density of the zeolite,
leading to lower activity per unit of zeolite.
Catalyst suppliers can increase zeolite content up
to a point, depending on the catalyst family, but
beyond this point, the refiner will have to consider
alternate catalyst formulations or higher catalyst
additions if in-unit activity is not maintained.
Figure 1 shows the relationship between FCC
gasoline octane and zeolite unit cell size in
traditional FCC catalysts.
In recent years, the company has
commercialised a new catalyst technology that
produces both high octane gasoline and high value
alkylation feedstock, preferentially making C4=
(when compared to a traditional light olefin
additive).
The solution incorporates isomerisation
activity within the catalyst by using two different
types of zeolite – a traditional Y zeolite and a
specially-tuned pentasil zeolite. The incorporation
of isomerisation activity into the catalyst particle
itself results in a more desirable yield pattern than
would be realised by use of a traditional octane
boosting FCC additive. The catalyst yields both a
higher octane FCC gasoline and an improved
butylenes-to-propylene ratio when compared to
ZSM-5 additives. The zeolite isomerisation activity
increases the yield of FCC butylene and isobutane,
keeping the alkylation unit full and maintaining
refinery pool octane.
Case two: additive solution
In addition to catalytic solutions, many refiners
have experience using light olefins (LO) additives
as another way to boost LPG olefins as alky feed
and increase FCC gasoline octane. Conventional
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Figure 2. Effect of ZSM-5 additive on LPG olefins and gasoline RON.
Figure 3. Reduction pathway of thiophenic sulfur species to H2S.
Figure 4. Reaction mechanism of sulfur removal.
LO additives, generally containing ZSM-5 zeolite, are
designed to increase propylene and butylene yields
at the expense of low octane gasoline range
molecules. These incremental LPG olefins can be
sent to the alkylation unit to produce higher octane
alkylate for the refinery gasoline pool. Many of these
conventional LO additives tend to be more
propylene selective, thus providing an excellent
source of propylene if the refinery is integrated with
a chemical plant. These additives can also be
modified to isomerise low value straight chain
olefins in the FCC naphtha into higher octane
branched components.
Figure 2 illustrates the effect of conventional LO
additives on LPG olefins yield. The extent of
September 2017 52 HYDROCARBON
ENGINEERING
incremental LPG
olefins depends on
several different
factors, including
operating conditions,
feedstock, base
catalyst, and the
additive itself. High
activity additive and
low hydrogen transfer
base catalyst is the
recipe to maximise LPG
olefins at a constant
additive usage.
Conversely, low
activity additive and
high hydrogen transfer base catalyst will
reduce the extent of improved LPG yields.
The effect of conventional LO additives on
gasoline research octane number (RON) is
seen in Figure 2. As base RON increases, the
incremental improvement diminishes,
therefore, the starting or base octane must
be considered when using LO additives.
Due to increasing demand for higher
octane gasoline in an ultra-low sulfur
environment, many refiners are looking for
ways to fill the alkylation unit. This creates
a higher demand for butylenes, as they are
better alkyl feed components than
propylene. As a response to this demand, a
novel family of additives has appeared that
are more butylenes-selective than
conventional LO additives. These
butylenes-selective additives are
formulated specifically to help refiners fill
their alkylation units with a preferred
feedstock.
Selection of additive types will
ultimately depend on unit objectives,
market demand, and downstream unit
integration. Regardless of the additive
selection, using an additive approach allows
refiners to quickly respond to market needs
and changes without going through a
catalyst reformulation. This approach helps refiners
to maximise unit profitability and minimise risk of
poor unit performance.
Case three: gasoline sulfur
reduction technology
One disadvantage of using a higher severity of
gasoline post-treatment to achieve desulfurisation is
the subsequent decrease in post-treated octane. As a
result, many refiners around the world, including
North America, have used FCC gasoline sulfur
reduction technology as a means of minimising this
negative impact on octane. Furthermore, many
refiners in North America are currently evaluating
the option to utilise FCC gasoline sulfur reduction
 Drawing upon the
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Grace custom catalyst solutions, co-developed with
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chemistry. They’re designed to add to your bottom line.

In some cases, the difference between our refinery

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value to its customers
through collaboration.

Visit grace.com/value
technology as part of their overall strategy to
comply with Tier 3.
North America is not the first region to face the
challenge of achieving 10 ppm gasoline sulfur. Japan
was the first country to implement such a national
limit in January 2008. However, the Japanese
petroleum industry moved on a voluntary basis to
this level at the beginning of 2005. The size of this
challenge was even bigger considering that a
maximum of 10 ppm sulfur was imposed, rather than
the weighted average of 10 ppm sulfur under the
Tier 3 legislation.
The chemistry of sulfur reduction in the FCC has
been heavily studied and documented in prior
works. Sulfur reduction mechanisms and
effectiveness vary depending on the technology
employed and the feed and unit conditions. Figure 3
shows the general pathway for the reduction of
thiophenic sulfur species in FCC gasoline.
Furthermore, as part of its product development
and research efforts, Grace’s R&D team undertook
extensive efforts to analyse the exact mechanisms
of sulfur reduction in the FCC. The reaction
mechanism for sulfur removal from the FCC has
been proposed based on that work (Figure 4).
One of the important aspects of this mechanism
is that the sulfur in the thiophenic species is
catalytically converted to H2S in the FCC unit,
Constantly changing market conditions demand new approaches. That’s why we offer
tailored services to tackle your evolving challenges. The goal: to make your plant even
more profitable. The name says it all: PerformanceXperience®
resulting in no incremental formation of regenerator
SOX . In all commercial applications, the incremental
H 2S created is so small that it is within the
measurement error for detection in the FCC mass
balance.
Conclusion
Tier 3 gasoline regulations, as well as other low
sulfur gasoline regulations around the world, will
put increasing pressure on refiners to maintain
octane pool levels while meeting ever lower levels
of sulfur content in refinery gasoline. Refiners have a
variety of options to manage pool sulfur, depending
on their configuration and local markets. Operating
strategies include the selection of FCC cut points
and reactor temperature. Feedstock selection can
also play an important role in octane production;
shale and other paraffinic feedstocks can be
detractors to octane, and naphthenic and aromatic
feedstocks can be contributors. Catalysts and
additives specifically designed to either produce
higher octanes, higher LPG olefins (especially C4=),
or both, can add significant value to refiners’
operations. Finally, catalytic gasoline sulfur
reduction can play a role in minimising octane loss
in gasoline post-treaters. Many refiners will consider,
and ultimately employ, several of these strategies in
parallel to maximise refinery octane.
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R E L I E F
Ron Butterfield, Tom Ventham,
Paul Diddams and Martin Evans,
Johnson Matthey, explore how
to prevent FCC afterburn in the
downstream industry.

H
eartburn can ruin someone’s day if it is not
controlled or prevented. For a fluid catalytic
cracking (FCC) engineer or operator, ‘afterburn’
can also ruin a day if it is not controlled or
prevented. Afterburning is any increase in the flue gas
temperature that may occur in the dilute phase,
cyclones, or flue gas where there is less catalyst
present to absorb the heat of combustion. It can lead
to regenerator inefficiency, high cyclone temperatures,
lower than optimum riser temperatures (if circulation
limited) and carbon monoxide (CO) emission
excursions. CO promoting additives are used to control
afterburning and minimise CO emissions. Both platinum
and non-platinum based CO promoters can achieve
afterburn and CO emissions control. However, platinum
based promoters generally increase NOX emissions

HYDROCARBON 55 September 2017

ENGINEERING
 substantially, while non-platinum based promoters are
normally used to minimise NOX emissions.
The basic function of the FCC regenerator is to
remove the carbon, in the form of coke, from the
circulating catalyst to restore the equilibrium catalyst
activity for cracking in the riser. Carbon combustion
can be considered to take place in two steps in the FCC
regenerator.
Figure 1. Afterburn vs regenerator dense bed
temperature.
Figure 2. FCC Air Distributors.1
Figure 3. NOX emissions (ppm vs days).
Figure 4. NOX ppm vs Ecat Pt ppm.
September 2017 56 HYDROCARBON
ENGINEERING
C --> CO Low heat of combustion (111 kJ/mol)
C --> CO 2 High heat of combustion (394 kJ/mol)
CO --> CO 2 High heat of combustion (283 kJ/mol)
The first reaction step burns the carbon on the
coked catalyst to CO with a low heat of reaction. The
second reaction oxidises the CO to carbon dioxide
(CO 2) with a much higher heat of reaction. The second
reaction needs to take place in the dense bed of the
regenerator where the catalyst can utilise its higher
specific heat capacity vs the gas phase to absorb the
heat of combustion, which is transferred to the riser to
heat and vaporise the feed and help drive the
endothermic catalytic cracking reactions. In most full
burn units, some of the carbon is not fully oxidised to
CO 2 in the dense phase because of slip, imperfect
mixing, or simply because the residence time in the
regenerator bed is insufficient to complete this
reaction. The dense bed coke burning capacity can
become limited due to insufficient oxygen (air blower
capacity), poor air distribution, high feed carbon
content, low catalyst levels in the regenerator or higher
than normal feed rates. If all the CO is not burnt to
CO 2 in the dense bed, the remaining CO will continue
to burn in the dilute phase where there is insufficient
catalyst present to absorb the heat of CO oxidation,
thus resulting in a high temperature rise of the flue gas
that is referred to as ‘afterburning’.
Regenerator afterburning
The increase in flue gas temperature as a result of
afterburning may limit overall unit throughput or
feedstock flexibility. High levels of afterburning may
also result in serious damage to internals, leading to
premature shutdown and costly repairs. Typically, there
are two types of afterburn observed: kinetic limited
and distribution induced. Kinetic limited afterburning
occurs due to insufficient regenerator bed residence
time for complete combustion. Distribution induced
afterburning is caused by poor air and/or catalyst
distribution, and is frequently caused by inherent
design features and/or air grid mechanical failures.
Kinetic limited afterburning
Kinetic limited afterburning is characterised by well
dispersed afterburning across regenerator cross section,
high superficial velocities, low bed levels and low bed
temperatures. The typical solution is to raise the bed
level, increase bed temperatures and add CO promoter.
Kinetically limited units generally respond well to CO
promoter (Figure 1).
Distribution induced afterburning
Distribution induced afterburning is characterised by
localised afterburning, which is induced by poor air
and/or catalyst distribution, resulting in the mixing of
CO and O2 rich zones above the dense bed. This type
of afterburning does not respond as well to CO
promoter. If possible, the hotspot temperature should
be monitored as promoter concentration increases.
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 The hotspot temperature will decrease until the excess
O2 is fully consumed in the affected region. Continuing
to increase promoter additions after the temperature
drop has ceased has little or no effect on the
regionalised afterburning. A normally well functioning
unit, which begins to have increased afterburn along
with a change in losses or equilibrium of power
spectral density (PSD) indicates air grid damage
(Figure 2).
CO promoters
There are two basic types of CO promoters that
improve the kinetics (speed) of the oxidation of CO to
CO2 in the regenerator: platinum and non-platinum
promoters. Platinum based promoters can improve the
kinetics (speed up the reaction of CO to CO2) but have
a high propensity to catalyse the production of NOX
from feed nitrogen that ends up in the coke.
Non-platinum based promoters incorporate a
proprietary mixture of metals that also improve the
kinetics of CO to CO2 , while producing significantly
less NOX than platinum containing additives.
Figure 5. Afterburn vs days.
Table 1. Johnson Matthey’s COP-NP effectively
controls NOX
Average NOX Average additions
(ppm) (lb/d)
Additive X 48 95
Additive P 43 75
JM COP-NP TM
40 59
Figure 6. NOX ppm decrease.
September 2017 58 HYDROCARBON
ENGINEERING
CO promoter NOX response
Commercial data shows the decrease in NOX emissions
with the shift from platinum based CO promoters to
non-platinum CO promoters such as Johnson Matthey’s
COP-NP that contains no platinum (Figure 3).
NOX emissions are directly related to the
equilibrium catalyst COP platinum content (Figure 4).
COP-NP controls the regenerator afterburn, allowing
lower addition rates (Figure 5).
Back-to-back commercial data
A major western European refinery performed a set of
three back-to-back trials on the FCC unit to find the
optimum low NOX CO promoter for operations. In this
case, NOX emissions are a concern because the refiner
elected to use antimony to passivate the negative
effects of nickel coming in with the feed. Use of
antimony, which is common with residue FCC units and
FCC units that suffer from wet gas compressor or delta
coke constraints, has been observed to significantly
increase NOX in many cases. The NOX producing effect
of antimony can be magnified, for example, in a unit
that has mitigated other sources of NOX , such as
removing platinum based CO promoter, minimising
maldistribution of spent catalyst and air, and reducing
excess oxygen to the lowest level for stable operation.
There are also cases where the regenerator design
greatly impacts the sensitivity of NOX to antimony use,
e.g. combustor-style regenerators generally produce
low baseline levels of NOX , hence these types of unit
can be susceptible to relatively large NOX increases
when introducing a NOX catalysing material such as
antimony.
In the case of this European refiner, historical
attempts to introduce antimony had resulted in a 300%
increase in NOX . In another case, a small amount of
foreign antimony entered the FCC unit and increased
NOX by 130%. If the refiner performing this
back-to-back test was to be permitted to add antimony
to its FCC operation continuously, then its baseline
NOX would have to be brought down sufficiently to
allow the increased NOX (expected when introducing
antimony) to be accommodated without exceeding
maximum NOX emissions limits.
Three low NOX CO promoters were tested in a
commercial FCC unit in sequence (Table 1).
NOX control
NOX reduction was improved by 17% when using
COP-NP, compared to the base case. The observed NOX
emissions were also more stable for this promoter, at
15 – 17% lower than the base case (Figure 6).
CO promoter addition rates
Each promoter was placed at a consecutively lower
average daily addition rate. Since all low NOX CO
promoters can catalyse the formation of NOX , lower
observed NOX emissions can be derived from requiring
to add less CO promoter. This is only achievable if the
CO promoter that is being used is more effective for
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 afterburn and CO control. The required COP-NP
average daily addition for effective afterburn control
was 37% lower than the base case (Figure 7).
NOX and promoter addition rates
The company’s promoter provides low NOX emissions
with a tight distribution. This can be of critical
importance as the repeatability of response can be
equally or even more important to refiners to ensure
confidence that emissions limits will not be exceeded
when the operation is otherwise stable.
Part of the reason for the disturbed and
inconsistent response in the first low NOX CO
promoter trial may be due to the CO promoter being
added as a pre-blend in the fresh catalyst. This
approach gives many disadvantages as blending
additional additive components can be non-ideal,
meaning variable amounts of CO promoter are
Figure 7. CO promoter decrease.
Figure 8. NOX ppm histogram.
Figure 9. CO promoter usage histogram.
September 2017 60 HYDROCARBON
ENGINEERING
unintentionally entering the process, resulting in a
fluctuating response.
In addition, CO promoter is not a concentration
based additive as it is highly effective at reducing
afterburning when initially added, and its use should be
minimised to avoid excessive NOX . CO promoter daily
addition rates are typically fixed at the minimum
addition level to control normal levels of afterburning,
while supplementary manual additions are made or the
addition rate is adjusted if afterburning changes are
observed. By blending in a fixed concentration with the
fresh catalyst, the ability to optimise afterburning at
minimum NOX is lost. For example, additional amounts
of CO promoter are added to the unit when increasing
the fresh catalyst addition rate. This additional
promoter is usually unnecessary and unadvised (due to
increased NOX and costs). In addition, pre-blended CO
promoter is typically blended at an elevated level for
the worst case scenario or for periods of low fresh
catalyst addition, in the cases where no supplementary
addition is possible. This means normal CO promoter
addition is excessive, only giving negative connotations.
To achieve tight control of FCC NOX emissions, it is
vital that a high quality low NOX or non-platinum CO
promoter is added separately through a reliable and
accurate addition device. A second low NOX promoter
trialled was added separately through a non-Johnson
Matthey addition system. And the final trial with
COP-NP used the company’s INTERCAT additive
addition system. In the back-to-back trials, COP-NP was
effective at much lower addition rates (Figures 8 and 9).
Conclusion
Afterburn can be a big problem just like heartburn if it
is not controlled or prevented. FCC afterburn results
when the coke on a catalyst is not burned completely
to CO2 in the regenerator dense bed. The remaining CO
will continue to oxidise in the dilute phase and upper
portions of the regenerator. The high heat of
combustion for CO to CO2 and the low catalyst density
can result in higher than desired temperatures, which
can cause serious damage to internals that leads to
premature shutdown and costly repairs. Kinetic limited
afterburning is due to insufficient reaction volume in
the dense phase and can be effectively controlled with
CO promoter additives. Distribution induced
afterburning is characterised by localised afterburning,
which is induced by poor air and/or catalyst
distribution and may, or may not, be effectively
controlled with platinum or non-platinum based CO
promoter additives. Platinum based CO promoters can
increase NOX formed from combustion of nitrogen in
coke. Avoiding platinum by using a non-platinum
promoter allows for more effective afterburning
control where there is a need to minimise the
production of NOX in the regenerator.
References
1. WILSON, J. W., ‘FCC Regenerator Afterburn Causes and Cures’,
Wilson P.E., Barns and Click, Inc., AFPM Annual Meeting 2003,
AM-03-44.
Dr Suresh S. Agrawal and Meena S. Agrawal,
Offsite Management Systems LLC, USA,
discuss the design of a fuels blend header for
an in-line blending system.

T
he upgrading of manual fuels blending to an in-line fuels
blending system requires that blending components flow
simultaneously to a common collection point called a
blend header. The blend header is a piece of pipe with all
component pipes connected along its length. The product then
flows from the exit end to the final destination product tank via a
pipeline. Figure 1 shows a representative in-line fuels blending system.
The design of an automated in-line blending system involves the
automation of field equipment, computer hardware and software,
online analysers, distributed control systems (DCS), and interfaces. All
of these automation modules need to be integrated. While these
in-line blending automation modules have been discussed in
technical literatures, the purpose of this article is to present and
discuss the design considerations for a fuels blend header.

