February 10 - 12, 2026 Houston, Texas
Official newspaper published by PTQ / Digital Refining
models that can withstand the knock- on impacts of political and regulatory changes. A special thank you goes out to our long- standing partner, PTQ / Digital Refining, whose continued support across our global portfolio is greatly appreciated. Their commitment to delivering high-qual- ity industry content aligns with our goals for NARTC. We also extend our thanks to our Advisory Board, sponsors, and partners, without whom we could not run this event. I have been particularly struck by their enthusi-
asm for what we are trying to achieve here. We are truly grateful for your support, and I hope you enjoy the conference you helped us put together. As you engage with the sessions and activities, I encourage you to engage actively, exchange ideas freely, and, most of all, enjoy the conference. Thank you once again for joining us. Here’s to a successful NARTC! Elizabeth Cannon Portfolio Director – North America World Refining Association
Welcome to the North American Refining Technology Conference 2026! We are thrilled to be back in Houston, the energy capital of the world, to host another exciting edi-
inside
Biofeed FCC co-processing and maximising low-carbon propylene yield Biocrude’s role in charting a lower-carbon future
3
5
tion of our programme. Our goal for the next few days is to cre- ate a platform for networking, innova- tion, and knowledge sharing that will help build resilient, forward-thinking business
Honeywell UOP Biocrude upgrading is fuelling the future of energy HARNESSING BIOMASS For cleaner seas and skies
New Honeywell UOP Biocrude Upgrading
10% More Renewable Fuel than other biomass- to-fuel pathways.
converts biocrudes into high yield, moneymaking renewable fuels.
Honeywell UOP technology
Renewable Fuels to help reduce transportation emissions.
turns these waste materials into energy-dense, easily transportable biocrude.
There are over 180 billion tons
of solid biomass waste generated every year This includes non-food forestry and agricultural residues. These waste materials are typically burned or discarded, providing minimal value.
Lower Cost of Production than today ' s renewable alternatives.
Executive Board summary
Making the grade: how the right grading catalysts can maximise unit performance 6 Artificial intelligence and process centricity 7 Demystifying vacuum ejector systems 9 Precious metals: real-world dynamics 10
In preparation for the 2026 North American Refining Technology Conference (NARTC), the World Refining Association convened its esteemed advisory board to delve into the key priorities, pressing challenges, and commercial opportunities refiners are facing today. The Advisory Board met the week after President Trump announced sweeping tariffs on imports. The timing was signif- icant; not only was it the beginning of a new administration, but it marked a period of heightened regulatory uncertainty. The board gathered to discuss how refiners could remain resilient amid shifting policy, economic volatility, and evolving market dynamics. At the time, there was cautious optimism – many expected clarity on energy regu- lation by fall 2025, and Trump’s agenda, focused on generating jobs and investment in the US, was seen as potentially favoura- ble for refining. Six months on, we checked in with our Advisory Board, including senior leaders from Chevron, Marathon Petroleum, ExxonMobil, Par Pacific, Delek US, CITGO, HF Sinclair, and more, to see how the industry has navigated this ambiguity and whether their priorities have shifted. What has changed since the Advisory Board meeting? This year, North America’s refining indus- try has experienced a period of continued
Efficiency extends beyond energy perfor- mance to wider operational effectiveness, including labour, maintenance, turnaround management, and performance optimisa- tion. In a competitive commodity market, maintaining a low cost per barrel remains essential to long-term resilience. However, cost management must be balanced with capability. Workforce reductions have cre- ated competency gaps, and the talent pool available to join the industry is smaller. Closing this gap through structured train- ing and faster time-to-competency will be key to sustaining future performance.
adjustment as companies respond to per- sistent regulatory uncertainty and evolving market conditions. While tariffs have faded from the headlines, their impact remains and, in some cases, has intensified. IOCs have announced workforce reduc- tions and internal restructures as part of broader efforts to streamline operations and focus Capex on higher-return activi- ties. Several companies have scaled back their ambitions in renewable projects, cit- ing investor caution and uncertainty sur- rounding the future of these markets. Instead, we have seen a renewed focus on reliability, efficiency, and operational excel- lence in conventional refining to reduce the cost per barrel and improve profit margins. Refiners have seen some improvement in diesel margins over the summer, providing some relief. However, oversupply in spe- cialty products such as solvents and base oils continues to place pressure there. What are the characteristics of top- performing refiners in North America? The characteristics that define the most successful refiners are a strong cost dis- cipline, efficient operations, and effec- tive asset utilisation. The best performers maintain competitiveness across these key metrics and, importantly, sustain this dis- cipline throughout market cycles, avoiding the tendency to ease cost controls during an upturn.
What about renewables and energy transition projects?
Over the last two years, excitement sur- rounding renewables has waned. While there have been some developments, such as progress on the revised Low Carbon Fuel Standard, Production Tax Credit, and Blender’s Tax Credit, further clarity is needed. The lack of consistency has cre- ated hesitation among investors, limiting refiners’ ability and incentive to commit to new renewable projects or expansions. In several cases, smaller renewable facilities have closed or changed output, reflecting the limited financial support currently avail- able. It will likely take time for renewed con- fidence to translate into new projects, and many acknowledge that long-term viability cannot depend solely on subsidies.
