ERTC 2025
Reimagining the hydrocracker
Jeff Pro Shell Catalysts & Technologies
Act now: Flexibility without the wait Shell Catalysts & Technologies has a long track record in supporting refin- ers in repositioning their hydrocrackers through revamps, configuration changes, and cycle-to-cycle catalyst optimisa- tion. These actions are enabling faster responses to market shifts, access to new product value streams, and progress on decarbonisation by improving energy effi- ciency and hydrogen management, while also enabling co-processing of renewable and circular feeds. For example, at one European refinery, a fuels-focused, two-stage hydrocracker that was originally geared towards mid- dle-distillate production was reconfig- ured to feed a new ethylene cracker in an adjacent petrochemicals facility. It was converted into two parallel, single-stage reactors operating at reduced conversion, enabling it to produce ethylene cracker feedstock with a fresh feed capac- ity around 300% of that of the original design. The revamped system also deliv- ered a catalyst cycle length of two years, and all with only modest capital expend- iture, contributing significantly to overall site economics. Increasingly, refiners are taking the opportunity to implement energy tran- sition enablers. These include reduc- ing hydrogen consumption, improving unit energy efficiency, and incorporat- ing renewable or recycled feedstocks through co-processing. Shell Catalysts & Technologies has helped customers tai- lor catalyst systems for novel feedstocks such as pyrolysis oil or renewable diesel components, enabling early progress on emissions targets while maintaining per- formance and cycle life. What flexibility looks like in practice Hydrocracker flexibility means different things to different refiners. But common themes include: ○ Processing heavier, lower-cost feeds . A US Gulf Coast refiner re-optimised its catalyst system to handle more challeng-
Designing flexibility from the outset For new grassroots projects or site recon- figurations, hydrocracking remains a cor- nerstone technology. Shell Catalysts & Technologies is supporting customers who are designing full-conversion complexes around hydrocracking, enabling the pro- cessing of heavier, lower-cost crudes while building in the ability to swing the product slate towards steam-cracker feed, lubri- cant base-oil feed, or fuels, depending on market conditions. Even where large new builds are off the table in Europe, the same principle applies: configure or revamp for an expanded oper- ating window now so that the asset can transition more easily between product slates in the future. This means thinking beyond the process configuration. Reactor internals design and catalyst selection play just as critical a role – not only in shaping operating flex- ibility, but also in enabling long cycles, pro- tecting margins, and reducing the unit’s carbon intensity. Questions worth asking For European refiners seeking to main- tain a competitive edge, the hydrocracker deserves a second look. Could it be config- ured to process heavier or lower-cost feed- stocks? Is it still tied to transport fuels, or could it pivot towards higher-value outputs such as petrochemical or lubricant base- stock feed? Are modern catalyst systems and process optimisation tools being used to their full potential – and if not, what value might be left on the table? In an era of rapid change and long investment cycles, the ability to adapt existing assets could prove to be a powerful differentiator. Hydrocrackers may not generate head- lines like sustainable aviation fuel (SAF) mega-projects or world-scale carbon cap- ture hubs. However, their potential to qui- etly improve margins, reduce risk, and support the energy transition should not be underestimated.
As European refiners navigate the dual challenge of volatile market conditions and the longer-term energy transition, one asset is emerging as quietly essen- tial: the hydrocracker. Originally designed to convert vacuum gas oil (VGO) into die- sel and kerosene, the hydrocracker is now being reimagined as a strategic tool for both near-term profitability and long-term adaptability. While many refiners are pursuing major decarbonisation initiatives such as carbon capture, plastics pyrolysis, and renewable fuels production, these projects are typi- cally complex, capital-intensive, and years in the making. By contrast, hydrocrackers are already present at many sites and, with the right upgrades, they can be reconfig- ured relatively quickly to support enhanced commercial and strategic outcomes. From fuels production to a platform for transformation Hydrocrackers are being pushed further than ever before. No longer confined to their traditional role, these units are now being adapted to process heavier, lower- cost feeds such as deasphalted oil (DAO), heavy coker gas oil, and slurry oils. They are being configured to produce high- purity naphtha streams or specific mol- ecules for petrochemical crackers. Some are being operated at lower conversion to supply premium unconverted oil streams for base oil production. This shift reflects a broader trend among European refiners: reducing exposure to road-transport fuels and capturing greater value from petrochemical and lubri- cant markets. In one example, a refiner advanced a residue-upgrading scheme centred on solvent deasphalting and hydrocracking, followed by investment in a Group II base oils complex to enter higher- value markets. Elsewhere, Shell’s Pernis refinery in the Netherlands revamped a residue hydroprocessing unit into a DAO hydrocracker, enabling a wider crude diet and reducing fuel-oil output, based on site- specific operational data.
ing, higher-severity VGOs as well as new streams, such as coker gas oil, without adding new reactors. The unit now pro- cesses 55% more than its original design capacity, based on site-reported data, while maintaining long cycle lengths. ○ Producing petrochemical feedstocks . A Chinese refiner increased heavy naph- tha recovery by 7% through catalyst upgrades, unlocking significant value when considering the impact on the hydro- cracker and the improved conversion in the downstream chemicals complexes, based on the site’s economic assessment. ○ Generating lubricant base-oil feed . At a major Asia-Pacific refinery, hydrocracker conversion was reduced from 70% to 50% to supply high-quality hydrowax for a new base oil plant. The upgrade also deliv- ered a 15% increase in throughput and a 33% longer cycle. These examples illustrate the range of options available to refiners, and the opportunity to align hydrocracking strat- egy with both market signals and long- term positioning. did you know? Shell Catalysts & Technologies has a long track record in supporting refiners in repositioning their hydrocrackers through revamps, configuration changes, and cycle- to-cycle catalyst optimisation
Contact: jeff.pro@shell.com
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