HYDROCARBON 61 September 2017

ENGINEERING
 Role of a blend header
The role of an in-line fuels blend header is to connect all
incoming blending components to a common point, mix it
well and pump it out to the final product tank. The main
criteria for a good blender design are outlined below:
Physical dimensions
The physical length and diameter of the blend header is
determined by the blend rate range and inter-connection
distance of the component pipelines connected along the
header length.
Mixing
It should have a well mixed pattern, so the final product tank
will only need to be circulated for a short period, or not at all,
to save on energy costs. This will also alleviate the need for a
static mixer in the product tank or separate mixer after the
blend header.
Transportation
The transport of blend component from input tanks to the
final blend product tank is facilitated by a component tank’s
static pressures and pump discharge pressures, taking into
account any pressure loss along the way. The blend header
pressure should be high enough to flow to the final product
tank without a pump between the two. This will be valid if the
product tank is close enough to the header. However, booster
pumps will be needed for remotely located product tanks.
Component connections order
Each blend component differs in properties, such as flow rate
regime (based on Reynolds number), density and reid vapour
pressure (RVP), so one should dictate their connection order
along the blend header length to ensure the proper mixing of
heavy (density) and more evaporative (RVP) material.
Design parameters
The design procedures for each of the design parameters for
the blend header are discussed in the following section.
Physical dimensions
The diameter and length of a blender header is based on the
flow regime (laminar vs turbulence) for components entering
the blend header as well as blended product flowing through
and exiting the header.
Reynold (Re) number measures the degree of flow regime
as follows:
Re = (1)
Where:
Dh = hydraulic dia. of the header, its characteristics
travelled length.
Q = volumetric flow rate (m3/s).
A = pipe inner cross-sectional area (m2).
V = mean velocity of the fluid (m/s).
μ = dynamic viscosity of the fluid (kg/(m.s).
ϧ = kinematic viscosity (m2/s).
ρ = density of the fluid (kg/m2).

Equation (1) can be transformed to calculate the hydraulic

diameter of header as follows:

Dh = 1.273277 (2)

The recommended range of Re is >4000 for turbulent

regime ensuring adequate mixing. However, in reality, Re is
much higher than 4000 (Table 1) for various fuel types. Usually,
the blend diameter for gasoline fuel range between 12 – 18 in.,
still ensures a turbulent flow regime. Table 2 shows typical
component data for a gasoline blending system with
component pipeline diameters ranging between 3 – 10 in. and
Re number in turbulent regime.1-3 This ensures a thorough
mixing in the blender at the points of component
Figure 1. Representative in-line fuel blending system. connections.
A blend rate of 12 000 bbls/hr for gasoline blender
has been assumed for illustrative purposes (Table 1).
Table 1. Estimation of blend header diameter for various The length of a blend header is determined by
fuel blenders considering fully turbulent flow, and is characterised by
Fuel Re Q Kinematic Density Diameter entrance length (Le). This is the distance for flow to
type viscosity achieve a fully developed state when suddenly
bbls/hr m3/hr m2/hr kg/m3 cm in. changed from the pipe entrance. The component flow
Gasoline 710 071 12 000 1908 0.01098 721.90 31.17 12.27 enters the header across, not along, and thus disturbs
the flow pattern in the blend header. Therefore, a
Diesel 140 000 1775 282 0.01080 904.25 23.77 9.36
certain distance must be allowed between two
Fuel oil 10 000 1200 191 0.10800 901.85 22.49 8.86 connection points of the component at the blend

September 2017 62 HYDROCARBON

ENGINEERING
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 header to enable the full development of the flow regime
again, as shown in equations 3 and 4.
≈ 0.06 (ReD) = for laminar flows Re <2300 (3)
≈ 4.4 (ReD)1/6 = for turbulent flows Re >4000 (4)
As all of the component flows are in the turbulent region
(Table 2), the entrance length for each of the component and
entrance length by diameter (the ratio of entrance pipe
length/pipe dia. for a fully developed laminar or turbulent
flow) can be calculated, and it ranges between 25 – 36 ft. If the
diameter of the blend header is 12 in., the interconnection
distance of blend component can be between 25 – 36 ft.
However, this separation distance can be adjusted up or down
depending upon the actual construction of a blending system
at a refinery site. For a blending system consisting of 12
components, the blend header could be in the range of
300 – 450 ft. However, there should be longer distances of
40 – 50 ft between the last component connection points to
the blender exit to facilitate fully developed turbulent flow
before entering the product tank. Figure 2 shows a typical
piping and instrumentation diagram (P&ID) for a blending
component circuit.
Header inlet/outlet pressures
The normal flow path for the blend material starts from the
component tank and goes through the pump
suction/discharge, flow controller, blend header, static mixer
(optional), booster pump (optional) and then, finally, to the
product tank. The blend header exit pressure should be
greater than the static head of the product tank, in case there
is no booster pump required due to the product tank’s vicinity
to the blend header. The engineers’ hydraulic calculations take
into account the pressure losses due to valves, strainers, pipe
elevations, control valves and pipelines to ensure that the final
pressure at the blend header inlet is sufficiently high to pump
into the product tank without any pump for nearby tanks. The
typical range of blend header pressure is 70 – 80 psi, indicating
a pressure drop of 30 – 35 psi from pump discharge
(110 – 115 psi) to blend header pressure inlet.4-6
Mixing
It is important that the final blend product should be mixed
well without any pockets and/or segregation of its qualities.
Hence, refiners adopt various additional methods to mix the
product before dispatching it. These mixing methods can be
applied individually or together, depending upon refinery
facilities.
Internal tank mixers
Some product tanks may be equipped with internal mixers to
facilitate final mixing, although these are rarely employed,
except for old plants and manual blending systems.
Recirculation pumps
After blending is complete, the product tank is recirculated
for 6 – 8 hrs for manual blending and approximately 2 – 3 hrs
for in-line blending. Since in-line blending
already has well mixed product due to its
turbulent flow regime in the header, some
refiners still prefer to recirculate the tank
to avoid any concentered quality pockets.

External static mixer

In addition to, or instead of, product
Figure 2. Typical P&ID for a blending component circuit. recirculation, refiners can install another
static mixer between the blend header
and product tank. It can
Table 2. Typical gasoline component properties be important to use a
Component Typical Density Dia. Dia. Kinematic Maximum Maximum Normal static mixer if the
recipe (kg/m3) (in.) (cm) viscosity flow rate flow rate Re product tank is further
(%) (m2/hr) (m3/hr) (bbls/hr) number away from the blend
LLCN + THLCN 35 652.10 10 25.4 1.0801E-02 659 4145 305 864 header, such as export
quality blends stored
HLCN 29 787.00 10 25.4 1.0799E-02 546 3437 253 654
away in distant tanks that
MLCN 24 719.80 10 25.4 1.0886E-02 458 2880 210 855
must be pumped using a
Alkylate 13 706.00 8 20.3 1.0801E-02 242 1520 140 203 booster pump.
THCN 12 719.60 8 20.3 1.0801E-02 224 1410 130 053
M-xylene/toluene 5 873.00 6 15.2 1.0801E-02 100 630 77 481 Components
Heavy aromatics 5 880.00 6 15.2 1.0799E-02 103 650 79 950
connection order
A blending system
MTBE 5 747.00 8 20.3 1.0801E-02 98 615 56 727 typically mixes 6 – 12
HYC LSR 7 663.00 6 15.2 1.0799E-02 130 820 100 860 components for a
Raffinate 9 689.00 6 15.2 1.0801E-02 169 1060 130 361 gasoline blend or 4 – 8
Buffer oil 1 779.00 3 7.6 1.0801E-02 22 140 34 435 components for diesel
and fuel oil blends. It
C4LPG + C4C5LPG 9 610.00 6 15.2 1.0801E-02 167 1050 129 148
connects to a blend
Gasoline product 721.90 12 31.2 1.0977E-02 1908 12 000 710 071 header for an in-line

September 2017 64 HYDROCARBON

ENGINEERING
 Strategic Fuels Blending
Management and Technology
3 Days Comprehensive Seminar by
Dr. Suresh Agrawal
President
Offsite Management Systems LLC
Houston, Texas, USA
www.globaloms.com (T) 1-281-650-3707, (F) 1-866-450-4035
November 8-10, 2017
Mumbai, India
Venue: Hotel Near Mumbai International Airport

Fee: US$ 1,495/Person

Deadlines Early-Bird/Group Discounts Registration September 7, 2017
Full Payment due by October 7, 2017
For Registration Visit http://globaloms.com/OMS02D/Register
For Details Visit http://globaloms.com/OMS02D/Details
or send an email to s.agrawal@globaloms.com

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 connected farthest
away from the header
exit point to facilitate
proper gas-liquid mixing
while flowing to exit.
The component
properties data in
Table 2 were used to
Figure 3. Gasoline blender with weighted orderly connected component. sort the components
by individual properties
(Re number, density and
Table 3. Statistically weighted ranking based on Re number, RVP). Each parameter has its own characteristics,
density and RVP
e.g. components with a heavier density tend to
60% 25% 15% settle, and components with higher RVP generate
Component Reynolds Density Vapour Weighted Weighted more vapour phase. The turbulent flow ensures
number pressure average connecting that as the components enter the blend header
(Re) order along the length, both have vertical and
HLCN 2 3 10 3.45 1 horizontal mixing without any quality
LLCN + THLCN 1 11 3 3.80 2 segregation.
MLCN 3 6 7 4.35 3 This order is shown in Table 3, which does not
give any definite connection order of components.
Alkylate 4 8 8 5.60 4
Therefore, statistical weighted average method
THCN 5 7 12 6.55 5 was used by assigning the weight to each of the
M-xylene/toluene 8 2 9 6.65 6 properties as shown below using engineering
Raffinate 6 9 6 6.75 7 judgement and experience with fuels blending
C4LPG + C4C5LPG 7 12 1 7.35 8 system project implementations. This method
should be used as a guideline and one can use
Heavy aromatics 10 1 11 7.90 9
different weighing factors based on individual
HYC LSR 9 10 2 8.20 10 preference and experience.
MTBE 11 5 4 8.45 11 For a gasoline blend:
Buffer oil 12 4 5 8.95 12 „ Re number: 65%
„ Density: 25%
blending system. The blend components have different „ Vapour pressure: 15%
properties and play different roles during the mixing of the
blend in the header. There are three properties – namely For a diesel blend:
Re number, density and RVP – that affect the way the „ Re number: 65%
components should be connected to the blend header. „ Density: 35%

Flow regime (Re)
It is important that component flows coming into the
blend header are in the turbulent flow regime, as
determined by the Re number (>4000). The use of
component flow rate is incorrect, as even the higher flow
rate can be in a laminar regime based on the component
pipeline diameter. The components with the highest to
lowest Re number should be connected to the header in
order of farthest to closest, with respect to blend header
outlet point.
Density
The component density determines the inertia to movement
and, hence, relates to mixing. The heavy component should be
connected farthest from the blender exit point to facilitate
mixing while flowing to exit.
RVP
The component vapour pressure relates to the amount of
vapour present in the gas-liquid mixture of the component.
Higher RVP generates a higher amount of vapour. Hence, a
component with a higher vapour pressure should be
Table 3 shows the component connecting order, based
on the sorted weighted average of the component
properties for gasoline blends. Figure 3 shows the graphical
diagram of the component connection order for the gasoline
blend header. The component connection orders can be
calculated for diesel and fuel oil blenders using the same
methodology discussed in this article.
Conclusion
This article has discussed the design of a fuels blend header
for an in-line blending system in terms of its physical
dimension, inlet/exit pressures, mixing methods and,
importantly, how components should be connected to the
blender header based on their properties.
References
1. http://www.engineeringtoolbox.com
2. http://www.vicopedia.com
3. https://www.eng.fsu.edu/~shih/eml3016/lecture- notes/pipe%20
flow%20considerations.ppt
4. S-Oil Refinery, Seoul, South Korea, Blending revamp project FEED
Review consultation by authors.
5. OMS Webinar, 'Design of Fuel Blend header', (June 2015).
6. OMS Training Course Manual, 'Strategic Fuel Blending Technology and
Management'.

September 2017 66 HYDROCARBON

ENGINEERING
 Thomas R. Kline, Structural Technologies, USA, explores how
a solution-oriented response and effective decision-making can
restore a refinery safely after a fire incident.

F
ire events can have a damaging effect on
petrochemical facilities, causing potentially
hazardous conditions to operating personnel and
to the general population in the surrounding
community. While never scheduled nor planned, a quick
response to a fire is of primary importance in protecting
life and property. Using available resources for fire
suppression/extinguishment and appropriate evaluation
and repair technologies, reinforced concrete structures
can be readily assessed and repaired to restore
serviceability and process production in such critical
petrochemical operating facilities.
A fire started in the early hours of the morning at an
oil refinery along the US Gulf Coast, affecting both the
residual oil supercritical extractor (ROSE) and the vacuum
units. The fire damage was severe, but was confined to a
small area of the plant. The ROSE unit was a total loss,
requiring complete removal and replacement, while some
lesser affected areas, such as the vacuum unit, ancillary
plant equipment, piping and electrical wiring, were

HYDROCARBON 67 September 2017

ENGINEERING
 repairable (Figure 1). Although complete repairs to the
refinery took over a year in total, the vacuum heaters
were repaired and re-commissioned on a fast-track basis
to bring significant refining capacity back to the facility.1
According to eyewitness reports, a 6.5 hr duration
hydrocarbon ‘pool’ fire occurred below two adjacent
vacuum heaters. The effects of this fire manifested itself
around the vacuum heater foundations in various forms,
including:
„ Pools of aluminium metal (presumably melted
aluminium electrical conduit) were observed in areas
believed to be adjacent to the pyrogenic epicenter
(i.e. focus of the fire).
„ Discolouration of fire-impinged foundation concrete
and cementitious materials.
Figure 1. Side view of vacuum heaters damaged „ Extensive cracking, delamination and open surface
by fire. Note the reinforced concrete foundation spalls in reinforced concrete support members.
damage, structural steel deformation and ancillary
piping/utility damage associated with the fire prior to
the installation of structural support shoring. Concrete behaviour during a fire
Considering the behaviour of concrete as a material, it
should be noted that fire introduces high temperature
gradients and, as a result, the hot surface layers tend to
separate and spall from the cooler interior of the body
mass. Crack formation begins to propagate at joints, in
poorly consolidated parts of the concrete, or in planes of
reinforcing bars. Once reinforcement has become
exposed, it conducts heat and accelerates the action from
high temperature exposures.2 For practical purposes,
approximately 1100˚F (595˚C) can be considered as a
limiting temperature for the structural integrity of
concrete members made from non-refractory concrete,
such as the vacuum heaters’ short foundation columns
(Figure 2). This limit pertains to the surface temperature of
the concrete member element itself and not the
temperature of the flame or of the gases (Table 1).
When initially exposed to high temperatures,
concrete cools its contact surfaces with free-moisture
and chemically-released moisture from interior regions
Figure 2. A typical vacuum heater foundation column of the concrete mass. Concrete, with its network of
exposed to a long duration hydrocarbon-fuelled fire pores, small conduits or capillaries, allows the passage
event, creating near surface delaminations, exposing
of water from interior to exterior regions. However, as
embedded reinforcing steel and damaging anchor
moisture moves within the concrete, small amounts of
bolts.
soluble salts are in solution, which deposit within the
pores of the concrete as the water evaporates during a
Table 1. Estimating fire temperature3 fire event. As the salt deposits fill-in voided areas, the
Exposure Concrete Strength reduction concrete pores become blocked and do not allow
temperature colour further transfer of water to cool high temperature
32 – 570˚F Unchanged Unchanged contact surfaces. Therefore, the water accumulates
(0 – 300˚C) behind this barrier and is phase changed from a liquid
570 – 1100˚F Pink or red 0 – 55% to a gas. This gas or steam expands in volume and
(300 – 595˚C) pressurises the concrete within unblocked pores. The
1100 – 1650˚F Grey 55 – 85% steam pressure ultimately exceeds the tensile capacity
(595 – 900˚C) of the concrete, creating a surface spall. This
1650 – 2200˚F Buff 85 – 100%
mechanism is why poorly detailed thin ‘feather-edged
(900 – 1205˚C) patch’ repairs to fire damaged concrete members do
not work, as the patch will fail explosively during the
Greater than Yellow Complete decomposition of
2200˚F (>1205˚C) the cement paste or ‘glue’ next fire event. Steam builds along the repair
where calcium hydroxide material/concrete bonding interface and ‘hurls’ the
converts to calcium carbonate patch along with a thin layer of parent concrete that
(lime) has failed in tension.