Competitive imbalance in petrochemical market calls for North American refiners to boost efficiency 11 Advantages of high-throughput comparative catalyst testing for naphtha reforming changeouts 13 Reimagining the hydrocracker 14
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Honeywell UOP
2 4 8
Sabin Metal Corporation
W.R. Grace
Process Consulting Services World Refining Association
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Topsoe
1
NARTC 2026
Biofeed FCC co-processing and maximising low-carbon propylene yield
R González and S Brandt W. R. Grace
Pilot plant testing will help understand the magnitude of changes in oxygenates and water, CO, and CO₂ yields. In addition, a close collaboration with the catalyst sup- plier will help discover areas of concern and monitoring requirements. Conclusion The drive towards decarbonisation and the energy transition is prompting the refining industry to adopt a new way of thinking, reconsidering value chains and associated process schemes. The importance of the FCC process in refining, coupled with its high flexibility, makes it a key candidate for adaptation to new opportunities that are emerging. Besides lower-carbon-intensity trans- portation fuels, one of the target prod- ucts of the FCC process is propylene. The demand for low-carbon-intensity and bio- derived polyolefins is increasing, and the adaptability and sophistication of the FCC process are ideal conditions to contribute meeting the demand for bio-derived poly- mers. Grace is supporting several refining customers on their paths to decarbonise the FCC unit’s operation and products. In addition, its expertise in product purifica- tion by adsorbents or hydrogenation and downstream processing to polyolefins is providing solutions for the new challenges that can arise with the co-processing of bio-derived feed streams. References 1 Lee, G., Brandt, S. and Holder, D., Maximising renewable feed co-processing at an FCC, PTQ , July 2023. 2 Peréz, E, et al., Decarbonize the FCCU through maximizing low-carbon propylene, Hydrocarbon Processing , March 2024. 3 Cipriano, B., Cooper, C. and Brandt, S., Paving the way to low-carbon propylene from the FCC unit, Decarbonisation Technology , November 2023. 4 Gonzalez, R., Bescansa, M., Fernandez, A., Mena, A. and Rivas, C. Defossilizing the FCCU via coprocessing of biogenic feedstocks: From laboratory to commercial scale, Hydrocarbon Processing , July 2023. 5 Riley, B., Brandt, S. and Bryden, K. Co-processing of bio-based feedstocks in the FCC unit, Decarbonisation Technology , August 2022. 6 den Hollander, M., Wissink, M., Makkee, M., Moulijn, J.A. Gasoline conversion: reactivity towards cracking with equilibrated FCC and ZSM-5 catalysts, Appl. Catal. A: General , 223 (2002), 85. 7 Seiser, R., Olstad, J. L., Magrini, K. A., Jackson, R. D., Peterson, B. H., Christensen, E. D. and Talmadge, M. S. Coprocessing catalytic fast pyrolysis oil in an FCC reactor, Biomass and Bioenergy , 2022. 8 Harding, R. H., Zhao, X., Qian, K., Rajagopalan, K. and Cheng, W.-C. Fluid catalytic cracking selectivities of gasoil boiling point and hydro- carbon fractions. Industrial and Chemical Engineering Research , 35 (1996), 2561. Contact: stefan.brandt@grace.com
With the refining industry’s strive towards decarbonising operations and pivoting towards the production of lower-carbon- intensity products, new challenges and opportunities arise. Close collaborations between partners are vital to the adoption of existing refining industry assets and ensuring rapid progress in the world’s jour- ney towards lower CO₂ emissions.¹ Propylene is one of the main petrochemi- cal products from crude oil refinery opera- tion. While current global market conditions for propylene are suppressed, C₃= demand is projected to grow by an annualised 4% through 2030, which will drive demand for fluid catalytic cracking (FCC) propylene accordingly.² Propylene produced by FCC already has a favourable carbon intensity compared to other on-purpose processes.³ Additionally, the application of ZSM-5- containing technology to increase FCC pro- pylene yields is preferred because of its neutral impact on the heat balance of FCC units and therefore Scope 1 emissions. In addition to its favourable carbon intensity, the carbon impact of FCC C₃= can be further reduced by the use of ZSM- 5-based technology and/or co-process- ing biogenic feedstocks to the FCC unit. Grace has been partnering with a num- ber of refineries globally to contribute to assessing the opportunities and risks of co-processing bio-derived feeds, as well as closely monitoring commercial trials and servicing continuous operation. 1,2,4,5 FCC proceeds via a β -scission mecha- nism on the active sites of the catalyst ( Figure 1 ).⁶ The end product of β -scission is C₃=. To further reduce the carbon inten- sity of the FCC C₃= co-processing, bio- derived feed streams to the FCC unit can be considered.³ The higher the co-processing rate, the bigger the impact on the carbon intensity of the related FCC products. Assuming an equal distribution of renewable car- bon among the FCC products, the co-pro- cessing rate (mass-based) can be directly related to a reduction in carbon inten- sity; consideration of the oxygen content of the renewable feed source is required. The oxygen content in the renewable feed is mostly converted to water, carbon mon- oxide (CO), and CO2 yields. It can be esti- mated that, considering a co-processing rate of 10 wt% renewable feed with an oxygen content of about 10 wt% (in the range of many seed oils), the carbon inten- sity of the resulting C₃= would reduce by 9%. The ultimate impact of co-processing renewable feed components on the yield structure is likely to be different to this the- oretical mass balance approach. However, this must be determined in FCC unit pilot plant testing and commercial applications, as they depend on the fossil feed type, unit conditions, and FCC catalyst proper-
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Figure 1 Catalytic cracking reaction mechanisms²
mental yield concept,⁸ it is estimated that palm oil yields 6-7 wt% FF C₃=, nearly dou- ble the yield of the fossil-based VGO in this particular case. While Figure 2 illustrates the potential increase in C₃= from renewable co-pro- cessing, challenges with co-processing should be considered. These challenges are often associated with the significantly higher oxygen content of the renewa- ble feed component relative to traditional feedstocks. Despite the absence of added hydrogen (H₂), the FCC process offers a high degree of deoxygenation of renew- able feed streams. Most oxygen species are converted to hydrocarbons and water, CO₂, and CO, which exit the FCC unit on the reactor side and could pose challenges downstream. In pilot plant testing of renewable feed co-processing, the effects of trace oxygenates are often not considered. Nevertheless, these are likely to occur with oxygen-containing feed streams. Trace amounts of oxygenates are commonly found in fossil feed-based FCC product streams like liquefied petroleum gas (LPG) or cracked naphtha. Increasing the com- bined FCC feed oxygen content by the co- processing of renewable feed streams like vegetable oils will increase the number of these oxygenate species. This might neg- atively influence the downstream process- ing of the FCC unit products, while also causing products to exceed specification limits.
