Expert Panel Discussion on Considerations for Heater Optimization and Future — Part 1
Gasoline Processes
Facilitator:
Matt Hutchinson, Axens North America
Moderator:
Joong Yang, Chevron U.S.A. Inc.
Panel:
Amit Gupta, Heurtey Petrochem Solutions
Bill McLaughlin, ExxonMobil Product Solutions Company
Ethan Spielvogel, Marathon Petroleum Corp.
Randy Stier, Valero Energy Corporation
Vivek Sundaram, LyondellBassel Industries
We are producing petroleum products in the current environment in which emissions reduction is demanded amidst rising consumer demand. The panel discussion will focus on safe operation and optimization of process fired heaters, including limitations with existing technologies to reduce emissions, and challenges with emerging technologies, e.g., hydrogen firing and electrification.
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CSB Lessons Learned: Fired Heater Tubing Failure
Fired Heater, Lessons Learned
The CSB will discuss its investigation of the November 19, 2023, fired heater tube rupture at a refinery in Martinez, California. The incident occurred during the initial startup of a renewable diesel hydroprocessing unit, resulting in a fire that seriously injured one employee. Topics will include fired heater safe operating limits, worker proximity to fired heaters, safety instrumented systems that detect low process flow into fired heaters, burner operation, valve misalignments, and corporate oversight.
Participants will: Gain an understanding of both the process-side and combustion-side causes that contributed to the tube rupture; Identify potential deficiencies that may exist at their own units; and Review the CSB’s industry recommendation to API for suggested revisions to API RP 556 (Instrumentation, Control, and Protective Systems for Gas Fired Heaters).
Moderator:
Willis Jernigan, AFPM
Speaker:
Melike Yersiz, U.S. Chemical Safety Board
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SMR Heater Tube Inspection and Reliability
Lessons Learned, Fired Heater, Hydroprocessing
This session will cover the topic of using a SMR heater tube inspection technology and using the inspection results to increase hydrogen production.
Moderator:
Diane Dierking, Johnson Matthey
Speakers:
Scott McArthur, Phillips 66
Edgar Remedios, FOERSTER Instruments Inc.
Oliver Smith, Air Products and Chemicals
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Ensuring Safe and Efficient Transitions from Full Burn to Partial Burn
Lessons Learned, Fired Heater, FCC
This session will cover KPIs and operating scenarios for partial burn FCC units, including the challenges and consequences of maloperation. Additionally, this session will focus on considerations taken to ensure safe operation of the CO Boiler. Attendees will come away with a fundamental understanding of the key principles and potential hazards associated with partial-burn operation.
Moderator:
Joe Colmone, Honeywell UOP
Speakers:
Luis Bougrat, W.R. Grace & Co.
Zach Word, Phillips 66
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Refinery Wastewater Upset Lessons Learned: Maintaining Production and Avoiding Negative Environmental Impacts
Environmental, Sustainability
The oil refining process generates a significant volume of wastewater that contains a suite of challenging contaminants, from hydrocarbons to heavy metals and organic compounds. Oil production at a refinery relies on efficient and reliable wastewater treatment as it is impossible for the facility to operate without treating its effluent. Issues with the wastewater treatment systems can result in production limitations, as well as significant environmental impacts and violations. These systems can be complex, and they are sensitive to upset conditions due to poor feed quality, unexpected contaminants, or equipment breakdown.
This presentation will discuss a significant upset condition that impacted both the primary and secondary wastewater treatment system at a large West Coast refinery. We will present the processes that allowed for detection of the upset, and the steps taken by the operations group, technical team, and vendor support that helped maintain target production rates and avoid any environmental violations or impacts. The mitigation steps allowed for storage and post-upset treatment of the problematic effluent streams. The technical team evaluated options for treatment and environmental compliance, and the water treatment vendor supplied specialty biological treatment technology to get the system back online as quickly as possible. All of this contributed to a successful upset response and the implementation of best practices that can help all refineries facing a wastewater oil contamination.
Moderator:
Dan Harbs, Veolia
Speakers:
Angela Wharton, Chevron U.S.A. Inc.
Kai Zhang, Chevron U.S.A. Inc.
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Unlocking the Future of Refining: The Transformative Power of Perchloroethylene (PCE or PERC) – Regulations, Safety, and Sustainability
Gasoline Processes, Environmental
The intersection of refining and petrochemical manufacturing has never been more significant as industries navigate the dual challenges of efficiency and sustainability. This session will explore the critical role of Perchloroethylene (PERC) in modern refining processes while also highlighting its applications in petrochemical production.
PERC is recognized as one of the safest catalyst activators during normal operations, as well as a regenerator for spent catalysts. Utilizing less efficient materials can necessitate larger quantities of hazardous substances being kept onsite, thus increasing exposure risks. Other chlorinating agents are either restricted by the EPA or are inherently more hazardous, making PERC a preferable option.
Attendees will gain insights into how PERC enhances refining technologies through processes such as isomerization and catalytic reforming, which help ensure compliance with environmental regulations. Industry experts will discuss the extensive benefits of utilizing PERC, emphasizing innovations that contribute to both safety and operational efficiency.
Moreover, we will review advancements in safety protocols that facilitate the effective handling of PERC, ensuring minimal exposure and adherence to rigorous regulatory standards. By fostering dialogue among leaders in refining and petrochemical manufacturing, this session aims to identify collective strategies for driving innovation and achieving sustainability goals within the industry.
Moderator:
Alex Kniuksta, Honeywell UOP
Speaker:
Scott Wozniak, Honeywell UOP
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Heater Health for Maximum Efficiency and Throughput
Coking, Fired Heater
Facilitator: Sam Lordo, Becht
Speakers:
Belal Hassoun, Becht
Frank Liu, Becht
Crude, Vacuum and Coker heaters can be considered the hearts of their respective process units. Monitoring the accumulation of internal tube fouling is important and challenging. This discussion will cover good practices applied to monitor fouling prone heaters with the intent to safely and reliably maximize equipment value generation and efficiency. Topics will include tube skin thermocouples, infrared thermography, Goldcup contact pyrometry and how these measurement tools can be utilized for pulse checks of the system. Key turnaround checklist items for heaters will also be discussed.
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