September 2017 68 HYDROCARBON

ENGINEERING
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Figure 3. Structural steel pipe columns supporting
vacuum heater loads, including refractory brick
liner and steel plate ‘box’ members. Note the steel
reinforcing bars were augmented if affected by fire
and all anchor bolts were removed and replaced
during demolition activities.
Using Table 1, the residual strength for non-refractory
concrete can be approximately judged; generally, concrete
that has changed colour to pink or beyond is suspect, and
concrete past the grey stage is probably friable and
porous.
In addition to the indicators, other sources were
available on-site to assist with assessing contact
temperatures during the fire, which included:
„ Melted aluminium conduit pipe (aluminium melts at
1220˚F [660˚C]).
„ Sagging and distorted structural steel sections just
above the reinforced concrete foundation support
columns (structural steel softens and undergoes phase
changes above 1360˚F [738˚C]).
„ No evidence was observed or reported of structural
steel melting (structural steel melts at
2550˚F [1400˚C]).
Based on the evidence, it was reasonable to
conclude that the vacuum heaters’ concrete foundation
column elements that were affected by the fire were
subjected to exposure temperatures ranging from
570 to 1360˚F (300 to 738˚C). As determined during the
drill probe and core sample extraction programmes, fire
damaged concrete extended from 2 to over 8 in. deep
(50 to over 200 mm), when measured from original
exterior concrete foundation column faces. The most
deteriorated column conditions existed along the north
half of the vacuum heater structures. It should be noted
that considerable damage to existing anchor bolts were
observed at the foundation column tops, including
bending and localised yielding due to structural steel
member growth associated with high temperature/long
duration fire event exposure.
Based on the information developed during the
course of the investigation, the reinforced concrete
foundation columns supporting the vacuum heaters had
September 2017 70 HYDROCARBON
ENGINEERING
a greatly diminished load path of sound concrete at its
core, reducing the as-designed foundation column
bearing capacity. In total, 20 of the 28 structural support
columns were damaged during the fire. With over 70% of
the foundation columns damaged, the vacuum heaters’
foundation support system was considered at-risk. As
such, all non-essential personnel were barricaded away
from the structures’ envelope (i.e. footprint).
Additionally, a shoring programme was immediately
implemented to stabilise the vacuum heater structures
and preclude unplanned structural movement. A
comprehensive repair programme was then developed
and implemented on a fast-track schedule.
Vacuum heater structural
stabilisation/support shoring
Engineering design and construction services were
immediately secured from locally available
engineering/fabrication firms to expeditiously design
and install a temporary structural pipe tube shoring
system, founded on existing undamaged subsurface
reinforced concrete foundations. The temporary shoring
design incorporated the capacity to support loads
associated with the vacuum heaters and were detailed
enough to allow repair construction of the individual
concrete foundation columns without compromising
repair design integrity. The installation involved
fabrication of new structural steel members offsite,
sawcutting, the removal of existing pavement slab
regions at shoring placement locations, excavation of
existing backfill soils down to the top of the existing
vacuum heater foundation, placement and erection of
the pipe shoring, and the refilling of excavation regions
with backfill materials (Figure 3).
Selective demolition of foundation
support columns
Once stabilised, work crews were assembled to allow
multiple locations to be repaired simultaneously. As a
measure to provide additional workspace below the
structure, vacuum heater bottoms were cut out and
removed. Crews of 10 workers operating 2 x 12 hr shifts
were able to mark-out areas of partial and full-section
foundation column repairs and then sawcut along repair
perimeters, establishing repair ‘shoulders’. Using 15 lb class
chipping guns with pointed gads, regions within sawcut
perimeters were excavated, with the top 2.5 ft (0.76 m)
removed in all cases to accommodate damaged
anchor-bolt removal and new anchor-bolt placement.
Demolition and surface preparation techniques were
performed in accordance with International Concrete
Repair Institute (ICRI) guidelines.
Reinforcing steel
preparation/augmentation
Upon exposure, sound reinforcing steel bars were
abrasive grit-blasted to remove any remnants of partially
bonded concrete materials and corrosion products. It
was evident that some fire damaged reinforcing steel
bars, especially at column tie locations, required removal
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Figure 4. Typical view of repaired reinforced
concrete vacuum heater column after wrapping
with moisture-saturated burlap during the three day
wet-curing period and subsequent to strength
development and shoring support removal.
and replacement. When suspect reinforcing conditions
were encountered, new steel bars were added or lapped
onto existing reinforcing bars in accordance with
American Concrete Institute (ACI) guidelines. Due to
relatively thick sections, additional welded wire fabric
(WWF) was placed within the formed cavities to assist in
mitigating early age and long-term shrinkage cracking of
the new concrete repair materials.
Forming new foundation column
cross-sections
Subsequent to existing concrete and steel reinforcement
preparation, as well as new anchor-bolt placement
activities, new mortar-tight column formwork was
installed at each of the 20 repair locations. The
formwork was site constructed and specifically designed
to resist the hydraulic pressures associated with ‘form
and pump’ placement techniques. The placement
technique required the formwork to include ball-type
check valves with pressure gauges installed at injection
port locations to regulate pumping and vent ports, to
allow the evacuation of trapped air prior to formwork
pressurisation. The premise of the repair methodology is
to hydraulically pump cementitious repair products,
under pressure, through injection ports, into sealed
cavity formwork following ‘port-to-port’ communication
techniques. Essentially, the repair materials are pumped
from the lowest to highest points, thus ensuring minimal
air-voiding (i.e. honeycomb) with concrete member
consolidation accomplished using flowable material
consistencies and external formwork vibrators.
Re-establishing new foundation
column cross-sections
Re-establishing the structural section of the foundation
columns meant placing rapid setting, high quality, dense
shrinkage compensating repair concrete within formed
September 2017 72 HYDROCARBON
ENGINEERING
cavity areas using ‘form and pump’ techniques. Repairs
to the concrete elements did not involve significant
volumetric quantities. However, consistent material
characteristics and properties were required and, as
such, pre-bagged repair products were incorporated into
the repair programme. The repair materials were jobsite
mixed using portable mortar mixers, chuted to a
hydraulic concrete pump hopper, and then conveyed
from the concrete pump, via pump hose lines, to
injection port locations.
Once the individual form cavities were full and
vented, the formwork was pressurised between
15 – 20 psig and the check valves were closed.
Subsequent to initial repair material ‘set’, the check
valves were removed and the repair material cured in
accordance with the manufacturer’s recommendations
(Figure 4). Once cured, the repaired foundation column
surfaces were ground to match the original foundation
column surface contours, and a concrete surface
sealer/curing compound was applied to exposed
surfaces.
Structural repair programme
implementation
Having re-established the structural foundation to the
vacuum heaters, the owner disengaged and removed
the temporary shoring system and then began
planning/implementing repairs to process lines and
product feed systems. Removing the at-risk hazards
associated with unplanned structural movement, the
owner was free to accelerate the process repairs and
bring the vacuum heaters back on-line, once support
systems were repaired and/or upgraded. The
foundation repair programme took a total of 15 days,
safely working a total of 30 shifts and approximately
3600 man-hours – an achievement between the owner,
engineer and contractor.
Conclusion
The rapid response and team-focused approach to the
fire event provided the owner/facility operator a
streamlined approach to assess and subsequently repair
the effects of the fire on reinforced concrete foundation
elements. An emphasis on safety, as well as the
determination of the extent/depth of deterioration,
provided an auditable process to ensure that the
members were not ‘under-repaired’ with the owner
protected from over-paying for repairs to sound
concrete directly adjacent to ‘un-sound’, deteriorated
concrete. The process proved highly successful and
provided a verifiable ‘audit-trail’ satisfying facility
insurance underwriters.
References
1. KLINE, T., HALL, R. and VICIDOMINA, V., 'Solution-oriented, Team
Effort Brings Units On-Line After Fire', MC-04-95 Technical Paper,
National Petrochemical & Refiners Association (NPRA) 2004
Annual Conference, San Antonio, Texas, US.
2. KLINE, T., 'Fire Hazard', Hydrocarbon Engineering, (January 2004),
pp. 56 – 57.
3. NEVILLE, A. M., 'Properties of Concrete 4th Edition', John
Wiley & Sons Inc., New York, US, ISBN-0 -582-23070-5,
ISBN-0-470-23527-6; pp. 385 – 390.
KEEPING A
WATCHFUL
EYE Scott W. Sexton, Haldor Topsoe Inc., USA, discusses how
monitoring furnace fireboxes, burners and tube temperatures
improves operations, safety, reliability, efficiency and life cycle.

F
ired heaters in refinery processes are critical to overall
operating success and process optimisation. Process
upsets from heater problems, in turn, upset refinery
economics. Process upsets result from heater fires,
heater tube failures, poor burner operation, and heater
mechanical equipment failures. These upsets have traditionally
required plant personnel to look inside the heater firebox to
evaluate equipment and process status. This interaction has
inherent risk. While this risk can be mitigated with personal
protective equipment (PPE), danger remains when a human
interacts with a fired heater.
Digital furnace firebox monitoring technology reduces the
dependence on human interaction with a firebox. By using a
system of image collectors operating continuously, millions of
images and data points can be collected annually. Alarms
activate when temperatures go out of range, or when burners
malfunction. Images and data are stored in a historian for easy
retrieval. Continuous firebox monitoring technology minimises
furnace-firebox personnel safety risks. When not looking into
a furnace, personnel can perform important work, such as
troubleshooting, diagnoses, data analysis, collaboration with
colleagues and planning maintenance work.
System description
The system is designed to capture images embedded with
data. Images are collected with multiple image collectors fixed
permanently on the firebox. These image collectors send the
images to the data collectors where initial analysis is

HYDROCARBON 73 September 2017

ENGINEERING
 performed immediately. Stored images and data are then
ready for additional processing and analysis. Alarms for the
plant operators occur when limits are exceeded in the
regions-of-interest areas established with the operator’s
Figure 1. Continuous, digital firebox monitoring
system.
Figure 2. Typical furnace monitoring equipment.
Figure 3. Side-fired burner rows.
September 2017 74 HYDROCARBON
ENGINEERING
insight. The support organisation outside of the plant can also
see problems as they occur, and collaborate on a path forward.
Asset protection
Asset protection is a very high priority in refinery operations.
Carburisation and creep of process tube metal occurs over
time, resulting in process tube overheating. Coking and
decoking of refinery heaters is a constant challenge.
Continuous, digital firebox monitoring indicates tube
overheating when it occurs, so operators can take corrective
action with the help of built-in alarms. The system indicates
poor burner performance, and provides information to help
plan burner maintenance activities. Leveraging its data
collection capability, the system is paid back in a couple weeks
by avoiding shutdowns from tube failure.
Outage avoidance economic payback example
„ 5000 bpd furnace throughput.
„ US$5/bbl refining margin.
„ US$50 000 furnace repair cost.
„ US$400 000 digital monitoring system cost.
„ Simple payback: (US$400 000 – US$50 000) / (5000 bpd
x US$5/bbl) = 14 days.
Tube temperature monitoring
Time and temperature are fundamental to furnace tube life.
The Larson-Miller (LM) parameter quantifies the relationship
between time-to-rupture for metals relative to temperature of
operation. The equation associated with the LM parameter
relates tube-life-until-rupture from metal creep rate to
differences in temperature at a constant stress value. A 5%
increase in absolute temperature will typically increase the
rate of creep by a factor of 10.
Time-in-operation is easy to measure, whereas
temperature-in-operation for metal surfaces in a furnace
firebox is difficult to measure without technology. The
continuous, digital, firebox monitoring of process tubes
captures tube temperatures over time. The root-cause
determination, in case of tube failure incidents, can be found
with this data. When most flame sensing systems are inactive
after auto-ignition temperature is reached, continuous, digital
firebox monitoring provides asset protection up through
normal operation.
Burner balancing, training and incident
avoidance
The system provides the information to guide operations
through the burner balancing process by providing images and
data before, during and after adjustments. Fuel savings of
1 – 2% result at the same production rate, where savings of up
to US$100 000/yr in a balanced firebox can be realised.
The training of new and existing personnel on firebox
operations, based solely on field experience, is difficult, costly,
and can be hit-or-miss. By sharing firebox images and data,
training is enhanced and up-to-date, and collaboration can
occur with common documentation.
Outages are costly and best avoided. Paybacks are fast for
contributors to avoided outages. For example, if a digital
monitoring system costs US$400 000, and helps avoid an
outage, and start-up/shutdown and repair costs US$200 000,
Topsoe Furnace Manager

You’ve never seen

your furnace like this
How often do you physically examine your furnace? Wouldn’t it be helpful to have access to an up-to-
date tube wall temperature and a picture of every burner whenever you need it from the safety of
your control room? Well, now you can, thanks to the Topsoe Furnace Manager.

Online monitoring protects your furnace 24/7 and ensures operation at ideal conditions in a safe
environment. Early warnings of failures will provide you with peace of mind and protect your investment.

Advantages of the Topsoe Furnace Manager:

• Asset protection
• Operational excellence
• Energy efficiency improvements
• Safety improvements
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 and lost margin is US$25 000/d, then simple payback is:
(US$400 000 – US$200 000) / (US$25 000) = 8 days.
Firebox exposure and burner monitoring
Continuous firebox monitoring enables remote location of
personnel and reduces risk exposure frequency. With the
Figure 4. Firebox flame detection.
Figure 5. Tube temperature charts and graphs.
Figure 6. Colour coded image with regions-of-view,
temperature chart and graph.
September 2017 76 HYDROCARBON
ENGINEERING
continuous monitoring system, furnace exposure is not
required on the same frequency as in the past.
Low NOX industrial furnace burners are difficult to see
with the human eye, as hydrogen-based flames cannot be
detected. Continuous firebox monitoring ‘sees’ difficult flames,
providing alarms when the flame is underperforming.
Operational excellence
Support groups can collaborate using the same images and
data available to operations. Historical information is available
‘on demand’ without relying on an operations group for
retrieval and storage. Compliance data is available at all times.
Subject matter experts have remote access to furnace
operational images and data for immediate assistance to
operations.
Case study: start-up of a new, modular
plant
Background
A new furnace required design validation as part of a new
highly integrated plant. There were unknowns in the area of
heat distribution and temperature control of the modular
furnace. Burner heat release, especially with mixed fuels, was
not fully validated before commissioning. Project timing
prevented execution of an extensive R&D, or testing,
programme to validate the burner/furnace interactions, and
the economic decision was made to install a digital
monitoring system. Although the furnace had ignitors, pilots,
and flame scanners on each burner, there were problems
encountered during start-up.
Validation process
The validation process began with proof of a pilot flame prior
to light-off of main burners. During pilot lighting, it was found
that the flame scanners did not provide constant verification
of flame, especially during initial lighting when the flames can
be naturally unstable. Since the burners were located on six
different levels on the firebox, physical personnel movement
between levels was more difficult when attempting to light
and stabilise the flames. There was frustration and worn
patience on the part of the operations team when attempting
to light multiple pilots only to lose the flame signal sensed by
the flame scanners, which required restarting the lighting
process from the beginning.
Safety decision point
Operations management was faced with difficult decisions.
One decision involved bypassing certain burner management
safety (BMS) devices, and another decision required constant
human verification of the presence of flame at each pilot and
main burner. These decisions each represented compromises
in their safety philosophy by either compromising an
engineered safety system, or exposing personnel to firebox
hazards, or both.
Technology solution
In order to safely light and stabilise flames in the firebox
without requiring direct human interface with the firebox and
flames, the digital monitoring system was utilised as an
 administrative safeguard. The presence of flame was verified
from the control room display screen so that flame scanner
adjustments could be made prior to trip-out of the BMS.
Flame quality, including size, shape, colour and intensity
could be adjusted with fuel and air adjustments seen on the
digital monitoring system so that safe and efficient startups
were conducted with no direct human/firebox interaction
required.
furnace operation. The immediate cause-and-effect of the
modifications were captured and recorded with digital
firebox monitoring. Additionally, as the furnace temperature
was increased, the process tube growth and mechanical
integrity of each tube was monitored and recorded. The
impact of any stray burner flames that had a tendency to
impinge on the process tubes, was also noted and recorded
so that proper adjustments could be made.

Data gathering Summary

Once the initial burner and furnace adjustments had been
determined involving some amount of trial-and-error, they
were documented with digital images and stored in the
system’s historian, as well as in the plant’s operating
procedures for future reference.
A potentially risky start-up situation was mitigated by
utilising the digital imaging system for administrative
verification of flame, and for operational adjustments after
initial start-up, all the time with minimal exposure of
personnel to inherent firebox hazards.

Furnace stabilisation Conclusion

After safe, initial burner light-off, the next challenge was to
distribute heat evenly across the process tubes. With digital
monitoring strategically placed in the arch (roof) of the
furnace, all burners and all process tubes were monitored
continuously from the control room. The ability to literally
‘see’ inside the firebox during the heat-up phase of
operations enabled the operations team to share their
progress with each other and the management team. Several
minor modifications were required at the burners to better
manage heat distribution. Air damper modifications, removal
of refractory interference, and fuel mixing and pressure
regulation modifications were all required to attain stable
Several factors must be considered during the life cycle of
furnace operations and maintenance, including safety,
reliability, efficiency, and operability. There are a couple of
strategies to manage and safeguard against hazards –
engineering and administrative safeguards. Utilising technology
that is available today, continuous, digital firebox monitoring is
a proven personnel and process safety option for furnace
fireboxes that provides an engineered-administrative
safeguard. Additionally, immediate economic benefits are
gained by avoiding furnace incidents and outages, by
improving long-term reliability, and by enhancing operational
excellence.

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 Chris Wajciechowski, Alfa Laval, USA,
explains how the introduction of welded
plate heat exchangers has optimised
naphtha hydrotreater efficiency at a
major refinery on the US Gulf Coast.