ties. To assess the amount of C₃= stem- ming from the renewable feed component, highly sophisticated analytical methods for modern carbon determination might be required.⁷
DID YOU know? The importance of the FCC process in refining, coupled with its high
Data from testing some renewable feed types within Grace showed that the renew- able carbon-containing feed might be pref- erentially converted to C3= compared to fossil feed (FF) components. Figure 2 shows bench-scale pilot plant testing results, which indicate that the C₃= yield in this case increased by about 0.3 wt% FF by blending 9 wt% palm oil with the vac- uum gas oil (VGO). Considering the incre- flexibility, makes it a key candidate for adaptation to new opportunities that are emerging
SR-SCT MAT pilot plant test result
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Figure 2 SR-SCT MAT results of C3= yield for 100% fossil-based VGO and a blend with 9 wt% palm oil²
3
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1
NARTC 2026
Biocrude’s role in charting a lower-carbon future
Leigh Abrams honeywell uop
Maritime shipping plays a key role in global trade, providing transportation for roughly 80% of goods bought and sold inter- nationally.¹ At the same time, maritime vessels generate significant emissions, accounting for around 3% of total world- wide emissions,² which is comparable to the annual emissions of certain developed countries. The need for reliable, affordable, low- carbon energy has never been greater or more attainable. The shipping industry has the potential to reduce emissions through advancements in renewable fuels that bal- ance environmental and economic needs. New technology and supply chain inte- gration are making it possible to produce renewable marine fuels at scale, especially as new processes unlock the potential of biomass sources and streamline upgrad- ing steps. Refiners are under growing pressure to meet rising global energy demand while navigating a rapid shift toward renewable fuels, including sustainable aviation fuel (SAF) and renewable marine fuels. At the same time, changing product slates, higher capital costs, feedstock volatility, and the risk of stranded assets are squeezing mar- gins. To remain competitive, refiners must deploy flexible, efficient process solutions that improve asset reliability, energy effi- ciency, and speed to market. As renewable fuel demand accelerates, refiners are expanding the range of feed- stocks they process to meet regulatory requirements, support the energy transi- tion, and protect profitability. Honeywell UOP has a long track record of helping operators adapt to these challenges and continues to expand its portfolio with technologies designed to increase prod- uct diversity and quality. Modular, scalable solutions enable faster deployment while reducing capital risk, allowing refiners to adapt as markets evolve. Technologies such as Ecofining ® , co- processing, FT Unicracking ® , eFining ® (methanol-to-jet), Ethanol-to-Jet, and fast pyrolysis allow refiners to convert a broad range of renewable feedstocks into SAF, renewable diesel, and other low-car- bon fuels, providing the flexibility needed to compete in a rapidly changing energy landscape. potential of biocrude Meeting energy demand within the mari- time industry requires an additive approach that leverages a variety of fuel sources to help the maritime industry shift to lower- emission alternatives. One promising solution is the use of biocrude, hydrocarbon-rich oil produced through the thermochemical processing of inexpensive and abundant biomass. Common sources for biocrude include
Honeywell UOP Biocrude upgrading is fuelling the future of energy HARNESSING BIOMASS For cleaner seas and skies
New Honeywell UOP Biocrude Upgrading
10% More Renewable Fuel than other biomass- to-fuel pathways.
converts biocrudes into high yield, moneymaking renewable fuels.
Honeywell UOP technology
Renewable Fuels to help reduce transportation emissions.
turns these waste materials into energy-dense, easily transportable biocrude.
There are over 180 billion tons
of solid biomass waste generated every year This includes non-food forestry and agricultural residues. These waste materials are typically burned or discarded, providing minimal value.
Lower Cost of Production than today ' s renewable alternatives.
