Refineries have increased focus on processing unfamiliar opportunity crude oils to improve profitability. However, the introduction of these new crude slates brings uncertainties that can impact refinery operations. One major challenge is crude incompatibility due to asphaltene instability, which affects desalters, emulsion stability, preheat trains and furnace fouling.
For decades, the industry has recognized the importance of tracking asphaltene stability. Suppliers and refineries employ diverse equipment to assess feeds stability including benchtop microscopy and titration equipment. Unfortunately, those methods can require time-consuming offsite laboratory testing.
Now, utilizing a portable, handheld near-infrared (NIR) analyzer, crude oil tanks and other refinery feeds can be assessed for stability and blending suitability with near instantaneous results. NIR spectra from crude oil samples are collected and compared against a database of crudes and crude unit feeds with known asphaltene stability parameters. Asphaltene stability parameters are modeled and reported with a stability assessment.
In the presentation, we will delve into the fundamentals of these available tools, showcasing real-world case studies where they have been successfully applied for crude blends and crude pretreatment to improve and optimize desalter operations and crude preheat train fouling.
Facilitators:
Cliff Avery, Ketjen Corpotation
CJ Farley, TPM Solutions
1. Commercial Results of 100% Vegetable Oil Processing in an FCCU
Speaker: Andrea de Rezende Pinho, Petróleo Brasileiro S/A - PETROBRAS
In 2023, Petrobras and the Riograndense Refinery (RPR) successfully processed 100% vegetable oil in a Fluid Catalytic Cracking (FCC) Unit. Petrobras' technology is based on three pillars: i) triglycerides, such as soybean oil used in the commercial test, ii) ReNewFCC line catalyst and iii) unique operating conditions compared to conventional FCCUs. Biogenic products such as renewable aromatic hydrocarbons (BTX - benzene, toluene and xylene), renewable LPG, and renewable propylene were produced during the commercial trial. Commercial yields, quality of the products, operational challenges and technical adaptations for the trial will be presented.
2. U.S. HEFA Co-processing – Past, Present, and Future Projects
Speaker: Eamon Cullinane, Turner, Mason & Company
HEFA co-processing at U.S. oil refineries has historically not seen the same success as standalone RD/SAF refinery conversions. So why has co-processing in the U.S. been limited in the past and why might we see more of it in the future? We will explore historical production levels of co-processing, economics vs standalone RD/SAF facilities, the regulatory landscape and credit incentives (RINs, BTC, CFPC/45Z, CA LCFS, etc.) driving these economics, and future prospects of co-processing in the U.S.
3. Preheat Train Monitoring Methods
How do you reprocess slop oil in your refinery? Join us at this Town Hall session to discuss how others in the refining industry handle slop and best practices for success. Come share your experiences with the group and learn from industry experts about effective slop oil reprocessing techniques.
Pyrophoric materials pose significant safety risks during unit shutdown and maintenance activities, and pyrophoric incidents continue to occur across the refining industry. Effective strategies for prevention and mitigation of pyrophoric activity are critical aspects of turnaround planning and execution. This presentation will explore the underlying mechanisms of pyrophoricity and discuss best practices for managing pyrophoric risk, including chemical treatment, engineering, and procedural solutions. Additionally, the presentation will dig into a real industry incident that occurred in 2017, the root causes and the steps taken in the past seven years to prevent recurrence. By providing a comprehensive overview of pyrophoric activity prevention strategies, this session aims to equip refining professionals with the knowledge and tools to mitigate safety hazards and enhance operational integrity in high-risk environments.
Moderators:
Diana Cheek, Chevron U.S.A. Inc.
Katie Marshall, Refined Technologies, Inc.
Presenters:
Diana Cheek, Chevron U.S.A. Inc.
Katie Marshall, Refined Technologies, Inc.
Dan Wood, HF Sinclair
This session will focus on the increasing challenges posed by iron contamination of FCC catalysts and the latest industry efforts to better understand and mitigate iron contamination mechanisms. More specifically, this session will focus on recent advancements in laboratory testing and FCC catalysts and additives to help overcome iron contamination. Attendees will come away with a fundamental understanding of the key principles and latest solutions available to handle the widespread presence of iron in FCC feedstocks.
Moderator:
Andrew Mezera, Valero Energy Corporation
Presenters:
Jeremy Mayol, Johnson Matthey
Shankhamala Kundu, W.R. Grace & Co.
Successful turnarounds are crucial for the long term reliability and profitability of FCCs. This presentation offers process engineering best practices for FCC turnarounds including preparation, execution, and post start-up actions. Multiple topics will be discussed including scope determination, inspection protocols, equipment cleaning, project execution, documentation, and identifying future unit improvements.
Moderator:
Todd Hochheiser, Johnson Matthey
Speakers:
Nate Hager, Cenovus Energy Inc.
Herb Telidetzki, Becht
Canadian Refiner replaced the Shake Test with on-line UOP Mercaptide Sensors to monitor the extent of Merox caustic regeneration. Mercaptide Sensor use resulted in continuously trended data, reduced caustic exposure, and proactive process variable optimization, while vastly reducing off specification incidences and unnecessary bulk caustic replacements.
Units in the refinery are interconnected and operational changes to an upstream often create challenges for downstream units. We will review how normal and abnormal FCC operations impact Alky feeds. We will also discuss Alky feed specifications and the impact to acid consumption and alkylate quality.