ADVANTAGE
September 2017 78 HYDROCARBON
ENGINEERING
T
he need for hydrotreating is increasing as refiners
adapt to changing sulfur regulations in motor fuels. To
help meet these regulations for gasoline, a naphtha
hydrodesulfurisation unit is used; generically called a
naphtha hydrotreater (NHT). NHTs are critical refinery process
units that remove sulfur from gasoline components by reacting
with hydrogen in the presence of specialised catalysts. The
process is energy intensive and requires a high degree of heat
integration to lower the energy operating expenditures. In the
past, the energy was recovered with shell-and-tube heat
exchangers; however, more recently, refineries have been
boosting process efficiency by using welded plate heat
exchangers in key heat recovery positions. This article will
explore the benefits of using welded plate heat exchangers,
realised in a grassroots NHT.
A Gulf Coast refiner sought to build a hydrotreater to
comply with US Tier III sulfur regulations and retained a design
firm to perform the necessary process designs and refinery
modifications. A traditional design was drafted using
conventional shell-and-tube heat exchangers to perform the
heat transfer in the process. To improve energy recovery in the
process, the combined feed/effluent and feed/bottoms heat
exchangers were initially designed as multiple shell-and-tube
units in series. Any additional heat not recovered by these heat
exchangers would have to be supplied by energy purchased from
the hot oil heater and the reboiler. The refinery wanted to lower
capital and operating expenditures of the plant, so the company
directed the design firm to evaluate welded plate technologies
to optimise the process. Three services were selected to
evaluate whether performance could be improved with welded
plate technology: the combined feed/effluent exchanger; the
stabiliser feed/bottoms exchanger; and the hot oil heater.
Naphtha combined feed/effluent
exchanger (CFE)
In this heat exchanger, process feed is combined with hydrogen.
It is heated and boiled to a superheated vapour in a series of
heat exchangers. The heat source is reactor product vapours,
which need to be cooled, condensed, and then separated into
various components. Maximising this heat exchanger’s
performance by minimising the feed/effluent approach
temperature is critical as it drives the energy efficiency of the
entire process. Heat exchanger designers focused on the
hot-end approach temperature (hot side outlet T – cold side
outlet T = hot approach temperature or HAT) and the minimum
internal delta temperature (ΔTmin or the ‘pinch’) as limitations to
the thermal design. Pinch temperatures are a function of service
and heat transfer technology. For a shell-and-tube unit in the
hydrotreater CFE service, the pinch temperature is typically
between 22 and 44˚C (40˚ and 80˚F). Enthalpy/temperature
curves are provided to represent the HAT and pinch, aiding the
heat exchanger design (Figure 1). In a typical design, heat
recovery is limited to the performance of six to eight
shell-and-tube heat exchangers in series as this has historically
been determined to be the practical optimum between
investment costs and heat recovery benefits. This Gulf Coast
refiner’s process was originally designed with seven
shell-and-tube heat exchangers in the CFE.
Since the CFE design dictates several other design and
operating parameters, its performance should be determined
HYDROCARBON 79 September 2017
ENGINEERING
 early in the process design phase. This is the proper time to
evaluate alternative heat exchanger technologies such as the
performance of welded plate heat exchangers. Welded plate
heat exchangers extend the practical performance limits of
heat recovery by using engineered corrugated heat transfer
surfaces to generate three to five times the heat transfer
coefficient of traditional technologies while minimising the
fouling rate. The flow geometry also achieves close to
countercurrent flow, which is suitable for small temperature
differences and high heat recovery. Finally, a single welded
plate heat exchanger can replace several shell-and-tube heat
exchangers, reducing the amount of space required for
installation by 90%. Because there is a risk of salting or
Figure 1. Curve depicting the performance of seven gumming in the CFE, the Compabloc is designed to be fully
shell-and-tube units in series in a combined feed/effluent
exchanger. mechanically cleanable on both sides through hydroblasting
on site.1
The project team evaluated an alternate heat integration
for the CFE exchanger to capitalise on the advantages of the
higher performance provided by the Compabloc (Figure 2).
The results of the comparison showed a more than 50%
reduction in HAT and an internal pinch temperature that was
less than one-third than that of the shell-and-tube design.
Table 1 shows the temperature comparison between the
shell-and-tube heat exchangers and the Compabloc unit.
It should be noted that the shell-and-tube technology
can technically perform at the higher heat recovery levels;
however, due to the low temperature difference, more than
12 shells in series and a substantial amount of surface area
would be required to do so. The goal of the comparison was
to understand the practical amount of heat recovered in the
two technologies and its effect on the capital and operating
Figure 2. Improved performance and heat recovery. expenditures, not the least of which was the hot oil heater
duty. Because of the increased performance of the
Compabloc CFE, the hot oil heater duty was reduced by
Table 1. Temperature approach comparison 40%.
CFE heat exchanger Hot approach Internal pinch
temperature temperature
Stabiliser feed/bottoms exchanger
This position in the process recovers heat from the naphtha
Shell-and-tube 48.2˚C (86.8˚F) 22˚C (39.6˚F)
product and preheats the feed to the stripper tower. Heat
Compabloc 19.11˚C (34.4˚F) 6.7˚C (12.1˚F) recovery optimisation here will reduce the stripper reboiler
load, thereby lowering operating costs for the column. The
stabiliser feed/bottoms exchanger is also suitable for
welded plate technology instead of shell-and-tube
technology and this position was optimised around the
performance of a single welded plate exchanger. If
shell-and-tube technology were used to perform the same
duty, four or more shells in series – at considerably higher
cost – would be required.

Hot oil heater

Figure 3. Optimised naphtha hydrotreater unit using
Alfa Laval technology for a Gulf Coast refiner.
For this refinery’s process, hot oil – not a fired heater –
supplies the heat to warm the reactor feed to the required
reaction temperature. It is advantageous for the hot oil
temperature and flow rate to be as low as possible to reduce
operating costs; a hot oil temperature of approximately
16.6˚C (30˚F) above the reactor temperature was selected.
Because of the small temperature difference between the
fluids, several large shell-and-tube heat exchangers would be
required to perform the heating duty; even after considering
the 40% reduction in duty of the Compabloc CFE.

September 2017 80 HYDROCARBON

ENGINEERING
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In addition to the above two services, a single heat exchanger
was also selected to heat the reactor feed.
Case study conclusion
Substantial capital and operating cost benefits can be realised by
replacing shell-and-tube heat exchangers with welded plate
exchangers as a combined feed/effluent heat exchanger, hot oil
heater, stabiliser feed/bottoms exchangers (Figure 3). The value
of this performance improvement was calculated at the process
design stage and, early in the project cycle, drove the decision to
use welded plate technology. Throughout the project, the end
user, contractor and supplier worked together to design, install,
start-up and operate these heat exchangers. The exchangers
were installed and successfully commissioned in 2016.
According to the refinery’s process engineering manager, the
units are performing well with no increase in pressure drop that
would indicate fouling or salting. This Gulf Coast refinery is now
operating one of the most energy-efficient hydrotreaters in the
world, thanks to the use of welded plate heat exchangers.
Recommendations
„ It is important to consider how welded plate heat
exchangers may enhance heat exchanger performance
during the initial phases of a NHT design or revamp project.
Designs that rely on rules of thumb for the use of
traditional equipment limit the potential for performance
and cost optimisation.
„ Improved heat exchanger performance often has profound
effects on the cost and performance of upstream and
downstream equipment. The process designer along with
the heat exchanger supplier can recognise and monetise the
potential value by simulating improved heat exchanger
performance and its effect on the process.
„ Engaging key suppliers in the process design stage will not
only give the process designer the data to simulate
performance, but also to leverage that supplier’s experience
in order to ensure a good design results in reliable
operation in the field.
„ A heat exchanger does not necessarily need to be used in
a heat recovery service to benefit from the enhanced
performance of welded plate technology. Using welded
plate technology in certain positions, such as overhead
condensers, product coolers, or product heaters (e.g. the
hot oil heater), may also deliver measurable performance
improvements to refiners. Therefore, replacing
shell-and-tube technology with welded plate technology
in these positions may also prove beneficial.
Conclusion
The performance of many refinery and petrochemical processes
can be improved by welded plate heat exchangers. However, a
paradigm shift is required to study their performance at the
earliest stages of a project, where traditionally rules-of-thumb
are used to determine heat exchanger performance.
Collaboration with key suppliers is the key to unlock the value in
increasing performance; as evidenced by this US refiner.
Reference
1. MARK, W. and GRAY, G. L., 'Proper Design and Operation of NHT CFE
Equipment', Mucek, American Fuel & Petrochemical Manufacturers,
(2011).
HEATING
UP
Ilan Toledano, Wattco, USA, advises
on how to pick the right thermal
fluid heating equipment and provides
an overview of the use of circulation
heaters in the petrochemical industry.
T
hermal fluid heating and the use of circulation
heaters are excellent partners for efficient heat
transfer. Thermal fluid is passed through the
vessel chamber, heated using electric tubular
elements and passed through the arteries of a closed loop
system to heat up a system. This article will help define the
heating techniques used in petrochemical industries as
refineries focus on improving viscosity for the purpose of
flowing petrochemical liquids from one location to
another.
Thermal fluid heating is a form of indirect heating. The
basic premise is that the heat transfer medium is heated
and circulated within a loop system. This distributes heat
to one or more sources within the loop.
Heat transfer fluids are commonly used due to their
low maintenance, low corrosion, environmental safety, and
precise temperature controls. The most common thermal
fluids include oils, water, glycol, and glycol-water mixtures.
Selecting the right thermal fluids and heating
equipment for a specific process will maximise efficiency
and help to reduce costs. This article will outline the most
appropriate thermal fluids and thermal heating equipment
for an application.
Thermal fluid heating
Thermal fluid heating is used in a wide variety of industries
and applications, including downstream oil and gas. This
includes oil refineries and gas stations, as well as
byproducts such as lubricants, asphalt, propane, and other
related products. Asphalt, for example, is extremely dense
and requires a gradual heat in order to avoid carbonisation
and allow for heat penetration deep into the core product.
The focus of a suitable watt density is necessary (5 W/in.2
for asphalt) to heat it up without damaging its physical
integrity. In other situations, many petrochemical
companies strive to reduce costs and become more
efficient by preheating gas using thermal fluid heating,
specifically in explosion proof environments where
additional steps in safety are required. Finally, paint
facilities, for example, often require a heat transfer system
HYDROCARBON 83 September 2017
ENGINEERING
 in order to (safely) heat a viscous liquid medium using
indirect heat as opposed to heating up the medium
directly, which can bring up safety concerns.
Thermal fluid heating can use liquid or vapour as the
heat transfer medium. The former generally uses a closed
loop system (the liquid remains as a fluid as it travels
through the system). In vapour thermal fluid heating, the
medium starts off as a fluid and is vaporised either within
the system or externally through a flash drum. The main
advantage of vapour is that it provides more uniform heat
throughout the system.
The fluids must be viscous so as to move easily
throughout the system and must have a high enough
thermal capacity for its process. The four most common
thermal fluids are:
„ Water – the main advantages of water as a thermal
fluid is its low cost and environmental friendliness. The
main drawback is that water has a lower boiling point
than its alternatives, so it is not suitable for all
applications.
„ Glycol-water mixes – these can be used to speed up
the heating process and provide a higher boiling point
than water on its own. It is less costly than using pure
glycol fluids and can operate at higher temperatures
than water on its own.
„ Glycol – despite its higher cost, glycol can operate at a
higher temperature than glycol-water mixes or water
on its own.
Figure 1. Double skid 500 kW heater and controls.
Figure 2. Explosion proof flanged electric heater.
September 2017 84 HYDROCARBON
ENGINEERING
„ Oils – these offer the highest boiling point and are
highly versatile. Glycol-water mixes are generally
effective up to approximately 300˚F, whereas oils can
be effective up to 800˚F. Mineral oils are used in
residential, industrial and process heating. Silicon and
transformer oils are used for process and as an
insulator for high power electric transformers.
Thermal fluid selection
Temperature requirements
The fluid selected must be capable of meeting the
temperature requirements for the heating process. It is
important to consider the maximum bulk temperature, the
minimum operating temperature, and the minimum start-up
temperature. Glycol-water mixtures are sometimes used
when water does not meet the minimum start-up
temperature. The addition of glycols helps to speed up the
process.
Pumpability
Pumpability is an important factor when selecting a
thermal fluid. This is not only a consideration of viscosity
but of functional operating temperatures. If an application
is operating in freezing (or sub-zero) environments, the fluid
must be able to resist freezing so that it can be pumped
through the system.
Thermal efficiency
A low viscosity correlates with greater heat transfer
coefficients for moderate temperatures. When operating at
a low to moderate temperature, low viscosity fluids will
provide more efficient heating. However, for high
temperatures, it may be beneficial to add a more viscous
fluid or a secondary fluid.
Thermal fluid equipment sizing
considerations
Flow rate and watt density are two of the main sizing
considerations for thermal fluid heating equipment. Sizing
considerations should be made based on the watt density
of the fluid. Typical applications use 6 in. and 8 in. flange
heaters but there are many that go up to 12 and 14 in.
flanged heater and vessels.
Flow rate becomes a major factor when considering the
size of the heater. The majority of projects that involve
fluids use skid mounted systems that have all encompassing
materials such as expansion tanks, heaters, controls, pumps
and various other pieces of equipment.
It is also important to consider pressure and fluid
gravity. Pumps should be sized to accommodate pressure
drops in the system. The size of the expansion tank will be
affected by the operating temperature, fluid selection and
total system volume.
Selecting thermal fluid heating
components and materials
The components used for thermal fluid heating equipment
will be made mostly according to thermal fluid selection,
process and application. Some of the components to
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 consider include piping, flanges, gaskets, studs,
insulation, valves and pumps.
Piping for thermal fluid heating systems, for
example, will generally be 3 – 6 in. This allows for a
good flow with minimal heat loss. The pipes will
typically be made with steel, as it offers corrosion
protection, excellent heat transfer qualities, and lower
costs. As such, steel is commonly used for flanges in
thermal fluid heating processes.
Safety considerations for thermal
fluid heating
The type of fluid used is an important safety
consideration. The fluid must suit the temperature
requirements to prevent any issues. Also, fluids should
ideally be non-poisonous and stable, this is for
environmental and employee safety.
Proper fluid flow will also ensure a longer lifespan
and better system integrity. If the flow is too low, it
may result in overheating, fluid degradation or heater
failure. To avoid these issues, the pump must be
designed for use with its thermal fluids at operating
temperature and should be tested for proof of flow.
Finally, appropriate temperature controls must be
used to ensure the safety of operators, the medium
and the heating system itself. Fluid excess temperature
protection should be put into place, as well as stack
excess temperature limits.
Circulation heaters in petrochemical
applications
Circulation heaters are widely used in the
petrochemical industry for heating fluids, chemicals,
and other mediums. Circulation oil heaters consist of a
tube-like heating element, which is immersed in the
medium to be heated. Thermostat control panels allow
for temperature variation during petrochemical
processes. From chemical processing to gasoline
refining, process heaters are used in every
petrochemical industry.
Design configurations
Most circulation heaters are designed either in open
loop or closed loop configuration. A closed loop
system is one in which the medium or fluid to be
heated circulates in a closed loop. Once heated by the
circulation heater to the desired temperature, the fluid
is sent back through the pumps to the vessel.
A medium can be heated in closed loop
configuration either through indirect or direct heating.
In the former, the chemical is heated in the industrial
heater as it flows through it. The heated medium keeps
on circulating in the vessel, covered with twisted pipes
or coiled tubes. In direct heating, the heated medium is
sent directly to the vessel or the closed loop system.
However, selecting the right watt density according to
the nature of the medium is very important.
Open loop systems are directly connected to the
application. Circulation heaters when used in open loop
configuration heat the medium to the set temperature and
September 2017 86 HYDROCARBON
ENGINEERING
then directly discharge the heated medium where it is
required.
Applications in the petrochemical
industry
Circulation heaters have several uses in the
petrochemical industry. They can be used to preheat and
raise the temperature of fluids, chemicals, gases and
other mediums used in the commercial industry.
Depending on the design and heating capacity of the
temperature controller, circulation heaters can boost the
heating process from 300 kW up to 1000 kW. The heat
controller present in these heaters allows heating of
petrochemicals, oils and other fluids to the right amount
so they can easily flow through pipelines.
Influencing factors
Several factors can influence the application, efficiency
and precision of circulation heaters when used in the
petrochemical industry, including the following:
„ Viscosity, density and specific heat of the medium
being heated.
„ Corrosive properties of the medium and corrosion
resistant properties of the heater.
„ The extent of contamination and nature of
contaminants (reactive or non-reactive) present in
the medium.
„ Watt density and heat resistant properties of sheath
material used in the heater.
„ Rate of heat flow of the heated material.
„ Material and design of the vessel containing fluid to
be heated.
„ Temperature and pressure threshold values of the
fluid being heated.
Maintenance
There are several methods that can help extend the
lifespan of circulation heaters:
„ Disconnect all the electric supplies and detach all
the removable parts before clearing up the heater.
„ During the clean-up process, carbon and sludge is
often deposited on the inner walls of the heater.
The outlet pipe can be used to drain out all of the
debris from the heater.
„ It is important to ensure that the bolts are tightened
during the maintenance process. This will help to
prevent the heater from corrosion.
„ Disbanding the detachable parts before maintenance
can make the device easy to handle.
„ While using the heater, the thermostat should be
checked. This can help evaluate the efficiency,
performance and durability of the equipment.
Conclusion
It is essential for oil producing companies to keep costs
under control and maintain an efficient operating
environment both in the production and
transportation/distribution of their product. Circulation
heaters and thermal fluid heating are an excellent
combination that can help manufacturers achieve this
goal in an extremely competitive environment.
 Harpal Singh, Bartec Singapore, explains why heat tracing systems
are a crucial element of petrochemical production, with reference
to a recent project carried out for PTT Phenol in Thailand.

D
emand for phenol and acetone is continuously
increasing because the products can be used as
the precursors for various industries that are
essential for daily life. For instance, phenol is
primarily used in the manufacture of important
polymers, including polyamides (nylons), polycarbonates,
phenolic resins and the epoxy resin. It can also be used
to produce disinfectant, which is widely used in
household cleaners. It is a white crystalline solid at
ambient temperature, which smells of disinfectant.
Meanwhile, acetone has a number of industrial
applications such as methyl methacrylate, bisphenol A
and solvents. It is a co-product of phenol via the
cumene oxidation process, and is a colourless, volatile
and flammable liquid.
The Thai company, PTT Phenol Co. Ltd (an affiliate of
the PTT Group) has a 215 000 m2 factory that
manufactures phenol and acetone. The factory is
located in the Hemarach Eastern or Map Ta Put, Muang
Rayong District, Rayong Province, which is 180 km
southeast of Bangkok, Thailand. Recognising the
increased demand for these products, the company
started a project to enlarge the capacity of Thailand’s
raw materials in the field of the petrochemical industry.
It conceived of the ‘Phenol 2 project’ to extend its
phenol manufacturing capacity.