Figure 1 Biocrude Upgrading is fuelling the future of energy 1 F. Güleç, et al. Progress in lignocellulosic biomass valorization for biofuels and value-added chemical production in the EU: a focus on thermochemical conversion processes, Biofuels Bioproducts & Biorefining, 18 (2023). 2 Based on Honeywell UOP calculations comparing conversion of pine biomass to naphtha, jet, diesel and marine fuel via pyrolysis and Biocrude Upgrading vs via once-through gasification pathways on a carbon basis. 3 Based on Honeywell UOP analysis comparing total production cost ($/MT of liquid product) using 1,500 MTD of pine biomass feed for Biocrude Upgrading vs used cooking oil feed for HEFA-based processes to make an equivalent amount of liquid fuel products.
tion can accelerate this shift. The process offers a pathway from solid biomass to 'drop-in' fuels that provide a cost-effec- tive and lower-carbon alternative to tradi- tional heavy fuel oil. This is possible in part because Biocrude Upgrading can produce up to 10% more renewable fuel than other biomass-to-fuel pathways.³ With higher energy density than many current biofuel alternatives, this renewa- ble marine fuel can extend a vessel’s range without requiring costly engine upgrades. Honeywell’s technology efficiently turns forestry trimmings, wood shavings, and timber debris – materials that are usually hard to use for fuel – into biocrude. This process handles their high oxygen and moisture content, making it easier for pro- ducers to use a wider range of feedstocks. Using abundant biomass as feedstock, along with straightforward technology, makes implementation easy for existing refiners while using existing infrastructure and equipment. Biocrude can then be transported and refined at large facilities into marine fuel, gasoline, or SAF, helping overcome the obstacles to converting biocrudes into fuels with performance comparable to conventional fuel. path forward Reducing carbon emissions is a top pri- ority for many large-scale organisations across all industries. Achieving lower ship- ping emissions will not be accomplished by a single solution; instead, it requires a comprehensive strategy that incorporates
renewable fuels, cleaner combustion sys- tems, digital optimisation, and more. The maritime sector continues to seek out renewable energy, but its pace depends on bridging the cost gap between tradi- tional and renewable fuels. This highlights a key role for refiners to enable wider use of innovative process technologies, such as upgraded biocrude, alongside lower- carbon fuels like liquefied natural gas (LNG), methanol, ammonia, and e-fuels, in collaboration with shippers, policymakers, and other stakeholders. Through embracing new technologies and fostering collaboration, refiners can accelerate the transition to cleaner fuels made from cost-effective renewable feed- stocks, helping reduce shipping emissions while diversifying product offerings and supporting the broader energy transition. References 1 United Nations Conference on Trade and Development. Review of Maritime Transport 2023: Towards a Green and Just Transition. United Nations , 2023. Accessed January 14, 2026. https://unctad.org/system/files/ official-document/rmt2023_en.pdf. 2 US Department of Energy, Office of Critical Minerals and Energy Innovation. Maritime Innovation. Accessed January 14, 2026. https:// www.energy.gov/cmei/maritime-innovation. 3 Based on Honeywell UOP calculations com- paring conversion of pine biomass to naph- tha, jet, diesel and marine fuel via pyrolysis and Biocrude Upgrading vs via once-through gasifi- cation pathways on a carbon basis.
agricultural residues and organic waste, making it a more sustainable option for fuel production compared to more established methods. Although biocrude has been around for some time, recent technological improve- ments in fast pyrolysis, such as larger did you know? Biocrude Upgrading offers a pathway from solid biomass to 'drop-in' fuels that provide a cost- effective and lower- carbon alternative to traditional heavy fuel oil unit capacity, improved feedstock intro- duction, and streamlined processes, have made it much more practical for large- scale use. This approach allows for steady progress with transitional fuels and paves the way for wider use of advanced renew- able fuels as they become commercially available. Honeywell’s Biocrude Upgrading tech- nology offers a glimpse at how innova-
Contact: RenewableFuels@Honeywell.com
5
naRTC 2026
Making the grade: how the right grading catalysts can maximise unit performance
Henrik Rasmussen, Xavier E. Ruiz Maldonado, and Maria J. L. Perez TOPSOE
Pressure drop and catalyst contamination can escalate rapidly in hydroprocessing units, turning smooth operations into costly unplanned shutdowns. This article exam- ines the common challenges facing refin- eries and the solutions offered by Topsoe’s versatile graded-bed catalyst technology portfolio, developed over several decades and applied in more than 10,000 hydro- treating unit replacements worldwide.
