PTQ Q3 2026 Issue

REFINING GAS PROCESSING PETROCHEMICALS ptq Q3 2026

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Q3 (Jul, Aug, Sep) 2026 www.digitalrefining.com ptq PETROLEUM TECHNOLOGY QUARTERLY

3 Where there’s a will, there’s a way Rene Gonzalez 5 ptq&a 19 Bankable metres: Treating reactor space as a strategic asset Austin Schneider Crystaphase

©2026. The entire content of this publication is protected by copyright. All rights reserved. No part of this publication may be reproduced, stored in a retrieval system or transmitted in any form or by any means – electronic, mechanical, photocopying, recording or otherwise – without the prior permission of the copyright owner. The opinions and views expressed by the authors in this publication are not necessarily those of the editor or publisher and while every care has been taken in the preparation of all material included in Petroleum Technology Quarterly and its supplements the publisher cannot be held responsible for any statements, opinions or views or for any inaccuracies. Sahithi Ravuluri, SK Shabina, Dr I R Choudhury, and Sarvesh Kumar Research & Development Centre, Indian Oil Corporation Limited 99 Technology In Action Soluble iron in hydroprocessing: The case for active filtration Crystaphase Process intensification through novel reactor internal: WMP outlet support grid Woven Metal Products (WMP) Achieving >90 LV% middle distillate yield in a two-stage hydrocracker Chevron Lummus Global Cover A close-up of Crystaphase’s ActiPhase ® Technology reticulated structure, which is designed to capture soluble and insoluble contaminants — helping protect reactor performance and extend run length. 23 Advances in feed conditioning for heavy hydroprocessing feeds Leontina Tompea, Mac McGuire, Carolyn Heyse, and Jimmy Wallum Filtration Group 31 Microbial contamination in diesel storage tanks Gabriela Feix Pereira, José Danilo Haick Tavares, and Gustavo Artur Silva Santos Dorf Ketal Brasil Alex Sandro Santos Campos Acelen, Brazil 37 Process simulation and dispersion modelling for leaks risk assessment Rodolfo Tellez-Schmill and Michelle Wicmandy KBC (A Yokogawa Company) 43 Every drop counts: Water strategies for refiners Carlos Cavalca Veolia North America Eric Ye Becht Karen Green Marathon Petroleum 51 Synergies between FCC naphtha and pygas Abdul Rahman Noah Abou Einein OMV Downstream GmbH 57 Design and operation of salt dryer for ULSD: Part 2 Prabhas K Mandal and Rajib Talukder Aramco 63 Evaluating steam injection in vacuum unit fired heaters Ankur Saini, Rupam Mukherjee, and Shilpa Singh Engineers India Limited 69 Design and application of e-houses in petrochemical plants Wang Xin CTCI Beijing 75 Hydrogen slippage from acetylene hydrogenation units Vikram Mohite Petrochemical Process Consultant 81 Missing inventory channel in oil market analysis Arif A Abdullah Iraqi Ministry of Oil 89 Procedure management in refinery operations Giulio Cattarin Octave 95 Practical CFD applications in refinery troubleshooting

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REFINING GAS PROCESSING PETROCHEMICALS ptq Q3 2026

The team behind the Crystaphase Experıence.

The science is solid.The technology is proven. But it’s the people we’re most proud of. Meet the crew behind 35+ years, 4,000+ installations, and 10,000+ samples analyzed.

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This. Advanced technology. Specialist talent. Field-tested methodologies.

Imagine working with experts who bring decades of operational insight, hands-on catalyst experience and a rigorous, data-led approach – to help you solve challenges with confidence.

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Editor Rene Gonzalez editor@petroleumtechnology.com tel: +1 713 449 5817 Managing Editor Rachel Storry rachel.storry@emap.com Sub-Editor Lisa Harrison lisa.harrison@emap.com Graphics Peter Harper Business Development Director Paul Mason Paul.Mason@petroleumtechnology.com tel: +44 7841 699431 Managing Director Richard Watts richard.watts@emap.com Circulation Fran Havard circulation@petroleumtechnology.com EMAP, 10th Floor, Southern House, Wellesley Grove, Croydon CR0 1XG tel +44 208 253 8695 Register to receive your regular copy of PTQ ptq PETROLEUM TECHNOLOGY QUARTERLY Vol 31 No 4 Q3 (Jul, Aug, Sep) 2026