HYDROCARBON 87 September 2017

ENGINEERING
 The Phenol 2 project will produce 250 000 tpy of
phenol and 154 206 tpy of acetone, based on 8000 hrs/yr
continuous operations. It is also situated in the Hemarach
Eastern industrial zone, covering 40 000 m2. The
company has been studying this project since 2011. Safety
and environmental preservation are at the forefront of its
plans and it supports green technology during its design
and manufacturing processes.
PTT Phenol intends to install a second phenol
complex, consisting of a Q-Max unit and the phenol unit
with a selective hydrogenation process producing
250 000 tpy of phenol from polymer-grade propylene
and benzene feedstock in Hemaraj Industrial Estate site
in Map Ta Phut as part of the existing phenol complex.
The quality of phenol and acetone product must be
Figure 1. Heating tapes and suitable control
technology are crucial for the success of every heat
tracing system.
Figure 2. Production of phenol and acetone is continously increasing as the
products can be used as the precursors for various industries.
September 2017 88 HYDROCARBON
ENGINEERING
suitable for use in the manufacture of bisphenol A,
which is primarily used to make polycarbonate and
epoxy resin.
Full-scope engineering
In order to bring the new facilities to production,
PTT Phenol selected Bartec as its partner for establishing
an up-to-date electrical heating system that meets all
regulations. The assignment included the design,
engineering, documentation, supervision and supply of
the electrical heat tracing system. The scope included all
modifications related to outside battery limits (OSBL) and
the tank facilities.
Heating cable
Heating tapes and cables are crucial for the success of
every electrical heat tracing system. As such, effective
thermal insulation is essential to minimise heat loss as
well as the capacity of the heat tracing system.
Self-limiting parallel heating tapes are the most suitable
option for impulse lines and instrumentation cabinets.
Nearly 20 000 m of HSB heating tape have been
installed during the PTT Phenol project, split into
295 heating circuits. The power junction boxes had to be
stainless steel according to the customers’ requirements,
and each one had to be customised according to the
power cable size. These stainless steel junction boxes,
along with heat tracing cables and accessories, were
delivered directly from Bartec Singapore to meet the
project schedule. Testing and commissioning was carried
out under Bartec supervision.
Self-limiting parallel heating tape
The HSB self-limiting heating tape is designed to meet all
frost protecting needs in industrial areas. It is
corrosion-proof and resistant to chemical attack due to
its protective outer jacket of fluoropolymer. The tape
enables the Syzran Refinery to maintain high process
temperatures. This is achieved
by a temperature-dependent
resistive element between two
parallel copper conductors,
which regulates and limits the
power output of the heating
tape. This output regulation is
carried out automatically along
the entire length of the heating
tape according to the prevailing
ambient temperature. If the
ambient temperature rises, the
power output of the tape is
being reduced. Thus the
self-limiting property prevents
overheating even when tapes
are crossed. As a result of the
parallel design, the heating tape
can be cut to any required
length on the construction site.
This simplifies project planning
and installation considerably.
Furthermore, the heating tape can be terminated at any is supplied through the use of a top-hat rail on the
point according to the circumstances. underside. The electrical connection is established by
One main distribution panel with a human machine means of screw-type terminals operating on the screw
interface was also part of the system. This human cage clamp principle, which ensures a reliable
machine interface has been installed in the main control connection and is also gentle on conductors.
panel, from which 14 pieces of Ex d panels were
connected, each in combination with 17 state-of-the-art Conclusion
model predictive control (MPC) controllers, so that PTT Phenol selected Bartec for full-scope engineering and
PTT Phenol is now able to monitor the temperature of supply of new heat tracing systems. The safety technology
each line from the control room through RS-485. The provider managed to address all of the project’s
TL Ex safety temperature limiter is a constituent part of challenges, especially the tight project schedule, and
the MPC system and is used to monitor heating and delivered it in due time.
heating circuits. The device
should be installed in
non-hazardous areas. The
heating or heating circuits
can be installed both in
media-protected and in
explosion-hazardous areas. If
Your EHS Issues are Our Issues
the temperature at the Pt100
sensor exceeds the set limit We support your operations from every angle to ensure
value, the TL Ex disconnects effective EHS strategy and streamlined EHS data management
the load output permanently.
At the same time, a floating
alarm contact is triggered. > Environmental
EEnviv ironm
nmene tall impact
impap ctt assessment
asses
essm
smeennt
The alarm contact status is
detected and processed by
> Specialized
S i li d expertise ti ini airi quality
llilit assessmentt
means of the digital inputs in and emissions management
the 8DI and 16DI modules and
> Air quality permitting and compliance management
the digital input in the TR16,
TR36 and TR38 power > Environmental and explosion modeling software
modules in the MPC
controllers. Once the > EHS
E S information management
manage g ment solutions
temperature drops by 2 Kelvin
below the switch-off point or
> Extensive
E xttens
tensiive
i ve professional
prof
p ofes
fessision
ionall training
tra
raiini
ining
ing on EHS EHS ttopics
opic
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pics
cs
after a fault has been
remedied, the limiter can be Contact us for a complimentary consultation at +1 (972) 661-8100.
re-activated by means of a
reset button on the device.
The TL Ex can transmit the
temperature detected at the
measuring input to the MPC
controllers by means of an
integrated sequential system
with a signal that is
proportional to the actual
value measured. This allows
the temperature at the limiter
to be evaluated in the control
system. The limiter function
can be suppressed by a digital
input when carrying out
servicing work on the heating
circuit, e.g. steam cleaning.
The TL Ex is installed in a
clip-on enclosure for TS35
mounting rails. The alarm
relay and the limit relay are
produced as changeover
contacts. The 24 DC voltage




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North America | Europe | Middle East | Asia
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Quinten Eyckmans and Daria Astakhova, Madesta,
Switzerland, outline the important role that steel
plays in the construction of storage tanks.

S
teel is the most important metal used in the
construction of oil and gas infrastructure. From
production and processing to the distribution of
refined products, vast quantities of carbon steel are
required. Carbon steel is an alloy of iron with up to 2%
carbon that increases the strength of the material and its
corrosion resistance. The steel also contains trace
quantities of other metals such as nickel or chromium. One
of the main constructions for the oil and gas industry is the
storage tank. The increased global demand and tapping of
new markets results in an increasing demand for oil and oil
derivates storage. Even as most producers are getting used
to the lower crude prices, storage demand is still increasing.
Carbon steel is the most commonly used material in
storage tank construction, and building storage tanks
requires a lot of steel. Between 10 and 15% of a project’s
total budget is reserved for carbon steel. Since storage
tanks are being designed and erected to strict industry
standards, quality control and full traceability are
paramount. From mill to construction site, chemical
composition is clearly monitored and well documented.
Every construction standard (e.g. API 650, EN 14015)
mandates plates to be of a certain quality. The chemical
composition and tensile strength combined with the
results of different test and quality inspections during
production, translate into steel grades (e.g. S235, A36).

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 Minimum requirements to make a certain grade are strictly
documented in different codes (EN, ASTM, GOST, etc).
All of this information is noted down on a material
certificate, the plate’s passport, while the plate itself is
identified by the hard stamp. During fabrication, every plate
is followed and documented. When cut, each individual
Figure 1. Steel parts prefabricated by Madesta used
in the construction of A1 jet fuel storage tanks at
Larnaca airport, Cyprus.
Figure 2. Construction of a new tank terminal in
Ghent, Belgium using prefabricated steel plates
supplied by Madesta.
Figure 3. Terminal construction in Nigeria using
prefabricated shell, bottom and roof plates and parts
supplied by Madesta.
September 2017 92 HYDROCARBON
ENGINEERING
piece or part will have a hard stamp to avoid traceability
errors. The worst nightmare for a tank erection company
would be to use the incorrect grade of steel, or not
knowing which plate is supposed to go where. Not having
the right certificates or traceability records might result in
the inability to commission the tank or for it to pass
post-construction testing.
As with many other industries, prices and project budgets
are under pressure. Most traditional oil and gas construction
companies are considering ways to save on operational costs
and overhead. The tank erection business has not been
spared from this trend, as companies increasingly hand the
work over to subcontractors. Apart from the cost saving
aspect, customers operating in more challenging
environments or regions tend to choose prefabrication above
local fabrication due to the risks involved or the lack of
infrastructure and expertise available locally.
Since entering the tank storage business, Madesta has
successfully completed projects in Africa, Latin America and
the US, while consolidating its market position in other regions
such as Sierra Leone, Mozambique, the Middle East and the
Caribbean. In 2016 and 1Q17, the company supplied several
substantial storage tank construction projects across Europe
using its four steel service centres in Latvia and Ukraine.
Case studies
Larnaca, Cyprus
At the start of 2016, the company was awarded a contract to
supply fully prefabricated steel plates for the construction of
three A1 jet fuel storage tanks at 2300 m3 each at Larnaca
airport, Cyprus. Due to the tight schedule, all plates were
containerised and shipped to the final destination using
just-in-time deliveries. A prefabrication capacity of
approximately 2500 t per month and high output
contributed to the project’s successful and timely
completion. Fabrication and preparing steel plates in remote
locations, or places lacking the necessary infrastructure, is
not easy. As such, the customer opted to have the plates
fully fabricated beforehand, shortening the total
construction time.
Ghent, Belgium
In spring 2016, a Belgian engineering, procurement and
construction (EPC) contractor used Madesta plates for the
construction of a new tank terminal in Ghent, Belgium. The
new terminal consisted of five 50 m dia. gasoline storage
tanks. The investment is part of a larger expansion project
spanning several years. For the project, 3000 t of steel were
shipped using just-in-time deliveries by trucks and bulk
shipments, straight to the construction site. All plates were
shot blasted, primed, cut, beveled and rolled in Madesta’s
Ukrainian facilities, with steel grades ranging from S275 to
S355. In general, operational terminals in Western Europe, in
contrast to greenfield projects, lack the space to
comfortably allow for onsite fabrication work and are
subject to strict safety rules. Due to the plate sizes, with
lengths up to 11 m and widths of 3 m, the total transport
cost when bought locally forced the customer to look for a
more cost efficient solution. Using bulk vessels and fully

Figure 4. Steel plates with prepared bevel for
welding.
fabricated steel plates proved to be the answer. All tanks
were erected using the traditional ‘jacking system’ where
the tank is built from top to bottom, each course jacked up
after welding. Since all plates were prepared for welding,
the construction company did not lose any time onsite. All
plates were marked and carefully numbered according to
the engineering provided by the customer, avoiding
downtime onsite. All five tanks were erected in 10 months
and on schedule. The new terminal is now fully operational
and was ready to receive its first product shipments in
July 2017.
Port of Antwerp, Belgium
The most significant project to date supplied in Europe was
a tank terminal expansion project, located on the left bank
of the Port of Antwerp. The terminal is a joint venture
between an independent international operator, specialising
in the downstream petroleum and chemicals sector, and a
global trading, investment and service enterprise. From late
2016 to 1H17, Madesta prefabricated and supplied over 800 t
of shell, roof and bottom plates for the project. In total,
two storage tanks were erected using a state-of-the-art
spiral construction method. This method was pioneered by
Midroc Rodoverken, a Swedish EPC and tank building
contractor. Madesta’s Belgian customer, Upgrade Storage,
introduced the method to Belgium. The first Belgian spiral
tanks were completed in May 2017.
The spiral storage tank design technique has proven
beneficial in storage tank construction, eliminating the need
for time (and money) consuming scaffolding and continuous
heavy lifting. The method comprises gradual rotation of the
tank upwards using hydraulic jacks and a rotation mechanism.
All the plates are welded onsite (at ground level), which
could offer significant benefits where construction is being
conducted, with limited accessibility or operational
terminals. Erecting a tank on a small site or with restricted
access to water often means that it cannot be pre-built and
transported. Furthermore, on the construction site, tanks
built using this method have no, or limited, height restrictions
compared to more traditional methods and it has been
heralded as one of the safest and fastest ways to erect a tank.
The fabrication of the tanks’ shell courses for spiralling
proved to be a challenge. Since the shell plates are
introduced into the spiral at a slight angle, the tolerances
on fabrication are very tight. Not having the right plate at
the right time will result in project downtime. Again,
traceability and production checks and inspections ensured
that the plates measured up to the required standard. In
addition to the tolerances, a large number of shell plates
per tank are unique.
The role of steel prefabrication in tank
storage construction projects
Steel tanks are durable and require little maintenance,
extracting maximum value from the resources invested in
the structure and minimising its whole life costs. They are
highly durable and do not age or decay as quickly as other
construction materials, lasting longer before refurbishment
is required. Therefore, steel will most likely continue to play
a significant role in the storage tank construction industry.
The prefabrication of steel is quite new in the storage tank
project supply chain and, as such, it is often necessary to
change the mind-set of tank builders and EPCs, as most can
perform steel processing by themselves. Steel prefabricators
help to lower steel costs and shift focus onto tank
construction and turnkey projects.
Conclusion
Steel will remain one of the most popular materials used to
construct storage tanks as it offers numerous advantages.
Despite being simple, steel should meet the requirements
for storage tank construction and be built to serve for
years.
CASTING
CALL
Uwe Kellner and Hans-Jürgen Steinhart, Zollern GmbH & Co. KG,
Germany, introduces high performance metals and alloys for use in
the downstream oil and gas industry.

T
he demands placed on the processing of
mineral oils, as well as systems in energy and
power generation are high. Equally, the
demands on the material of the components
installed within them are also high. Materials are
selected to suit the purpose and corrosive properties
of the process media. Furthermore, the materials and
components must be able to withstand adverse
operating conditions, cope with high temperatures and
defy severe strain.
In order to cater to the operator’s standards and the
complex operating conditions, an increasing number of
high performance materials are being used. These are
metals and alloys in increasingly specific compositions
that are, for example, cast in highly specialised
production processes to form exceptionally robust
products. Copper-nickel alloys are particularly suitable
for components used in refineries, as they are highly
resistant to aggressive media. Specifically, these are for
alloys GN10 and GN30, which are used in coolers,

HYDROCARBON 95 September 2017

ENGINEERING
 valves and pumps. As well as excellent corrosion
resistance, these alloys are increasingly resistant to
erosion and cavitation (the higher their nickel content
is, the higher the resistance). Rust and acid-resistant
sand-cast steels in ferritic and austenitic, ferritic and
martensitic or austenitic grades can, for example, be
used in mineral oil processing, as well as heat-resistant
sand-cast steel and non-magnetisable special materials.
Products such as cooler flaps, which are required as
forged parts, can be produced from copper-aluminium
or copper-nickel alloys.
High quality parts made from high performance
metals and alloys can be produced in investment
casting and sand casting procedures. Whether made
from steel, aluminium, copper or superalloys, castings
are flexible in design and economic to manufacture.
When components have to be highly resistant and
cater to sophisticated design standards, the advantages
of investment casting come into play. This high
precision procedure offers freedom of design. An
Figure 1. Almost every standardised alloy can be cast
at Zollern to create robust components.
Figure 2. In case of increasing requirements with regard to heat
resistance, weight and service life, the casting process for component
manufacture proves its worth.
September 2017 96 HYDROCARBON
ENGINEERING
increasingly large selection of alloys and superalloys
are processed to create robust components that may
be complex, and which in part feature very thin-walled
designs.
Special materials fulfil individual
requirements
High temperature-resistant steel castings, heat-resistant
steel castings and rust and acid-resistant steels are
particularly suitable for use in the energy industry and
power generation. A multitude of different alloys
ensures that the right material can be found for every
requirement. In this way, the material X 22 CrMoV 12 1
from the high temperature-resistant steel casting
category is, for example, especially suitable for turbine
construction and for components that are exposed to
fast temperature changes or a temperature shock. The
materials GS 17 CrMo 55 and GS 17 CrMoV 5 11 are used
in turbine construction, for pressure vessels and in
steam boiler engineering. The materials
G X 8 CrNi 13 and G X 7 CrNiMo 12 1 from the group of
rust and acid-resistant steels can be found in pump
parts, running wheels and running wheel blades,
wherever water and steam are used. On pumps for
material transport, for example, the properties of the
medium to be conveyed also influence the selection of
the suitable material. These media may be weak or
strongly corrosive, erosive or abrasive. In the field of
pumps and turbines, sand casting is also a good
production method, using high quality products that
can be manufactured from high performance metals. In
this way, housings and running wheels can be produced
in the sand casting procedure for pumps, impellers and
fan blades, as well as cooler housings and running
wheels for use in gas turbines, etc.
Alloy selection
As a specialist for copper and steel
alloys, Zollern is able to select the
respective appropriate composition
from 700 different alloys. The range of
materials extends from simple steel
through to corrosion-resistant steels,
heat-resistant steels, non-magnetisable
steels and copper-based alloys such as
brasses or bronzes, which are used in
floating head, channel or top cover
refineries, etc. The copper-nickel
casting alloys GN10 and GN30 feature,
for example, excellent resistance
against sea water, brackish water,
wastewater containing chloride and
brine solutions, and are suitable for use
in power plants, refineries, drilling
platforms, in fittings for the extraction
of crude oil, for valve parts and for oil
and water cooling tanks. The company’s
RG6 material from its series of
copper-tin and copper-tin-zinc casting
alloys is suitable for pressure-tight
Hydrocarbon
Engineering Online

