the residue hydrocracker unit. Significantly lower coke was also observed in the process equipment. Figure 5 shows the difference in temperature vs the vessel skin and the bulk liquid in the medium-pressure, high-temperature separator of the RHC unit. Generally, this separator is subject to severe fouling during the cycle. As coke and foulant build up along the wall of the separator, the temperature difference between the bulk liquid in the separator and the skin temperature indicator (TI) located on the external wall increases. As seen in the figure, with the ART dual catalyst system (Cycle D), the onset of foulant build-up in the MPHT was significantly delayed compared to the previous operating cycles with a single catalyst sys- tem only (Cycle A-C). Conclusion Ebullated bed residue hydrocracking has evolved as a superior solution for upgrading heavy residues, overcoming limitations of fixed-bed systems through continuous cata- lyst replacement and improved process flexibility. Catalysts play a central role in the EBRHC process, enabling hydrogen addition to reduce sediment and coke formation. In addition, catalysts provide the demetallation, desulphurisation, denitrogenation, and Conradson carbon residue removal required for optimum product quality. A unique catalyst advantage is offered using dual catalyst systems. The first case study demonstrated that switching to a dual catalyst approach improved feed rate, reduced catalyst consumption, enhanced conversion, and signifi- cantly lowered sediment, delivering significant economic
and operational benefits. A second case study illustrated a reduction in fouling rate that is possible, resulting in the extension of the refiner’s RHC unit cycle length through the efficient use of ART’s dual catalyst system. GRACE ® is a trademark, registered in the United States and/or other countries, of W. R. Grace & Co.-Conn. ART Hydroprocessing™ is a trademark of Advanced Refining Technologies LLC, a wholly owned subsidiary of W. R. Grace & Co.-Con. Colin Baillie is the Strategic Manager for resid hydroprocessing cata- lysts at ART, a Grace company. He has nearly 20 years of experience across FCC catalysts and additives, as well as hydroprocessing catalysts. Baillie’s earlier background is in organic chemistry and catalysis, and he holds a Master’s degree and PhD in chemistry from the University of Liverpool, as well as an MBA. Email: Colin.Baillie@grace.com Darryl Klein is is R&D Director for Hydroprocessing at ART, a Grace company. He joined W.R. Grace & Co. in 1999 as an R&D scientist focusing on ebullated bed catalyst development then began working with Grace’s joint venture with Chevron. He has more than 30 years of experience in hydroprocessing catalysts with Grace and Exxon. Klein holds a Bachelor of Science in chemistry from the University of Southern California, Los Angeles, and a PhD in chemistry from the University of California, Berkeley. He is an inventor on 28 US patents related to hydroprocessing. Email: Darrly.Klein@grace.com Sidhartha Mohanty is the Global Technology Leader for the residue hydrocracking segment at ART, a Grace company. He has more than 16 years of experience in residue hydroprocessing operations, technol- ogy, and catalyst development. Mohanty holds a Master of Science in chemical engineering from University of Saskatchewan, Canada, and a Bachelor of Science in chemical engineering from the Indian Institute of Technology Guwahati, India. Email: Sidhartha.Mohanty@grace.com
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