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Fouling and contaminant issues present significant operational challenges across hydroprocessing units. In addition, scale formation can migrate to distribution trays and catalyst beds, leading to increased pressure drop and reduced catalyst utilisa- tion. Topsoe offers a broad, science-backed grading catalyst and scale catcher portfo- lio designed to mitigate the impact of these challenges and protect unit performance. Its grading portfolio is shown in Figure 1 . A scale catcher prevents these scales from reaching the catalyst, while a distribu- tion tray, such as the Topsoe BoxVLT™, with drip points that are self-cleaning and unaf- fected by scales collecting on the tray is key to maintaining even distribution throughout the catalyst cycle. In high-fouling environ- ments, where corrosion products and solids challenge conventional grading layers, sed- imentation-based systems installed above the tangent line enable suspended solids to settle before reaching distribution trays. Suspended or precipitated particulates, such as iron sulphide, corrosion prod- ucts, asphaltenes and polymerised spe- cies, deposit between catalyst particles or within internal pore structures. While hydro- processing feed filters typically remove particles above 15-25 μm, smaller con- taminants bypass filtration and accumulate within the graded bed, driving premature pressure drop build-up and flow maldistri- bution. High-void, macroporous inert mate- rials with void fractions above 85% address this challenge in the upper sections of cat- alyst beds. Reticulated foam discs capture both coarse and sub-micron foulants while maintaining minimal flow resistance. Topsoe’s TK-18 TopTrap™, TK-22 TopTrap™, TK-24 TopTrap™ and TK-26 TopTrap™ are engineered to capture large volumes of fine and coarse contaminants, retaining more than their own weight in corrosion particu- lates, iron sulphide, polymerised gums, and other heavy foulants. These systems target contaminants from sub-25 μm fines to frag- ments above 1,000 μm, as shown in Figure 2 , capturing multiple contaminant classes, including corrosion byproducts and metal- laden particles, such as magnesium, sodium, calcium, chromium, silicon, and phosphorus, in a single high-capacity filtration layer. Milling control and solids precipitation with a high-void material Particle displacement, or ‘milling’, occurs
TK-30
TK-341 TK-743
TK-461 Silicon Trap™
TK-773
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TK-445 MultiTrap™
TK-467 Silicon Trap™
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TK-49
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1/20”TL
Activity
Figure 1 Topsoe grading portfolio
tha and renewable fractions. TK-453 SiliconTrap™ is designed for heavier hydro- carbons, while TK-343 SiliconTrap™ targets the circular plastics industry. These cata- lyst guard products provide higher alumina surface utilisation and silicon uptake on a per-volume basis, capturing silicon species before they reach the main bed catalysts. Beyond trapping capacity, these catalysts also exhibit high hydrodenitrogenation and hydrodesulphurisation activity. Managing phosphorus-based contaminants in conventional and renewable feedstocks Phosphorus appears in both renewable and conventional feedstocks as hydrogenated phospholipids, phosphorus-based chem- icals from anticorrosion and antifouling agents, zinc dialkyldithiophosphate from spent lubricants, and other phosphorus- containing species. In hydrotreaters, these compounds decompose and react with alu- mina catalyst supports, irreversibly block- ing the active sites. Specialised guard materials capture phosphorus and other multi-contaminant species from biofeedstocks, spent lube oils, renewable feeds, and opportunity crudes. Topsoe’s TK-3000 PhosTrap™ and TK-455 MultiTrap™ feature proprietary pore struc- tures that enable phosphorus compounds to diffuse deeply into catalyst pellets, ensuring full pore volume utilisation, as shown in Figure 3 . This design creates uni- form phosphorus distribution throughout the material cross-section rather than sur- face saturation, thus maintaining low pres- sure drop across the guard bed. Arsenic trap Arsenic ranks among the most severe poi- sons in crude oil, commonly present in syncrudes from Canada and crudes from California, Mexico, and South America. It typically exists as arsenic trisulphide (As₂S₃) on CoMo and arsenic sulphide (AsS) on NiMo catalyst active sites, causing rapid deactivation. Even at concentrations of 20-1,000 ppb, arsenic causes more severe
TK-26 Top Trap™
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designs. These catalysts use the same high surface area alumina and metal loading as main bed catalysts and are manufactured to ISO 9001:2015 quality standards. Combating organic silicon in conventional and renewable feedstocks Silicon contamination has emerged as a crit- ical challenge in processing coker-derived streams, renewable feedstocks, and dur- ing co-processing operations. Silicon com- pounds enter through antifoam additives in coker units and chemicals used as drag reducers during crude transport or tertiary recovery. High surface area, alumina-based guard materials effectively address silicon contamination. Topsoe’s TK-447 SiliconTrap™, TK-461 SiliconTrap™, TK-467 SiliconTrap™, and TK-449 SiliconTrap™ are optimised for lighter boiling-range feeds such as naph-
when horizontal forces across the catalyst bed exceed frictional resistance. High-void inert materials such as Topsoe’s TK-10 sta- bilise flow in the top of gas-phase reactors by absorbing horizontal momentum from inlet nozzles and promoting uniform veloc- ity profiles across the reactor cross-section. Olefin saturation control and radial temperature spread Uneven olefin saturation and localised temperature gradients contribute to radial temperature maldistribution, excessive pressure drop, and shortened catalyst life in hydroprocessing reactors. Ring-shaped grading catalysts with optimised pore sizes and surface areas enhance bed poros- ity and improve radial flow distribution. Topsoe’s TK-709, TK-711, and TK-831 fea- ture engineered ring shapes that provide a higher total void compared to conventional
6
naRTC 2026
ers offer more reliable solutions designed for liquid- or gas-phase applications to act as first-line barriers against solid contami- nants. These systems prevent early foul- ing, protect downstream catalyst beds, and reduce the grading bed materials required, leaving more room for the bulk catalyst. In liquid-phase applications, scale catch- ers route gas directly to the distributor tray while directing liquid through sedimentation chambers where larger particles settle by gravity. The liquid then passes through dou- ble-layer filter cassettes engineered to trap smaller particles. When filters become sat- urated, feed automatically bypasses them to avoid pressure drop build-up. Field data shows that implementing scale catchers can extend cycle length significantly com- pared to operations without this protection. Gas-phase scale catchers remove parti- cles entrained in the process stream based on physical parameters like size, shape, and particle density. They typically employ two-stage separation: gravity separation removes particles over 100 microns, while momentum and terminal velocity separation capture finer particles in a secondary zone. Measurable economic benefits Topsoe’s advanced grading bed cata- lyst technologies deliver measurable eco-
nomic benefits by extending cycle lengths and enabling the use of more challeng- ing feedstocks. Its optimised grading con- figurations are designed to push catalyst replacement cycles to the point where activity, rather than pressure drop, dic- tates replacement, resulting in a significant increase in the profitability of the unit sav- ings. By protecting main catalyst beds from contaminants while maintaining high activ- ity, these solutions allow refiners to use feed with higher levels of contaminants, including renewable feed and opportu- nity crudes, without compromising perfor- mance or product quality. When choosing a customised grading solution from Topsoe, comprehensive sup- port services are available for long-term success. One example is Topsoe’s con- nected platform ClearView™, which pro- vides real-time performance dashboards with intuitive key performance indicators for optimisation and faster support. Its spent catalyst analysis examines unloaded catalysts to determine metal content, poi- son pick-up capacity, particle size distribu- tion, and more. These insights are used to optimise future catalyst loadings to prove continuous performance improvements.