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The KºBloc is a fully welded
plate heat exchanger with a
solidly bolted frame which
consists of four columns, top
and bottom plates as well as
four side plates – and that´s
just one of the product
solutions Kelvion offers the
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 parts such as fittings and pump housings at operating
temperatures up to 225°C. Metals developed to fulfil
highly-specific requirements share a high surface
quality and accurate dimensional tolerances regarding
the finished castings. Casting methods include sand
castings, ceramic mouldings, shell-mould castings (also
known as Croning castings) and centrifugal castings.
Depending on the moulding procedures, the material
and other influences, different dimensions and weights
of castings are possible in the sand casting process.
Developing final properties
Casting is one of the ancient forming processes. During
casting, a liquid material solidifies to form a solid
object. Workpieces are cast if certain properties are
expected from them, or the production through other
procedures is economically inviable or not possible at
all. The starting point for sand castings is the models of
the end products. The models consist of one or more
parts wood, artificial resin, plastic, steel, aluminium,
hard foam or polystyrene. During the model
construction, it is important to take into account
changes in dimension (also known as the degree of
shrinkage) during casting, which are dependent on the
casting temperature, contour and mass. In the next
step, the model is placed in the appropriate moulding
box, which is filled and compacted using moulding
Figure 3. Special alloys are created in line with
specific customer requirements.
September 2017 98 HYDROCARBON
ENGINEERING
sand. At this point, the feeder through which the liquid
metal will subsequently flow is also positioned. By
removing the model after hardening – for this purpose,
a special hardener is mixed into the moulding sand – a
negative form of the workpiece to be produced is
created. The moulding boxes are then installed fixed to
each other and prepared for the casting on the swivel
table. At the same time, the individual components of
the required alloys are put together. Weighed out
accurately, the individual chips or pieces are sent to
the smelter on the electric furnaces. This smelter heats
the elements slowly to the stipulated melting
temperature. The liquid alloy is then transported to the
sand mould in a crucible and slowly poured via the
feeder into the mould. At the same time, the swivel
table and the mould are tilted so that the alloy slowly
flows into all of the cavities without causing
turbulences. The feeder also serves as a material
storage point. If the workpiece shrinks on cooling, the
feeder provides supplementary material and a dense
casting is created. After the final cooling of the mould,
which may take several days (depending on its size), the
moulding sand is knocked out to expose the cast
workpiece. This is then prepared for further processing
or inspection. Moulding material milling is a
newly-available process at Zollern.
Mould production without models
saves time and costs
In contrast to conventional methods, models are not
required during moulding material milling; this
constitutes a method of mould production without the
use of models. The mould is virtually created and
optimised based on a 3D computer-aided design (CAD)
data record. Next, the virtual moulds, which are ready
for casting, are dismantled into processable segments.
Instead of moulding, the shape and cut-outs are milled
out of the moulding material. Cores can be produced in
a 3D printing procedure. Extremely complex
geometries, even undercuts, are thus possible, and
mould draft angles are not required. The moulds are
less expensive than those used in conventional wood
or plastics model construction. No physical model is
required, and the production time is substantially
shortened.
Investment casting differs from sand casting, but
also represents an accurate or high-precision casting
method that is gaining in importance for reasons of
economic viability. In this way, increasingly large and
more complex casting pieces on the one hand, and
alloys and superalloys (which are becoming increasingly
difficult to smelt) on the other hand, can be
investment cast.
Investment casting
Due to its economic advantages, investment casting is
increasingly being considered in value-analytical
comparisons. It permits an optimised design like no
other casting procedure. Through designs suitable for
investment casting, technical solutions are frequently
achieved that are either not possible in any other way, or at least are
not possible at such low production prices. In particular with regard to
the increasing demands on alloys in terms of temperature or heat
resistance, weight and service life, the investment casting procedure is
characterised by its different casting technologies.
For example, Zollern distinguishes between low pressure casting
methods for aluminium, induction melting for open cast alloys and
vacuum induction melting for special alloys. On the one hand, the
vacuum casting procedure offers the possibility of penny technology
using disposable crucibles, and on the other hand the possibility of
vacuum induction melting (VIM) technology using permanent crucibles.
Using penny technology, components with a part weight of 20 kg can be
cast. Cycle times of 3 – 4 min. per casting are outstanding here. In this
way, rapid-prototyping components, small series and large series of
several million components per year can be produced in a cost-effective
manner. A vacuum induction furnace is to be used as a tandem system
for the melting and casting of alloys under vacuum. The system is
adapted for the use of preheated ceramic shell forms, which can be
produced in accordance with the lost wax process. The melting process
takes place in an oxide ceramic disposable crucible, and the gating takes
place automatically through a plug hole after the melting of a thin
metal plate, the so-called penny, which initially seals the casting
opening at the bottom of the crucible during melting. The material from
which the metal plate is made is identical to the cast alloy. The system
works within a vacuum range of up to 10-2 mbar.
With regard to the VIM technology, the charge weight of the VIM
system totals 100 kg. The system is designed for a molten bath
temperature of up to 1700°C. The alloy is melted in a partially
double-walled and water-cooled melting chamber in a ceramic crucible
over an induction field. The tipping of the crucible takes place via a
computer-controlled servomotor-supported tilting curve for optimised
mould shell filling. Using this technology, highly-complex components
can be realised for very different applications involving heat, such as
those in the turbochargers of industrial gas turbines or their derivatives.

From the master melt to the ready-to-install

product
The in-house manufacturing capacity at Zollern ranges from the master
melt right up to ready-to-install casting parts. The experienced
specialists cast virtually all standardised alloys. Non-standardised
special alloys are also produced to customer specifications or modified
using existing alloys.
A competent selection of materials is essential for meeting the
requirements imposed on equipment and components in the
downstream oil and gas industry. Materials engineering offers an
enormous range of possibilities to specifically achieve and improve
desired material properties using carefully selected metals and alloys.
Copper-nickel alloys, for example, are a good choice for refinery
components, which need to be very resistant to corrosion. The metals’
resistance to erosion and cavitation increases with a rising nickel
content. A suitable alloy can be developed and smelted to meet a
number of different requirements. Depending on the composition of
the alloy and the geometry of the component to be produced,
different casting procedures come into play. For example, superalloys
are cast under vacuum whereas the open casting method is used for
steel alloys. With great expertise in materials engineering and the
corresponding technical procedures, metals and alloys can be produced
for different areas of application in the high-performance sector, from
which sophisticated components can be cast into form as needed or
processed further in another procedure.
NEW
MEDIA
Gregory Hallahan and Caleb Smathers, ProSep, USA, and
Jeff Myers, Williams, USA, examine the effective removal
of BTEX from rich water to reduce the concentration of
BTEX in reclaimed methanol using a new media system.
W
hen reclaiming methanol from water, the
disparate boiling temperatures of the two
compounds are used to create separation
via distillation. The number of stages
within the distillation column dictates the level of
purity achieved, which is often set by the specifications
for the products for resale and reuse. The ability to
separate two components is further complicated by
the existence of many other components, some of
them in trace amounts, causing multi-component
interactions, affecting vapour pressures, and creating
azeotropes that affect the ability of a distillation
column to reach the purity levels required.
This is the case for the Williams’ Discovery Larose
gas processing plant, which is transporting and
producing natural gas from offshore Gulf of Mexico.
Some wells require methanol to be injected downhole
to prevent hydrate formation. Natural gas from these
HYDROCARBON 101 September 2017
ENGINEERING
 wells are saturated with methanol and cannot be
processed due to the damaging effects that would
be caused to gas dehydration molecular sieves
inside the processing facility. Extracting the
methanol out of the gas stream with a water
contacting tower as the gas arrives onshore at the
plant is necessary to prevent these effects. The
resulting rich water, which is 5% methanol and 95%
water, also contains trace amounts of gas
Figure 1. Gas processing in the Larose facility, in condensate components. These components,
regard to wash water.
particularly benzene, toluene, ethyl benzene and
xylene (BTEX), track with the reclaimed methanol,
thus contaminating the sales product and resulting
in a lower market price. Removing these trace BTEX
components increases the value of the methanol,
increasing revenue while also avoiding the logistics
of selling an inferior product.
Williams and ProSep deployed the proprietary
Osorb® media to reduce or remove BTEX
components from the reclaimed methanol stream
at Williams’ gas processing plant. This is a
proprietary, silica-based media that is hydrophobic
Figure 2. The proposed location of an Osorb media and does not absorb water. It is effective at
system in a gas processing sequence. During the separating free, dispersed, emulsified and soluble
demonstration, the system processed a slip stream of hydrocarbons, as well as some oilfield chemicals
the rich water flow.
from water streams. It is capable of repeated
regeneration cycles and is reusable, without
significant loss in performance. Additionally, the
organics and chemicals captured by the media can
Table 1. Target BTEX concentrations in reclaimed be collected during regeneration and fed back into
methanol the requisite process stream. This regeneration and
Species Concentration Target reuse of the media generates no waste stream, thus
without the Osorb concentration alleviating the need for waste disposal and
system* (wt%) (wt%)
transport, as well as the storage of replacement
Benzene 0.050 <0.024 media.
Toluene 0.027 <0.011 The mechanism by which the hydrocarbons and
Ethyl benzene 0.0044 <0.0007 oilfield chemicals are removed from the
contaminated water is unique. It is both an
Xylene 0.0187 <0.001
adsorbent and absorbent, with no permanent
*Estimated from previous sample analysis chemical bonds formed between the media and
the contaminants. It is this lack of permanent
bonding that allows the media to be fully
regenerated and reused while also recovering the
captured components. While absorbing free,
dispersed and emulsified hydrocarbons and
non-polar organics, the matrix structure of the
media reorganises and expands to provide
increased capacity and bed life.
The report below outlines the results of tests
performed, the requirements needed to scale up
the technology to treat the full rich water stream,
and the cooperative work ProSep performed with
Williams to provide a final, engineered, easily
regenerated full process system for the removal of
BTEX from the rich water stream to enhance the
quality of the reclaimed methanol product.

Figure 3. The Osorb media system for System setup

300 – 500 bpd of water. The wet natural gas enters Williams Discovery
Larose plant (Figure 1) containing methanol, BTEX

September 2017 102 HYDROCARBON

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 and hydrocarbons. It is first processed in the wash
water tower. In the tower, the wash water removes the
methanol injected for hydrate inhibition, but also
dissolves some BTEX and hydrocarbons in the process.
The exiting natural gas is directed to further processing
and the wash water (now called ‘rich water’ because it
contains methanol, BTEX and hydrocarbons) is
processed to reuse the wash water and recover the
methanol. The problem at the Larose facility is
Figure 4. Samples collected from the inlet and outlet
of the Osorb media system.
Figure 5. BTEX levels in rich water at the inlet and
outlet of the Osorb media system.
Figure 6. The average reduction of BTEX in reclaimed
methanol during tests 1 and 2.
September 2017 104 HYDROCARBON
ENGINEERING
contamination of the reclaimed methanol with
BTEX at the methanol reclamation tower.
Based on laboratory testing, ProSep suggested the
set up shown in Figure 2 for the Osorb media system
at the plant. This process would remove the BTEX
from the rich water, but allow the methanol/water
solution to be sent onward to the methanol
reclamation tower. The reclamation tower recovers
the methanol and provides lean water for reuse.
Removal of the BTEX components with the media
system prior to the reclamation tower provided a
cleaner methanol product compared to the existing
setup.
The regeneration of the media was completed
using a small steam generator supplied by ProSep.
Following the regeneration of the media, the system
was put back into service to test the regenerated
capture capacity of the media.
Following the laboratory study, a pilot test was
completed to verify that an Osorb system could
reduce the BTEX in the reclaimed methanol to the
required specifications as outlined in Table 1. By
meeting this target specification, the reclaimed
methanol value substantially increases.
Testing
The system contained two 18 in. vessels, each with
35 kg of Osorb media, valves, instruments, and
intra-connecting piping on a 4 x 8 x 6 ft skidded
package. The piping was configured for water
treatment in series. The system was connected to
the washwater pump skid where a slip stream
could be directed to the media for treatment and
then returned to the wash water skid (Figure 3).
Tests 1 and 2
The first test was carried out treating 15 – 20% of
the total rich water flow. Reclaimed methanol and
rich water inlet and outlet samples were collected
and sent to a third-party independent laboratory
for analysis. The inlet and outlet samples visually
demonstrated the ability of the media to remove
free and dispersed oils, while the third-party
laboratory samples confirmed its ability to
simultaneously capture soluble components, such
as BTEX. Figure 4 shows a few inlet and outlet
samples collected and sent for testing.
The BTEX concentration at the inlet and outlet
of the media system is shown in Figure 5. As
laboratory tests indicated, the system removed
99.9% of the BTEX from the rich water with inlet
BTEX concentrations ranging from 14 – 36 mg/l.
The system maintained high efficiency BTEX
removal for 48 hrs.
As predicted, the reduction of BTEX in the rich
water resulted in a reduction of BTEX in the
reclaimed methanol. The system provided 99.9%
BTEX removal for 20% of the rich water flow, while
concurrent samples of the reclaimed methanol
demonstrated a 20 – 30% reduction of BTEX in
 ARKEMA’S
both tests. The media regeneration between both CARELFLEX ®

SULFIDING
tests was completed by purging the vessel with 275˚F
steam (Figure 6).

Results SERVICE HAS

YOU COVERED
The goals of the demonstration were to reduce the
concentration of BTEX in the reclaimed methanol
and demonstrate media regeneration and reuse. The
system achieved a substantial reduction of BTEX in A global leader in thiochemistry, Arkema
the methanol during both tests. Additionally, the manufactures one of the most efficient
media was regenerated between tests and regained activating agents, dimethyl disulfide (DMDS),
its performance capabilities after the regeneration.
in the U.S., Europe, and Asia.
This proved that a full-scale system could be
designed based on the pilot testing, thus providing a
system to increase revenue for reclaimed methanol Carelflex® sulfiding service offers:
byproduct. • Sulfiding procedures, technical guidance,
The Osorb system treated a slip stream of rich training, and 24/7 coverage during activation
water before the methanol reclamation tower. While • Patented, low-odor DMDS Evolution®2
treating only a small portion of the water, at a
• Dedicated high capacity pressure equipment
maximum of 20%, the reclaimed methanol displayed
a significant reduction in BTEX components. During • High pressure pumping
test 1, an average reduction of 25% was observed • H2S analysis with remote data access
from the baseline of 1118 mg/l BTEX in the reclaimed during activation
methanol. During test 2, an average reduction of 21% • Arkema amines available for passivation of
was observed with a baseline of 1984 mg/l BTEX in hydrocracking catalysts
reclaimed methanol. Treatment of the full stream, as
the commercial system is set to do, will provide the
full removal of BTEX from the reclaimed methanol, Our global logistics network and experienced
providing a superior product than is currently Carelflex® sulfiding service team stand ready
obtained. for your next activation.
ProSep, along with Williams and the media’s
supplier, also tested a pressure swing adsorption For Customer Service,
(PSA) system that quickly regenerates the media
call 800.628.4453
within 1 – 2 hrs. The process is simple, fast, and
provides a close to brand new media quality with
the restored 100% capture efficiency rates for BTEX
and condensate components. The PSA system also
delivers a clean contaminant stream that can be
comingled with other natural gas products present
at Williams’ Discovery Larose gas processing plant.
These advantages of the PSA system provided a final
system design for implementation at Williams.

Conclusion
The implementation of a full-scale Osorb media
system will allow the system to meet or exceed the
required specification for BTEX in reclaimed
methanol. The expected average methanol flow rate
is 1.3 gpm, for a total of nearly 2000 gal./d of
reclaimed methanol. Once implemented, the system
will not only provide reliability for processing the
rich water from the contacting tower, but also yield
an estimated internal rate of return (IRR) of up to
40%.

Note
ProSep would like to thank Williams Discovery Larose plant
for allowing it to conduct this demonstration and propose an dmds-evolution.com
economical solution. The company would also like to provide
a special thanks to the Larose plant operations team and
Jeff Myers for all their assistance.

Carelflex and Evolution are registered trademarks of Arkema.

© 2017 Arkema Inc. All rights reserved.
 Hydrocarbon Engineeringg questions a
number of water treatment experts about
R&D, regulatory compliance, productivity
improvements and the overall market outlook.

Septem
Se 017 106 HYDROCARBON
ember 20 ENGINEERING
Johanna Ludwig, Chief Technology Officer, akvola Technologies
Johanna Ludwig has over 10 years of experience in water treatment technology development, application and
commercialisation. Her expertise in the field of water reuse and membrane technology has received many awards,
including the ‘European Water Innovation Award’ and the ‘IDA Leadership Award’, and her career landed her on the
‘Forbes 30 under 30’ list. At akvola Technologies, Johanna has guided the R&D activities since its founding in 2011.

Sid Dunn, Global Technical Director, Water Treatment – Baker Hughes, a GE company (BHGE)
Sid Dunn has 39 years of experience in the water treatment industry, and currently serves as the Water Treatment
Global Technical Director at Baker Hughes, a GE company. Throughout his career, Sid has held many technical roles,
with a focus on engineering, sales, and business development. He owns three patents and has authored numerous
technical presentations and papers. He is currently an advisory council member and discussion leader for the
International Water Conference.

Mike Preston, Project Engineer and Industrial Water Treatment Section Leader, Black & Veatch
Mike Preston holds a BS degree in Chemical Engineering and is a registered professional engineer. As a Project
Engineer, he has spent his 29 year career in Black & Veatch’s Power and Oil and Gas Businesses, evaluating and
designing industrial water and wastewater treatment systems. His responsibilities have ranged from licensing
support and conceptual design studies to detailed design and startup, as well as commissioning support of
clients around the world.

R.C. Krichten, Global Boiler Group Leader, GE Water & Process Technologies
Rick joined GE Water (Betz) in 1976. Over the following 40 years he has worked with water systems design and
troubleshooting in most heavy industries, particularly refining, chemical and power. His product line experience
covers all water systems – steam, cooling, wastewater and influent. He is currently global boiler group leader for
chemical product applications. He is a contributing author to the Betz Handbook of Industrial Water Conditioning.