Where there’s a will, there’s a way W orld oil stockpiles are approaching historically low levels following the clo- sure of the Strait of Hormuz (SoH), exposing structural vulnerabilities in global refining systems. About one-fifth of globally traded crude oil and significant volumes of liquefied natural gas ( LNG) normally transit the waterway, making prolonged disruption difficult to offset s olely through inventory drawdowns. This supply imbalance affects refining regions from Asia to the US West Coast, where many facilities are engineered for specific crude slates and cannot rapidly substitute feedstocks without yield penalties, instability, or higher hydrogen consumption. For now, Saudi Arabian and Iraqi crude exports through the SoH remain largely inaccessible. Iraq alone exported roughly 10 million barrels through the strait in April, volumes that historically supplied refineries configured for medium and heavy sour crude processing. Numerous Asian refineries invested billions in high- complexity conversion units to economically process heavier, higher-sulphur crudes. Replacing these feedstocks with lighter sweet crudes often results in lower middle distillate output, altered vacuum residue balances, and reduced utilisation of upgrading units, undermining refinery economics despite potentially lower sul - phur handling requirements. According to the US Energy Information Administration, China previously imported approximately 1.1 million BPD of Iraqi crude, while India imported roughly 0.9 million BPD. The loss of these volumes introduces competition for alternative supply streams from West Africa, Latin America, and the Atlantic Basin. Analysts at Goldman Sachs recently noted that “the speed of depletion and supply losses in some regions is concerning, with the more easily accessible refined products buf - fers approaching very low levels fast”. The concern extends beyond crude availability to refined-product inventories, particularly diesel, jet fuel, and marine fuels. Once inventories decline below opera- tional minimums, price volatility can accelerate disproportionately due to precau- tionary purchasing and supply-chain hoarding behaviour. The SoH disruption has also changed global product trade routes. Jet fuel cargoes are increasingly mov- ing from Nigeria to European markets, while Australian importers have reportedly sourced aviation fuel from Texas refineries. Longer voyages increase freight costs, tie up tankers, and elevate insurance premiums associated with geopolitical risk. These logistics constraints contribute to sharply higher delivered aviation fuel prices, with some destination costs approaching $1,400 per metric ton in late May compared with levels observed in mid-March. Refiners may respond by maximising middle distillate production through operational optimisation or capital projects. Potential strategies include increasing hydrocracker catalyst activity manage- ment, debottlenecking hydrogen networks, or upgrading two-stage hydrocrackers to enhance jet fuel and diesel yields from vacuum gas oils. Refineries with access to alternative crude sources are reporting elevated utilisation rates, although profit - ability has not always matched the strong crack spreads seen in 2024. Increased throughput also raises utility demand for steam, cooling water, and hydrogen. While it is difficult to predict the end of the Persian Gulf crisis, Global Research (www.globalresearch.org) reported in mid-May that Iraq has announced a major new oil discovery near the Saudi border. This comes as Baghdad faces one of its most severe energy and economic crises due to the disruption of Gulf export routes. Instead of waiting for the SoH to open up again, the Iraqi government is considering reviving the historic Iraq-Saudi Arabia oil pipeline, which links Zubair in southern Iraq to the Saudi Red Sea port of Yanbu. As they say, where there’s a will, there’s a way! Rene Gonzalez

PTQ (Petroleum Technology Quarterly) (ISSN No: 1632-363X, USPS No: 014-781) is published quarterly plus annual Catalysis edition by EMAP and is distributed in the US by SP/Asendia, 17B South Middlesex Avenue, Monroe NJ 08831. Periodicals postage paid at New Brunswick, NJ. Postmaster: send address changes to PTQ (Petroleum Technology Quarterly), 17B South Middlesex Avenue, Monroe NJ 08831. Back numbers available from the Publisher at $30 per copy inc postage.

PTQ Q3 2026

Rethinking Old Problems

More with Less

Revamp projects are difficult. Limitations imposed by plot space, congested pipe racks, and outdated equipment, to name a few, present unique challenges. Solutions that rely on excessive margins or comfortable designs lead to overspend. Now more than ever, process designers must find solutions that do more with less. P roven M ethods There is growing awareness that better scope definition earlier in the engineering phase saves time, reduces overall engineering cost, and leads to more successful projects. There is no argument that work completed during Conceptual and Feasibility phases is critical to getting a project on the right path. Engineers at Process Consulting Services, Inc. have developed a proven approach that makes the most of this precious time. At site, PCS engineers coordinate rigorous test runs, much of it through direct field measurements. Data collected is invaluable and often leads to low hanging fruit or hidden gems. Some refinery equipment performs better than design, and for various reasons others perform worse. Good test run data allows seasoned engineers to quickly identify what equipment needs investment and what equipment can be exploited. This way, solutions are developed that direct capital expense in the right areas and overspending is avoided. In one example, pressure drop measurements of a long crude oil transfer pipe showed the line could be reused, saving millions of dollars. Contact us today to learn how PCS’ proven methods can help you do more with less in your next revamp.