poisoning than silicon, phosphorus, nickel, iron, or vanadium, leading to irreversible catalyst deactivation. High-nickel surface area arsenic traps provide volume-based pick-up efficiency. Topsoe’s portfolio includes TK-49 and TK-51 as extrudates, and TK-45 and TK-41 as ring-shaped traps, offering structural robustness and effective arsenic capture. Heavy metals challenges Vanadium, nickel, and iron are well-known hydrotreating catalyst poisons. These met- als enter as organometallic compounds in the feed and deposit within catalyst pore structures and on external surfaces. While concentrated in residuum fractions, some organometallic compounds volatilise dur- ing distillation and appear in lower-boiling fractions, especially those boiling above 1,100°F. When feeds such as atmospheric tower bottoms enter vacuum gas oil (VGO) hydro- treaters, they significantly impact catalyst performance and reduce cycle length. This is particularly problematic because VGO hydrotreaters operate at higher space veloc- ities than resid hydrotreaters, increasing metal migration risk into main catalyst beds. High-activity demetallation catalysts with extremely high metal pick-up capac-
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Figure 4 Vanadium and nickel in entrained VGO fractions
ity on a volume basis can be installed above main catalyst beds. Topsoe offers TK-453, TK-743, and TK-773 for heavy vacuum gas oil (HVGO) and resid applications. These large-pore materials accommodate metal- containing molecules that require high sur- face-to-volume ratios for effective trapping. From traditional trash baskets to modern scale catchers Traditional trash baskets often disrupt flow profiles during operation, especially when fouled. Topsoe’s modern scale catch-
Contact: HWR@topsoe.com
Artificial intelligence and process centricity
Dipankar DAS MARATHON petroleum
Artificial intelligence (AI) is not a short- cut; it can serve as a significant advan- tage when deployed well and is poised to redefine business operations. AI is trans- forming the downstream hydrocarbon industry by enhancing process efficiency and operational effectiveness. This arti- cle emphasises the need to shift from peo- ple-centric to process-centric approaches to fully harness AI’s potential for business improvement. During my Fellowship in energy econom- ics in the mid-90s, I read articles from 1965 in which scientists argued that the information processing involved in cogni- tive performance could be formulated as a program and simulated on a digital com- puter. Fast forward to 2025, and the use of AI is now prevalent and here to stay. At the time, many experts felt that AI was not fully understood and often misused to describe any automated process. Some industry leaders and scientists even used terms like ‘red herring’ and suggested it could ‘spell the end of the human race’. Industry leaders, including Dr Stephen Hawking, Elon Musk, Sundar Pichai, and Ginni Rometty, have debated what con- stitutes AI and what does not. The key question remains: how can we responsibly design and implement AI in our field? This centres on process efficiency. Downstream Business Context Our industry is run by engineers who are focused, capable, and experienced. Indirectly, this engineering passion has naturally led us to adopt a people-centric approach to managing operations. While procedures such as standard operat-
V irtuous cycle of continuous i mprovement
Process centricity f irst: First adopt a process-focused approach to identify map and document ' ways of working ' (workflows).
AI implementation: Process interactions and quality data are prerequisites , unleashing the power of AI.
Quality d ata & i nteractions: Standardised process ensures quality data is generated.
Mutually reinforcing , or symbiotic , relationship between AI and b usiness p rocess w orkflows
Continuous improvement: AI improves process
Process enhancement: Automates, optimises , and extracts insights from processes to improve decision - making.
Value capture: Process owners to ensure value attribution a cross all attributes.
Generating
better data
Furthers AI
improvement.
Figure 1 AI and process centricity form a self-reinforcing cycle
actions align with operational practices. Comprehensive process knowledge sup- ports AI projects in delivering measurable and strategic outcomes. How AI Enables Process Centricity AI supports process centricity by automat- ing high-volume, rule-based tasks, such as data entry and invoice processing, freeing employees to focus on more complex pro- jects. It enables intelligent decision-making by analysing large datasets for patterns, predictions, and insights. AI tools quickly detect inefficiencies and risks, facilitat- ing prompt corrections and enhancing pro- cess agility. Leveraging natural language processing, AI can automatically build or update process maps from documents and discussions, reducing manual effort. Additionally, AI acts as a copilot, enhancing human judgement-based decisions. In conclusion, AI is no longer a C-Suite curiosity; it has become a board-level imperative to enhance organisational effi- ciency, adaptability to a changing environ- ment, and competitive power.