Paulo Gomes, Marketing Director EMEA, Kurita Europe GmbH

In 1998, Paulo Gomes started work in the Water Treatment business as Technical Manager. Over almost 20 years, he
has been in charge of several product ranges, working on product development and innovations. In 2007, he joined
the marketing department and in 2015 he took over the responsibility as Marketing Director at Kurita Europe. Since
January 2017, Paulo has been the head of Kurita’s Global Promotion team.

Dr Werner Arts, Founder and Board Chairman of LAR Process Analysers AG

Dr Arts’ occupational career started in 1986 as General Manager of BIFAU e. V., Berliner Institute for Analytics and
Environmental Technology. He was also Co-founder of LAR GmbH in 1986 and became General Manager in 1998.
After restructuring of the company into LAR Process Analysers AG, he became President of the corporation. He is
involved in the development of new analysers for water monitoring, process control and environmental protection.

John Tracy, Senior Director, Marketing & Commercial Operations, Oasys Water Inc.
John Tracy has over 15 years of experience in product management and strategic marketing, focusing on the
development and promotion of complex systems to international customers. He has over 10 years of power
industry and industrial water treatment experience with membrane systems. Prior to Oasys Water, John was a
Product Line Manager with Axcelis Technologies, and held engineering and business development positions with
ABB, Osmonics, and General Chemical Group.

Bill Perpich, Director of Business Development, Veolia Water Technologies North America
Bill Perpich’s focus is on the downstream oil and gas industry. He has over 25 years of experience in the
environmental field with expertise in the physical/chemical and biological treatment of industrial process water
and wastewater systems. His background includes assessing, identifying and implementing systems that provide
clients with a cost-effective, environmentally friendly and compliant solution.

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Q&A
Why is water treatment so crucial to the
downstream oil and gas industry?
Sid Dunn, Baker Hughes, a GE company (BHGE):
Water treatment technologies ensure water systems
are operating at optimal levels to maximise plant
efficiency and ensure reliability. This includes
preventing corrosion or scale in heat exchangers and
critical equipment that directly affect the plant’s
profitability. This same water also has to be
discharged from downstream facilities, which requires
extensive treatment to ensure that the discharge has
minimal impact on the environment.
Mike Preston, Black & Veatch: Water and wastewater
treatment is critical to downstream facilities to
preserve capital investments, ensure cost-effective,
sustainable operation and ensure regulatory
compliance.
Paulo Gomes, Kurita Europe GmbH: Water is
essential for all kinds of industrial processes. The
availability of water that can be used for production
and processes is a key cost and efficiency factor.
Smart water treatment technologies protect the
plant, decrease operational and energy costs and
improve occupational safety.
John Tracy, Oasys Water Inc.: Refining and
petrochemical operations consume large volumes of
water and contaminate that water when used in
various processes, from process unit cooling to
catalyst regeneration, to stripping processes.
Treatment requirements are becoming more complex,
either for reuse or discharge. In many geographies
around the world, water access is a bottleneck
related to the expansion of existing facilities or
construction of new facilities.
Bill Perpich, Veolia Water Technologies North
America: Water treatment is critical to the successful
operation of refineries and petrochemical plants. The
need begins with high quality supply water for process
operations, cooling water, and boiler feed water for
steam generation. Refining processes generate various
wastewater streams that contain oil, hydrocarbons,
carbon and nitrogen compounds, selenium and various
other contaminants. These waste streams require
treatment for the removal of these contaminants prior
to reuse or discharge. Physical, chemical, biological,
membrane and thermal treatment processes may be
needed to achieve the desired water quality,
depending on the intended use of the treatment plant
effluent.
Water reuse in refineries is becoming more
prevalent as source water availability and discharge
regulations become more stringent. An audit of water
consumers and wastewater generators at a specific
site is often the first step in developing a complete
water management programme. The water quality
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needed for each process step is taken into
consideration and internal systems for recycle and
reuse can be implemented to meet the water quality
requirements of the water-consuming processes.
Because of water availability restrictions and discharge
requirements in certain locations, some oil and gas
clients have found that a zero liquid discharge system
is the most economical and sustainable solution to
minimise water use and ensure regulatory compliance.
Q What are the main applications for your company’s
water treatment technology within the
downstream industry?
Johanna Ludwig, akvola Technologies: Our
proprietary flotation-filtration technology,
akvoFloatTM, could be used in three main applications.
Firstly, it can treat segregated effluents with the
highest oil content (e.g. desalter effluent, tank bottom
draws) in order to recover as much oil as possible and
de-risk the performance of the wastewater treatment
plant (WWTP). Secondly, it can replace conventional
primary treatment to deliver a higher quality effluent
(e.g. emulsion-free) to the biological treatment step.
Finally, it can be used in tertiary treatment, as a
pretreatment for any desalination technology in reuse
applications.
Dunn, Baker Hughes, a GE company (BHGE): Baker
Hughes, a GE company (BHGE) offers comprehensive
water treatment solutions throughout the entire
refining and petrochemical process, delivering
technologies and services from influent to effluent.
This includes raw water treatment, boiler
pretreatment, boiler water treatment, cooling water
treatment, process water treatment, and wastewater
treatment.
Preston, Black & Veatch: Black & Veatch is technology
neutral. Our value is our understanding of water and
industrial facilities as well as our ability to survey the
industry, evaluate alternatives, and implement
integrated, cost-effective solutions.
R.C. Krichten, GE Water & Process Technologies:
Main water treatment applications in downstream
industries follow the water from river to outfall, inlet
to waste effluent. GE Water & Process Technologies
designs, builds and operates most water pretreatment
equipment from clarification, filtration, ion exchange,
membrane systems, and electrodeionisation, to
temporary trailer-mounted systems, heat exchanger
monitoring, etc. The company provides water
treatment polymeric dispersants and corrosion
inhibitors for steam generators and cooling towers,
flocculants and coagulants for influent and effluent
total suspended solids separators (clarifiers, lime
softeners, gas flotation, sludge presses, digesters). In
activated sludge facilities, we manage the biology
 Innovative for our next generations,
we provide far-sighted and trusted solutions.
Kurita – responsibility for the future.

WE HAVE JUST THIS ONE EARTH. The generations that follow us deserve
WATER SOLUTIONS
a clean planet where life is worth living – with an environment where man and
For water and nature can live together in harmony. Every step we take in our research and
process treatment
PAPER SOLUTIONS development looks ahead to the future. You can therefore expect solutions
For the paper and
cellulose industry from us which focus equally on the sustainability, cost-effectiveness and
AL COMPOUNDS safety of your processes. With our latest innovations for water & paper
Products for waste
water treatment and for treatment and alumina-based products, we carry you further along your road
the manufacturing &
construction industries to success. As a globally active company we are always close to you with our
professional and customised service.

Kurita – increased efficiency for industry.

Kurita Europe GmbH

Giulinistraße 2
67065 Ludwigshafen
Germany

Phone: +49 621 5709 3273

Contact: info@kurita.eu
Visit us at: www.kurita.eu
Q&A
and health of bacterial organic conversion and
provide enzymes to enhance biological health.
In cooling tower systems, chemical applications
prevent inorganic scale from forming on hot process
equipment and tower fill. Chemical inhibitors prevent
corrosion of metal elements even in hot zones.
Biocides and biodispersants prevent the accumulation
of bacterial slime, fungi and algae, which form
heat-insulating deposits and under-deposit corrosion
if left unchecked. In the simplest case, a lack of proper
chemicals and chemical feed control will lead to
hotter process side, resulting in energy losses on
surface condensers and high vapour pressure going to
tankage, causing reprocessing. In complex cases,
improper chemicals can lead to exchanger leaks with
subsequent hydrocarbons contaminating the cooling
water, exceeding allowable volatile organic carbon
levels and resulting in serious environmental impact.
In steam systems, inferior chemicals and feed
controls can lead to turbine failure from scaling and
over speed, loss of energy for power production, gas
compression, or equipment failure from general
corrosion, pitting, or under-deposit corrosion. Proper
chemical programmes keep the steam side in a safe
pH zone to eliminate corrosion from acids or bases.
Polymeric dispersants prevent the accumulation of
inorganic salts – mainly calcium, magnesium or silica
– on hot tube surfaces. Oxygen scavengers rapidly
remove dissolved oxygen to avoid pitting corrosion.
Steam system chemicals are even co-ordinated with
process side chemistry to avoid amine-chloride
deposits in atmospheric crude overhead exchangers.
Gomes, Kurita Europe GmbH: Kurita covers the full
range of water treatment applications, from the
preparation of raw water (including products for
membrane processes) through cooling and boiler
water to the purification of wastewater.
Dr Werner Arts, LAR Process Analysers AG: The main
applications of LAR’s online water analysers are pure
water applications as water-steam-circuits. Here,
especially total organic carbon analysers are used to
monitor and control boiler feed water, steam and
condensate return. Further applications are the
monitoring of cooling water, which is relevant to
(almost) all processing stages within the downstream
industry. At the end of production processes, water is
led into WWTPs. Here, LAR’s analysers are used to
control the water influent to protect the WWTP
against shock loads and to optimise the treatment
processes.
Tracy, Oasys Water Inc.: Oasys focuses on treatment
processes to recover fresh water from impaired streams,
by separating and concentrating dissolved solids and
recovering a majority of fresh water, up to 80 or 90%.
Perpich, Veolia Water Technologies: In the
downstream industry, Veolia offers solutions for the
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entire water cycle, beginning with the supply water,
boiler feed water, demineralisation systems,
recycle/reuse systems, sour water treatment, desalter
brine, condensate treatment, and finally wastewater
treatment for reuse or discharge. Each application
differs depending upon the desired effluent quality.
Veolia has more than 350 proprietary technologies to
choose from in developing the best options for each
application, and we combine those with conventional
treatment options to provide fully integrated systems
delivered as engineer-procure, design-build or
design-build-operate projects for our clients based
on their needs, preferences and economic
constraints.
Q What was your company’s very first water
treatment related equipment or technology aimed
at the downstream oil and gas industry, and how did it
function?
Ludwig, akvola Technologies: akvoFloat is a
flotation-filtration technology based on novel ceramic
membranes. It is cost-effective in the treatment of
hard-to-treat oily effluents and has a high removal
efficiency (99% for oils and total suspended solids
[TSS]) at a competitive CAPEX and OPEX. The bubble
generator technology embedded in akvoFloat has also
been used stand-alone to revamp existing dissolved
air flotation (DAF) units in order to improve its
removal efficiency and reduce energy costs.
Dunn, Baker Hughes, a GE company (BHGE): From
the inception of the oil industry, there were problems
with water and oil separation. Producers were losing
profits and there were growing environmental
concerns. Pipeline operators and refiners refused to
accept emulsified oil due to its corrosive impact on
assets, and there was a risk of explosive steam
pressures when oil with high water content was
heated during processing. The unwanted
off-specification oil filled up pits and tanks, spilling
into nearby streams and rivers and taking up valuable
processing capacity. This industry-wide problem was
solved when William S. Barnickel invented the
Tret-O-Lite demulsifier in 1914. This technology was
the foundation of oil and water separation, and
continues to contribute success to water-related
issues across the oil and gas lifecycle.
Krichten, GE Water & Process Technologies: Our first
significant technology in downstream plants was a
cooling programme called Betz Dianodic, since it
contained both chromate and phosphate for inhibition
of general steel surface corrosion. Zinc was added
later to stifle pitting function. Along with an effective
dispersant for total suspended solids, this
combination treatment was the most highly effective
package geared specifically for hydrocarbon
processing facilities. When chromates were replaced
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secondary and tertiary deoiling, biological treatment (aerobic and
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Tel +1-800-337-0777
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Q&A
by phosphates for anodic inhibition, the solubility of
calcium phosphate became the greatest challenge.
GE Water & Process Technologies was able to patent a
highly effective polymeric dispersant, called 2020,
which was later replaced by HPS, to allow the use of
phosphates but avoid the serious scaling problems
from calcium phosphate. This combination allowed
the process industries to continue operating hot
distillation towers and reactor coolers without the
environmental impact of chromates.
Dr Arts, LAR Process Analysers AG: The first water
analysing related equipment was the online
total organic carbon (TOC) analyser QuickTOC®. This
analyser was equipped with a robotic horizontal and
vertical injection needle and a thermal combustion
method at 1200°C. Petrochemical wastewater is
characterised by suspended and dissolved pollutants
and has a significantly more complex water
composition than municipal wastewater. Due to the
injection system, solids were handled within the TOC
analyser, and the water samples were then
completely oxidised to CO2 . Typical incompatibilities
with high salt samples of measuring systems using
high temperature methods were fully avoided.
Q In what ways can water treatment technologies
help to improve regulatory compliance and
protect the environment?
Krichten, GE Water & Process Technologies: Water
treatment has a major environmental impact,
producing positive effects for water outfall and
vaporous air emissions, as well as reduction in
hazardous waste disposal. The use of total suspended
solids removal aids, such as polymeric coagulants and
flocculants in influent and effluent clarification, gas
flotation, and coker clarifiers, has a direct impact by
producing a wastewater with significantly reduced
suspended solids that would otherwise flow to
receiving bodies of water. In activated sludge or other
biological oxygen demand/chemical oxygen demand
removal processing units, bacterial health is vital to
the ability to maximise the conversion of complex
organics to CO2 , nitrogen, and low molecular
weight/low toxicity residual compounds. The use of
recent advances in bacteria health monitoring and
enzyme enhancement makes the wastewater plant
more capable and resilient. So, water treatment
reduces species that have environmental impacts by
enhanced settling, or bio conversion of aqueous
soluble hydrocarbons to more benign species.
Water and sludge treatment can do this at various
operating units where toxic waste is concentrated,
thereby reducing the loading at the wastewater bio
plant or at each stage of the industrial wastewater
plant.
Water treating equipment (e.g. ultrafiltration,
solids contact clarifiers and filters, reverse osmosis,
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electrodeionisation, and ultrafiltration membrane
bioreactors) has worked to increase the efficiency of
removal for total suspended solids and water soluble
toxic compounds. A membrane bioreactor (MBR) to
replace or improve standard activated sludge is
becoming common to allow greater bacteria contact
time and, therefore, conversion rates for soluble toxic
species such as phenol in refining wastewater. The use
of newer flexible membrane ultrafiltration box
cartridges gives absolute assurance of total suspended
solids (biological oxygen demand) removal and makes
it convenient to reuse industrial treated wastewater
after an additional polishing step with reverse
osmosis. In drought-stricken areas, secondary and
tertiary treatment is allowing refineries and chemical
plants to send treated wastewater back to cooling
and/or boiler makeup. This same equipment layout
allows treated municipal wastewater to become the
full influent for most industrial systems.
The areas in Los Angeles and Richmond, California,
US, have demonstrated just how far one can push
municipal reuse when incorporating sophisticated
membrane technologies. In fact, Betz Laboratories
first worked with the Hyperion project near Los
Angeles in the early 1970s to fine tune required
cooling water treatments to allow full reuse for
cooling towers without sacrificing tower heat duties.
Much more has been accomplished since those early
days. Now, refineries benefit from the reuse of Title 22
municipal effluent water due to advances in cooling
chemistry, particularly Halogen Resistant Azole that
allows free chlorine residual without harm to cooling
chemicals, and advanced calcium phosphate
dispersants that allow much higher levels of
phosphate without fear of deposition.
Air quality is improved with water treatment via
the detection and prevention of volatile organic
carbon emission from tower stacks. This often occurs
because of cooling water exchanger leaks in refining
gas or chemical plants processing low MW light ends.
Early detection is key, followed by rapid isolation of
the offending exchanger. GE Water & Process
Technologies makes TOC analysers used for online
monitoring. During troubleshooting, advanced
chemistry is used in the cooling tower to allow
ongoing plant operation without adverse corrosion
impact. Chlorine/oxidant resistant chemical treatment
(halogen resistant azole) allows for ongoing operation
with very high oxidant levels, thus preventing the
corrosive potential of sulfate-reducing bacteria. Prior
to chlorine/oxidant resistant molecules, the presence
of a hydrocarbon leak, particularly a sulfidic leak as
often occurs in refineries, would lead to excessive
corrosion and pitting in a short period of time. Boiler,
cooling, wastewater, and reuse technology has had
major impact on processing of hydrocarbons in
downstream operations.
Gomes, Kurita Europe GmbH: In downstream
processes, several water application fields need to be
 taken into account, such as raw water, cooling, heating
and wastewater treatment.
Optimal treatment solutions for water significantly
reduce corrosion, scaling and fouling, which is essential
for plant efficiency and lifecycles.
The generated wastewater contains oils and other
pollutants that need to be eliminated prior to discharge
or recycling. State-of-the-art treatment technologies
are able to remove the undesired substances effectively
to meet the regulatory compliance and optimise the
quality and the quantity of recycling water.
With the application of chemicals from renewable
natural resources, we help our customers to expand
operational runtime, reduce water and energy
consumption and thus support environmental
protection. We want to contribute to an environment in
which nature and man are in harmony.
Dr Arts, LAR Process Analysers AG: In recent years,
one of the most relevant projects for LAR was its
participation at a German-Vietnamese joint research
project named ‘AKIZ’. In Vietnam, more than 200
registered industrial zones (IZs) are without
sustainable wastewater treatment. As such, this
flagship project developed an integrated wastewater
concept for IZs to secure the efficiency and
sustainable operation of the whole wastewater
system, including all of its technical components.
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Using containerised pilot plants in different branches
of the Tra Noc IZ in Can Tho City, located in the
Mekong-Delta, high-tech solutions for pretreatment
of wastewaters, generation of energy from wastewater
and recuperation of valuable substances has been
adapted and verified by on-site pilot systems, taking
into consideration the local conditions. This project
highlights that water treatment technologies can help
improve regulatory compliance and protect the
environment in different ways.
Q How can water treatment solutions help to tackle
reliability issues and improve productivity in the
downstream oil and gas industry?
Ludwig, akvola Technologies: The composition of the
different water effluents in a refinery varies constantly
and these are prone to upsets (i.e. extreme peaks in
the concentration of a particular component like oil
emulsions). Conventional technologies (API, DAF/IGF
and biological treatment) are technologically limited
and unable to deal with such upsets, reducing the
reliability of the system as a whole. This translates
into higher operating costs by having to divert certain
effluents to the slop tanks (and reducing profit by
generating non-revenue oil), or worse, by
non-compliance penalties in the discharge.
We know TOC analysis
In more than 30 years LAR Process Analysers AG has
established itself as world's leading manufacturer of
high quality online water analysers.
ü Measurement of pure water to waste water
ü Reliable high-temperature combustion method
ü Precise and fast detection - whatever the conditions
www.lar.com/toc-process-analyzer
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Q&A
Ceramic membranes have proven their suitability to
handle challenging wastewaters and upsets by offering
an absolute barrier against oil emulsions and particles.
In terms of productivity, when segregated effluents
are treated, the recovered oil can be sent back to
upstream operations for re-processing, reducing the
amount of non-revenue oil.
Preston, Black & Veatch: Water that is properly
treated for the application should reduce unforced
outages and prolong the life of affected equipment.
Boilers are good examples. Proper water treatment
will minimise blowdown (increase energy efficiency),
reduce corrosion-related failures (reduce downtime),
and reduce long-term maintenance.
Water treatment solutions also allow downstream
facilities to minimise fresh water consumption and
wastewater discharge.
Dr Arts, LAR Process Analysers AG: The water quality
in water-steam-cycles, for example, is crucial for
productivity. Any contamination of feed water, high
pressure steam or low pressure steam used for
numerous production processes, can lead to increased
formation of deposits, foam and corrosion. In the
worst case, the entire boiler plant must be shut down.
Optimised online TOC analysers provide fast and
reliable determination of pollutants in steam and
condensate, so that in the case of pollution, only
contaminated water and not the clean water will be
drained off. Additionally, the processing of raw water
to pure water is costly and energy intensive.
Therefore, the detection of a shock load is just as
important as the degradation. Otherwise, expensive,
clean condensate is drained off.
In summary, the velocity and accuracy of
determining contamination in water streams, as well
as the water treatment, is crucial for productivity and
profitability in the downstream oil and gas industry.
Optimisation is only possible with fast and stable
monitoring and control. Water treatment solutions
also allow downstream facilities to minimise fresh
water consumption and wastewater discharge.
Tracy, Oasys: When water recovery for reuse is
accomplished with membrane processes as opposed
to with thermal processes, the scaling, resulting heat
transfer loss and higher maintenance frequencies can
be avoided. Well-designed membrane processes for
wastewater treatment can be run for greater than a
month between cleaning cycles, and those cleaning
cycles are ‘clean-in-place’, not requiring access to
tube bundles or confined space entry.
Q Talk us through your company’s design process for
new water treatment technologies or equipment.
Gomes, Kurita Europe GmbH: We at Kurita are
strongly committed to meet our clients needs. Our
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team provides services and can advise about
improvement potentials, as well as listen to our
customers and their needs. Our R&D centres in Japan
and Europe with around 350 scientists use this direct
feedback for further developments and designs of
new technologies – always focusing on our ecological
responsibility. Regular training enables our sales and
technical staff to improve existing applications and to
implement new technologies. As a result, our
customers benefit from economically and ecologically
efficient treatment programmes.
Tracy, Oasys Water Inc.: We first establish a design
basis for how the process must operate over time,
maximum and minimum flows, dissolved and
suspended solids levels, fouling or scaling
constituents. With a known process window, a
process design, piping and instrumentation diagram
(P&ID), and equipment list can be established.
Detailed design proceeds from these key pieces.
Customer review and approval of the design elements
along the way is critical.
Perpich, Veolia Water Technologies: Any new or
improved technology from Veolia begins with
addressing our clients’ needs. Once a problem is
identified, we begin to look for the best solution to
meet our clients’ expectations. Potentially, the first
step is laboratory-scale testing to define a new
process, or we may move to validation by pilot-scale
tests prior to full-scale implementation. As part of the
product development process, the impact of our
proposed processes on the environment, such as
environmental footprint, etc., is quantified through
various tools that Veolia has developed. We have a
research and innovation (R&I) team that is
continuously seeking to improve processes and
develop new solutions. However, the direction for the
research projects most often comes from the local
business units working closely with industry to solve
the challenges faced by our clients every day.
In addition to the R&I facilities, Veolia has research
capabilities with local business units that specialise in
particular technologies. Any business unit within the
company can apply for funding for research to meet a
need identified in the marketplace. Work carried out
locally is reviewed and validated by the corporate
group to ensure that our solutions will fulfil the
intended purpose. In this way, Veolia stays on the
cutting edge of new technologies and innovations.
Q Outline how water treatment technologies can
have a positive impact on local communities.
Preston, Black & Veatch: Improved wastewater
treatment improves water quality. Fresh water
demands to facilities can be reduced through
intentional water management principles and
expanded use of alternative water supplies (treated
 Under the Patronage of
His Royal Highness
Prince Khalifa bin Salman Al Khalifa
Prime Minister of the Kingdom of Bahrain