Projections for global supply and demand of refined products vary greatly depending on the pace of technological progress and degree of government policy enforcement associated with reducing greenhouse gas emissions. Without major advances in technology, it is hard to imagine a future without conventional fossil fuels over the next decade or two. Based on history, continued rationalization of refining assets is likely. Small, low-complexity refineries will struggle, while large, complex ones will thrive. Capacity creep through gradual improvement of refining units will continue to be a differentiating characteristic for remaining players. Focused revamps will play a critical role. Post-pandemic, inflation and a shortage of skilled construction labor have dramatically increased costs for refinery revamps. It is becoming increasingly difficult for many projects to meet corporate return on investment thresholds.

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pt q&a

More answers to these questions can be found at www.digitalrefining.com/qanda

Q What are the most interesting refining technologies to consider beyond 2030? A Abdallah Al Zyoud, Regional Marketing Manager, Refining Catalyst, BASF, Abdallah.al-zyoud@basf.com Looking beyond 2030, the refining technologies that will matter most are those that increase operational flexibility, strengthen the link between refining and petrochemicals, and deliver tangible improvements in environmental per - formance – without compromising reliability or economics. High-severity conversion units, such as fluid catalytic cracking (FCC) and advanced hydroprocessing, will remain central to this evolution. These assets are already being pushed to process a broader range of crudes, residues, and alternative feedstocks, while at the same time being asked to adjust product yields in response to shifting fuels and petrochemical demand. Continued advances in catalyst formulation, metals tolerance, and selectivity control will be essential to supporting this flexibility. Closer integration between refining and petrochemicals is also expected to accelerate. Technologies that enable higher yields of propylene, light olefins, and aromatics, whether through FCC operation, catalyst system design, or down - stream integration, are becoming increasingly relevant as demand growth continues to favour chemicals over transpor - tation fuels. Solutions that allow refiners to move along this spectrum with limited disruption will be especially valuable. Another important area is the co-processing of lower- carbon and circular feedstocks. Incorporating renewable or waste-derived streams into existing refinery units offers a pragmatic route to reducing lifecycle carbon intensity while leveraging installed infrastructure. This, however, places additional demands on catalyst robustness and unit oper - ability – areas where accumulated industrial know-how plays a critical role. Finally, digital tools and advanced analytics are steadily becoming part of mainstream refinery operations. When combined with strong process and catalyst fundamentals, data-driven approaches to optimisation and predictive maintenance can help refiners extract additional value from existing hardware while improving reliability. Overall, the most successful technologies beyond 2030 are likely to be those that deliver incremental but cumu - lative gains across flexibility, efficiency, and sustainability, building on proven refining platforms rather than replacing them outright. A Scott Sayles, Manager, Renewable Fuels and Alternate Feeds, Becht, ssayles@becht.com Emerging technologies will define the future of refining, but four years is too short a timeframe for meaningful trans - formation – most of the changes we might see by then are already in play today. The following expands the timeframe to 2030 and beyond:

The Paris Accord set greenhouse gas (GHG) emission targets with 2030 as the deadline and split the world’s leadership. Some regions (like Europe) reacted quickly, while others (like the US, India, and others) are changing slowly or not at all. These actions generally fall into two approaches for addressing transportation-related GHG emissions: renewables and fossil fuels. Renewable fuel conversion to transportation fuels (such as hydrotreating) was emerging about 10 years ago and is now an accepted practice. Looking beyond 2030, technol - ogy changes may become more dynamic. Refineries might switch from primarily fossil fuel processing to supplying transportation fuel, power, and other fuels. For example, nuclear power could be used for hydrogen production as well as power supply for process units and other customers. The conversion of refineries into electrical power suppli - ers seems like a natural change, with power demands for data exchange and EVs potentially fulfilled by these facili - ties. Operations may further shift toward producing more ecologically acceptable fuels, such as hydrogen via elec - Feedstocks could begin changing from crude oil to seed oils and waste streams, with more recycled streams processed, such as pyrolysis oils from plastics and tyres trolysis. Feedstocks could begin changing from crude oil to seed oils and waste streams, with more recycled streams processed, such as pyrolysis oils from plastics and tyres. These changes would alter the look and feel of the refin - ery. For example, small modular reactor (SMR) units need large areas (around 500 acres or more), and storage for materials like plastic bales could significantly expand the refinery footprint or replace existing tank farms. These shifts would also impact staffing, requiring different engi - neering and operational expertise and potentially changing management structures. During the transition, fossil fuel production by conven - tional refining technology will continue to supply most of the world’s transportation energy. Demand for fossil fuels is likely to remain strong approaching 2030 and beyond, as the alternatives require time to implement. However, the fossil fuels produced will increasingly be blended with renewables to reduce environmental impact. In the short term, shocks to the oil supply system (such as the Iran crisis) could potentially raise fossil fuel prices to levels approaching breakeven with renewable fuels. While the probability appears low, it could represent a tipping point.