focus on finding the real value by address- ing bottlenecks and uncovering significant challenges. Let us examine how these complement each other. The good news is that AI can help us build processes from unstructured paper-based procedures and manuals, find opportunities for improvement, and complete the full cycle – updating the pro- cedures and instructions for a complete digitisation cycle. Why is this so relevant for North America? First, the availability of required skills and the ability to attract talent glob- ally. Second, both national and global downstream industry leaders here are con- tinuously investing in transformation for improvement in their business operations. How Process Centricity Enables AI A process-centric approach provides standardised, consistent, and reliable data critical for accurate AI outcomes. Process mapping identifies automation and optimi- sation opportunities and guides AI imple- mentation. This approach enables AI to understand workflows, dependencies, and decision points, ensuring AI-driven
ing procedures (SOPs) and manuals exist and are followed, business process work- flows are often set aside as ’unneces- sary paperwork’. Initiatives to document, improve, and mine have been undertaken, but often remain buried in SharePoint fold- ers, untouched and unmanaged. Meanwhile, the downstream segment – and probably the entire hydrocarbon indus- try – is scrambling today to identify use cases for AI deployment. While use cases are necessary and such focused atten- tion will yield benefits, I would argue that a more process-centric and structured approach is needed to leverage such phe- nomenal scientific potential in new ways. It may be time for us to challenge ourselves and change our path. AI and Process Centricity: Virtuous circle AI and process centricity form a self-rein- forcing cycle in which momentum reduces effort needed over time, creating a virtu- ous cycle of growth and efficiency through strategies that attract, engage, and delight customers while aligning with inter- nal business aspirations (see Figure 1 ). More importantly, this approach helps us
Contact: DDas@Marathonpetroleum.com
7
AHEAD A long history of looking
For nearly a century, Grace catalysts have kept fuel and petrochemical feedstocks flowing from the industry’s largest refineries to the trucks, trains, planes, and ships that keep our world running. We are leveraging our long history of innovation in fluid catalytic cracking to develop products that enable lower carbon fuels and help meet the challenges of the energy transition.
grace.com
naRTC 2026
Demystifying vacuum ejector systems
Scott Golden, Tony Barletta, and Steve White Process Consulting Services, Inc.
Intercondenser thermal behaviour The first-stage intercondenser removes most of the steam and condensable oil load. Only a small fraction of vapour exits to the sec- ond stage, and a disproportionate amount of condensation occurs in the sub-cooling zone. Although this zone accounts for only about 5% of the exchanger duty, it can condense several thousand pounds per hour of steam. Loss of this duty due to bypass dramatically increases the second-stage load. Vacuum systems are highly sensitive to CW temperature and flow. Small increases in CW temperature or fouling can raise operating pressure, but if the long air baf- fle is intact, sub-cooling is maintained and vapour temperature remains below conden- sate temperature. This distinction is critical as general fouling and long air baffle bypass have different thermal signatures. Cracked gas rate and design margin Designing vacuum systems with unrealis- tically low cracked gas rates and minimal MDP margin reduces steam consumption but leaves no tolerance for fouling, CW variation, or mechanical defects. Systems designed with higher cracked gas allowances and ade- quate MDP margin can tolerate some loss of sub-cooling without immediate performance break. Lower actual cracked gas rates reduce vapour carryover, effectively increasing mar- gin and allowing higher outlet temperatures without overloading downstream ejectors. Second-stage ejector sensitivity Second-stage ejectors typically have lim- ited capacity to handle the incremental load associated with a poorly performing first- stage intercondenser. The incremental load can consume all available margin and cause a first-stage performance break, illustrating how even a minor long air baffle bypass can have system-wide consequences. Conclusion Vacuum ejector systems are commonly designed with minimal margins to reduce capital cost and utility consumption. Modern X-shell intercondensers with sub-cooling zones provide significant benefits, but only if they function exactly as intended. Failure of the long air baffle to seal properly allows vapour bypass, overloads the second-stage ejector, and frequently results in a first- stage ejector performance break. Vapour outlet temperature higher than condensate temperature indicates sub- cooling failure. Unfortunately, inadequate instrumentation often leads to incorrect diagnoses. To reduce risks of a performance break, ejectors should be shop tested to generate certified performance curves and verify true MDP. Adequate design margins should be applied to cracked gas rates, con- denser fouling, CW conditions, and MDP. While some operational variability is una- voidable, a performance break is often a design and mechanical issue. A robust inter- condenser design, proper execution, and realistic design margins are essential for reliable vacuum system performance.