MIDDLE EAST

The 11th Middle East Refining and

Petrochemicals Conference & Exhibition
BAHRAIN INTERNATIONAL EXHIBITION & CONVENTION CENTRE

CONFERENCE:
CO 7 - 10 OCTOBER 2018
EEXHIBITION: 8 - 10 OCTOBER 2018

EXHIBITION ORGANISERS

www.mepetrotech.com
Q&A
municipal wastewater, produced water, internally
recycled water, etc.).
Perpich, Veolia Water Technologies: Water is a
resource used by everyone. Our water treatment
technologies are one way that Veolia fulfils its stated
mission of ‘Resourcing the World’. By this, we mean
developing access to resources, as well as preserving
and replenishing them. In the downstream industry,
water reuse within plant processes enables facilities
to take less water from the rivers and streams,
preserving the resource for other purposes such as
drinking water and recreational activities. Our water
treatment technologies often produce effluent water
that is cleaner than the river water that the facility
takes in. In some locations, this clean effluent has
been used to recharge aquifers or replenish water in
rivers and streams. Studies have shown that in some
cases, the clean water from our treatment plants
improves the overall water quality of these receiving
streams to the advantage of the ecosystem and the
local residents.
Byproduct recovery is another way that our
treatment processes can have a positive effect on
local economies. Turning contaminants that were
previously discarded as waste into useful, saleable
products minimises the cost of disposal and provides
a new source of revenue while decreasing the volume
of waste in local landfills and preserving the
environment. In some cases, recycling byproducts to
the production process can offset the cost of using
virgin materials.
Q What has been your company’s biggest
achievement or technological breakthrough in
terms of water treatment?
Ludwig, akvola: akvoFloat has allowed a German
refinery to reuse 99% of its wastewater where
conventional and other membrane technologies had
failed. This project made it possible for the refinery to
reduce its intake of raw water and avoid discharging
most of the water back to the river.
Dunn, Baker Hughes, a GE company (BHGE):
Corrosion in cooling towers has been an ongoing
operational concern, leading to decreased efficiency
and even equipment failures. Traditional corrosion
treatments contain phosphorous, which can be
harmful to the environment. Because of this, new
regulatory guidelines may restrict the amount of
phosphorous in the plant discharge. Taking a
proactive approach to find an alternate solution to
address these limitations, Baker Hughes, a GE
company (BHGE) developed the LIFESHIELDTM NP
non-phosphorous corrosion inhibition programme.
This new technology contains zero phosphorous,
allowing operators to meet stringent environmental
regulations while still confidently managing highly
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corrosive water systems. This not only increases
operational flexibility, but also improves equipment
reliability and performance.
Preston, Black & Veatch: One recently completed
project allowed a chemical facility in the Midwest US
to switch from city water to treated municipal
wastewater as a primary water supply for cooling tower
makeup and boiler makeup. This reduced water cost for
the facility and improved the city water availability for
a community in a water stressed geographic region.
Gomes, Kurita Europe GmbH: Kurita has launched
many innovations in the last 2 – 3 years, most of
which are focused on water saving and process
optimisation. One of our latest developments is a
new molecule, Corrsave®, that provides corrosion
inhibition with a low content of phosphorous, which
significantly reduces the undesired phosphorous
content in the wastewater. Another technology is our
film-forming product range, Cetamine®. It provides
energy savings in boiler systems due to an improved
heat transfer. In addition, we recently launched our
rejuvenation technology for reverse osmosis
membranes, which helps to prolong the lifetime of
membranes.
Dr Arts, LAR Process Analysers AG: LAR’s biggest
technological breakthrough was the development of
TOC analysing equipment for the measurement of the
most complex wastewater compositions in the
industry. The analysers are able to handle samples
with a high particle density, high salt concentrations
as well as sticky, fatty and oily samples.
Tracy, Oasys Water Inc.: The ability to apply
membrane processes to difficult waters and to
concentrate streams to levels only achieved by
thermal technologies previously has been our biggest
achievement. To scale the technology from the
laboratory, to pilot, to commercial systems
processing >5000 m3/d of petrochemical plant
wastewater has been rewarding and has required the
capability to design and deliver complete systems,
beyond just the core pieces of technology that we
originally developed.
Perpich, Veolia: For the oil and gas industry, one
technology that stands out as a significant
development is our OPUS® technology. This
technology is an integrated system that was first
developed for upstream exploration and production
operations to minimise deep well injection and
enhance oil recovery. The technology, based on
pretreatment followed by reverse osmosis (RO)
operated at an elevated pH, has also been
implemented in the mining and automotive industries
to achieve zero liquid discharge. With some
modifications, it is now being applied as a zero liquid
discharge (ZLD) system for a refinery.
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Processes
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• Thermal Processes – Delayed Coker and other
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• RFCC – Applications in Residue Upgrading
• Hydrogen, Sulphur & Energy Management
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Reforming, Isomerisation
• Catalysts for FCC & Residue Upgrading
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Techniques & Procedures

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 Q
Q&A
How has the recent oil market volatility affected
the water treatment industry?
Dunn, Baker Hughes, a GE company (BHGE):
Successful water treatment is a necessity for plant
operators, regardless of market conditions. When
commodity prices are low, refiners look for ways to
successfully process discounted crude blends to gain
higher margins. This requires innovative technologies
that can handle the additional challenges that come
with processing heavy, acidic crude slates. When times
are good, processing plants are still focused on the
bottom line, but the opportunity shifts to identifying
areas where they can maximise throughput and avoid
bottlenecks. This includes confirming the plant is
operating at optimal rates and conditions, identifying
additional water re-use opportunities, as well as
reducing contaminants in wastewater that could result
in fines and penalties.
Tracy, Oasys Water Inc.: The downturn in oil and gas
prices all but stopped the adoption of new
innovations by either upstream or downstream
operators, as they were forced to cut back on capital
projects. There are now signs of life in cases where a
clear contribution to profitability, and where project
financing can be justified.
Q Where do you see the water treatment market in
10 years’ time?
Ludwig, akvola: Across all industries there has been
an ongoing trend to fully outsource (waste)water
treatment operations, due to the fact that these are
outside of the core business of industrial players. This
shifts most of the technological, operational and
financial risks to the water technology and treatment
suppliers, which have all the necessary know-how to
deal with them. Additionally, this gives these
companies an incentive to strive for the maximum
operational efficiency, fostering innovation in the
field.
We think that in 10 years’ time most end-users will
go for models such as build-own-operate (BOO), in
which water treatment is delivered as a service with
no capital expenditures for the end-users. In this new
paradigm, solutions will be transformed into services.
Dunn, Baker Hughes, a GE company (BHGE): There is
a huge opportunity for digitisation within the water
treatment industry, as well as the downstream oil and
gas market as a whole. Baker Hughes, a GE company
(BHGE) is already testing out new digital technologies
like sensors and monitoring tools that enable
automatic adjustment to chemical treatment feeds.
There are additional possibilities beyond automation
and control that can actually predict, and therefore
prevent, problematic conditions before they lead to
costly problems. Applying digital learnings and relying
e beer 20177 118 HYD
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on big data will have a dramatic impact on the
industry, improving efficiencies and reducing health,
safety and environment (HSE) exposure by limiting
human interaction where possible.
Gomes, Kurita Europe GmbH: The co-operation and
collaboration between consumers and chemical
service providers will be more intensive. Only together
is it possible to analyse and optimise processes with
the target to reduce water consumption and the
ecological impact. A deep understanding and
application of know-how is crucial for success.
Another big trend is the digitalisation and big data
management. Digital services and support will change
the way we are working together and will be key for
the future. Kurita is working on solutions in order to
provide customised offers to our clientele, which will
make our lives easier.
Dr Arts, LAR Process Analysers AG: Water is known
as the world’s most vital resource. Already today, the
water industry faces challenges that were not
discussed years ago, such as micro-pollutants. In the
future, more challenges will arise. Since fresh water is
a limited source, the importance of a circular
economy will increase significantly within the
upcoming years. Robust water treatment technologies
will minimise wastewater discharge and maximise
water recovery. So called ZLD solutions will be
beneficial to industrial and municipal organisations as
discharge, or effluent, will be avoided. Another trend
will be based on Industry 4.0, the so-called Water 4.0.
This buzzword describes the digitalisation and
automation processes focused on the strategy for an
efficient, flexible and automated water resource
management. Based on these developments, the water
treatment market will be subject to strong growth. In
particular, the monitoring of water will take over a key
role, since the control of water streams and water
treatment plant’s are only possible with reliable and
fast measurements.
Perpich, Veolia Water Technologies: The future of
water treatment will involve ‘smart’ water systems
outfitted with sensors and data collection
capabilities to optimise water treatment processes
and improve reliability. With cloud-based platforms,
these systems will enable operators to maximise the
performance of not only their water systems but also
their production processes that depend upon the
supplied water quality. The reliability of water
systems will be improved through predictive
maintenance programmes that alert operators to
potential problems before they occur. Machine
learning will ensure continuous improvements in the
performance of the water treatment systems. Thanks
to the cumulative data collected through these smart
systems, water treatment plants in the future will be
smaller, more efficient and more reliable than those
of today.
 AD INDEX
Page Number | Advertiser 109 | Kurita Europe GmbH

Advanced Refining Technologies / W. R. 113 | LAR Process Analysers AG

53 |
Grace & Co.
35 | Merichem Company
07 | Albemarle
115 | Middle East Petrotech
51 | AMETEK Inc.
45 | Neuman & Esser Group
105 | Arkema Inc.
65 | Offsite Management Systems LLC
IFC | BASF
15, 47, 65, 97,
| Palladian Publications
21 | Chevron Lummus Global 113

69 | CRI Catalyst Company 48 | Peinemann Equipment B.V.

63 | Criterion Catalysts & Technologies 23 | Pittsburgh Corning

IBC | Curtiss-Wright EST Group 37 | Quest Integrity

77 | Dunn Heat Exchangers, Inc. 24 | Rembe® GmbH Safety + Control

99 | Edelhoff Technologies GmbH 93 | ReZel Catalysts Corp.

100 & 117 | Euro Petroleum Consultants OBC | Rosen

11 | ExxonMobil 71 | Sabin Metal Corp.

75 | Haldor Topsoe 02 | Sandvik Process Systems

85 | Heraeus Precious Metals 94 | Selective Adsorption Associates, Inc.

54 | Hoerbiger 59 | Siemens

81 | Honeywell Process Solutions 17 | Sulzer Chemtech

04 | HTRI 103 | Tank Storage Germany

15 | Intergraph CADWorx 89 | Trinity Consultants

82 | Intertek OFC & 41 | UOP, A Honeywell Company

27 | Johnson Matthey Process Technologies 111 | Veolia

09 | John Zink Hamworthy 28 | Wattco

97 | Kelvion 57 | Zwick Armaturen GmbH

HYDROCARBON 119 September 2017

ENGINEERING
 15 FACTS ON...
SKILLS, TRAINING & RECRUITMENT
57% of job opportunities in the
US through 2035 are projected
Engineers and
technicians are
71%
to be in blue collar occupations, of CEOs in a
the most PwC survey list
with one-third of opportunities
in-demand ‘LEADERSHIP’
projected to be in management
jobs worldwide as the most
and professional fields
sought after
50% of oil According to Airswift’s GETI, industry skill
and gas CEOs over two-thirds of hiring
believe automation managers believe there
and other is a skills shortage in the
downstream sector
technologies
WILL NOT The human brain is In 2016,
decrease the 73% WATER. OVER
industry headcount, It takes only 2% 330 000
according to PwC’s dehydration to JOBS
‘20th CEO Survey’ affect your attention, were delivered
memory and other through or
More than
cognitive skills supported by
237 000 women the oil and
are currently working in gas industry in
Nearly 1.9 million direct job
the US oil, natural gas and
opportunities in the US oil, gas the UK
petrochemical industries,
and petrochemical industries
with over 114 000 The average
are expected through 2035
in management and HUMAN BRAIN
professional occupations Women are projected to fill is believed
to generate
Studies suggest that MORE THAN 290 000 approximately
MULTITASKING IS of the job opportunities
LESS PRODUCTIVE in the US oil, gas and 50 000
than focusing on a petrochemical industries THOUGHTS
single task at a time through 2035 PER DAY
AirSwift’s GETI suggests that Sphenopalatine Minority employment
the downstream sector ganglioneuralgia in the US oil, gas and
HAS A GREATER is the petrochemical industries will
PROPORTION medical RISE from approximately
of 18 – 24 year olds working term for one-quarter of the total
in it than other energy sectors BRAIN in 2015 to more than
(6% of the total workforce) FREEZE one-third in 2035

September 2017 120 HYDROCARBON

ENGINEERING
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