Vacuum systems are critical to maintain- ing low column operating pressure, maxim- ising distillate recovery, and preserving the economic value of refinery vacuum units. Despite this importance, vacuum ejector systems frequently perform poorly, even immediately after installation or following turnarounds. A common failure mode is a performance break, which can raise col- umn pressure by 20-40 mmHg and sharply reduce distillate yield. Performance breaks occur when the first-stage ejector operates at or above its maximum discharge pressure (MDP). Although there are many causes of poor vacuum system performance, a fre- quent and often overlooked cause is failure of the first-stage intercondenser to sub- cool the outlet vapour ( Figure 1 ). This article focuses on the importance of the first-stage intercondenser, particularly its sub-cooling zone. It explains how failure of this function commonly leads to perfor- mance breaks and unstable, elevated col- umn pressure. Fundamental concepts such as ejector performance curves, MDP, con- denser design, and component interaction are reviewed, along with critical design- phase considerations, including cracked gas rates, MDP margin, and system pres- sure drop. Ejector system design and interaction Most refinery vacuum systems use three- or four-stage ejector trains. Each stage con- sists of a steam ejector followed by a con- denser. Motive steam supplies the energy to compress vapour from the vacuum col- umn top pressure to the outlet pressure of the ejector. Each condenser removes con- densed steam and hydrocarbons, reducing the load to downstream ejectors. Cooling water (CW) rates are primarily set by the first-stage intercondenser, the largest and most critical exchanger in the system. Design optimisation typically focuses on minimising motive steam and CW consump- tion. The first-stage ejector can consume up to 70% of the total motive steam and often represents more than half of the installed cost of the vacuum system. Consequently, first-stage design conditions dominate sys- tem optimisation and represent the greatest opportunity for savings, but also the highest risk if margins are inadequate. Ejector performance is defined by com- pression, entrainment, and expansion ratios, which relate suction pressure, discharge pressure, and motive steam conditions. For a given suction load and pressure, the required motive steam increases with com- pression ratio (discharge pressure divided by suction pressure). Higher MDP designs consume more steam, so suppliers often minimise MDP to reduce utility consump- tion. Since end users frequently provide little guidance on required design mar- gin, systems are commonly designed with extremely thin margins. As a result, even small deviations from design conditions or underperformance of the first-stage inter- condenser can trigger a performance break.
design data rather than actual field meas- urements can lead to incorrect conclusions. Effective troubleshooting requires pre- cise measurement of small pressure drops (often only 3-6 mmHg across the first-stage intercondenser) and accurate tempera- ture readings. Even small thermocouple errors can obscure the temperature differ- ences that indicate sub-cooling failure. As with pumps, ejector performance cannot be evaluated without knowing actual flow rates, pressures, and performance curves. First-stage ejector suction load definition Proper vacuum system design begins with defining first-stage ejector suction loads. The vapour leaving the vacuum column con- sists of process steam, condensable hydro- carbons, and cracked gas/air leakage. These loads are converted to steam or air equiva- lents using HEI or DIN methods so they can be compared with ejector test curves. Process steam typically dominates the load and includes stripping steam, heater velocity steam, and water carried with the feed. It is usually well defined during pro- cess design. Condensable hydrocarbon load depends on column top temperature and pressure, steam usage, and stripping efficiency in the atmospheric crude col- umn. Poor stripping efficiency can signifi- cantly increase condensable load and lead to undersized vacuum systems. Cracked gas generated in vacuum heater tubes is much harder to estimate accu- rately. It depends on heater design, firing severity, residence time, crude type, and outlet temperature. Although cracked gas typically represents a small fraction of total load, it strongly affects condenser perfor- mance and should be assigned a generous design margin. Ejector performance and MDP Ejector performance curves define the rela- tionship between process load, suction pressure, and MDP. As long as discharge pressure remains below MDP, suction pres- sure is governed by process load. However, once discharge pressure exceeds MDP, suction pressure rises sharply and becomes unstable, marking a performance break. Certified performance curves based on shop testing are essential. When full-scale testing is impractical, scaled replica testing should be required. Field testing has shown that actual MDP can be 15 mmHg lower than vendor-stated values. In some cases, refiners have had to modify ejectors, such as moving motive steam nozzles, to recover lost MDP, frequently at the expense of suc- tion capacity.
1st stage intercondenser long air ba e bypass
1st stage intercondenser vapour outlet temperature is high
2nd stage ejector suction load increases
2nd stage ejector suction pressure increases
1st stage ejector discharge pressure exceeds MDP
1st stage ejector performance break
High vacuum column operating pressure
Figure 1 Cause and effect first-stage ejector break
typically X-shell designs incorporating a dedicated sub-cooling zone created by a long air baffle ( Figure 2 ). This configura- tion evolved from older E-shell designs and offers lower pressure drop and reduced steam consumption. Roughly 20-25% of the tube bundle is dedicated to sub-cooling. The long air baffle forces outlet vapour to pass over tubes cooled by the coldest CW, sub-cooling the vapour below the bulk con- densate temperature. This sub-cooling zone is essential because it minimises the vapour load to the second-stage ejector. The MDP of the first- stage ejector is selected assuming that the intercondenser performs as designed. If sub-cooling fails, additional steam exits the condenser as vapour, increasing the load on the second-stage ejector. This raises sec- ond-stage suction pressure, which, in turn, raises first-stage ejector discharge pres- sure. Once discharge pressure exceeds MDP, a performance break occurs. The most common root cause of sub-cool- ing failure is mechanical bypass of the long air baffle due to poor sealing, corrosion, damage, or installation defects. When the MDP margin is small, as is typical, a perfor- mance break becomes inevitable if bypass occurs. Thus, proper mechanical design, installation, and maintenance of the long air baffle are critical. Diagnosis and troubleshooting challenges The long air baffle bypass is relatively easy to diagnose conceptually: the vapour leav- ing the first-stage intercondenser should be cooler than the condensate leaving the shell. If the vapour temperature is higher, bypass is occurring. In practice, however, troubleshooting vacuum systems is difficult because instrumentation can be inadequate. Flow meters, reliable temperature meas- urements, and accurate pressure data are often missing. Analyses based on original
1st stage ejector vapour inlet
Cooling water outlet (typically 10˚F higher than inlet)
Tube bundles
Vapour outlet
Tube support
‘Long air ba e’
Cooling water inlet (coldest)
Condensate outlet
Importance of first-stage intercondenser Modern first-stage intercondensers are
Contact: TBarletta@revamps.com
Figure 2 X-shell long air baffle
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