PTQ Q3 2026

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A Colin Baillie, Hydro/Resid Strategic Marketing Manager, colin.baillie@grace.com and Stefan Brandt, Director, FCC Market Development, Stefan.brandt@ grace.com, W. R. Grace & Co. (Grace) Looking beyond 2030, the refining technologies we consider most compelling are ebullated bed residue hydrocracking (EBRHC) and the increasing integration of new raw mate - rials in refineries. EBRHC represents a unique growth area within refinery processes. It continues to be attractive to refiners because it offers several advantages over alternative residue upgrading processes, such as fixed-bed resid (FBR) hydrotreating, visbreaking, and coking. Another exciting trend to consider is the introduction of new raw materials in refineries, such as inputs derived from bio- or waste-derived origins or byproducts from power-to-liquids (PtL) processes. EBRHC converts a significant portion of vacuum resi - due (VR) into valuable distillates, reducing low-value fuel oil production, with up to 90 wt% (538+°C) conversion achievable. This is significantly higher than the 30-40 wt% conversion typically achieved with FBR hydrotreat - ing. Another advantage versus FBR hydrotreating is that fresh catalyst can be continuously added and withdrawn, maintaining high activity, extending unit run lengths and avoiding periodic shutdowns. In addition, EBRHC allows for greater feedstock flexibil - ity, unlocking additional refinery profitability through the processing of challenging, contaminant-laden crudes. For example, the maximum feed metals content for the EBRHC process is typically 700 mg/kg, which is significantly higher than the 200 mg/kg maximum associated with FBR hydrotreating. Whereas coking achieves residue upgrading through a carbon rejection process, EBRHC is fundamentally differ - ent in that it proceeds via hydrogen addition. This results in lower coke and sediment formation, leading to bet - ter yield and reliability, while hydrogen incorporation into the cracked products enhances product quality. Two new EBRHC units started up in late 2025, while an additional

seven units are either under construction or in planning. EBRHC is a particular area of focus for the proprietary ART Hydroprocessing technology. Beyond bottom-of-the-barrel conversion technologies, the integration of new raw materials entering refineries has long-term opportunities for the industry. The introduction of biomass-derived streams, such as fats, oils and greases, into refinery units is happening in multiple refineries globally today, and interest continues to grow. Co-processing in refin - eries is still in its nascent stages. However, as this becomes more important due to government incentives, subsidies, and product quality implications, refiners are uncovering ways to increase the processing rates of these unique feedstocks. Technologies to tackle these opportunities, such as new catalytic solutions that suppress the effect of oxygen intro - duction (see Figure 1 ) into FCC units,1 will support the refining industry in maximising co-processing opportuni - ties with biogenic feedstocks. The processing of waste-derived streams, such as plastics-derived pyrolysis oils (PDPO), is currently limited by the availability and processability of these feedstocks. Regulatory uncertainty and bankability are among the fac - tors hindering the development of upstream production capabilities. With further development of PDPO capacities, greater quantities of those feeds for the petrochemical and refining industry will become available, allowing more vis - ibility into potential opportunities for improvement. Available information highlights a significant change in the nature and concentration of contaminants in these feeds, resulting in more strain on equipment and catalyst deactiva - tion in refineries. Outstanding metals tolerance, paired with innovative approaches to new contaminants management, will become important for applications co-processing these feeds. Catalyst suppliers will continue to work on improving the metals tolerance of their catalyst offerings and/or come up with innovative designs for catalyst staging in fixed-bed applications to improve catalyst consumption or cycle length. PtL is expected to gain momentum in the mid-2030s, with initial plants expected to start up around that time. The chemistry of typically considered PtL approaches (via Fischer-Tropsch or methanol chemistry) enables the devel - opment of synthetic pathways for the specific production of olefins, gasoline, diesel, aromatics, and sustainable avia - tion fuel (SAF). Possible side products would be suitable for refinery processes to maximise carbon circularity through - out the transportation fuels and petrochemical value chains. For example, Fischer-Tropsch waxes or byproducts might become available as valuable feedstocks in existing assets of refineries.2 The continued advancement of EBRHC and the intro - duction of new refinery feedstocks represent compelling opportunities to enhance conversion, increase flexibility, and drive long-term value across the refining industry. One thing is clear: catalyst design and process enhancements will unlock the full value potential of these unique streams. 1 Hunt et al., Lessons learned from FCC biofeed coprocessing, Hydrocarbon Processing , January 2026. 2 Dupain et al., Catalysis Today 106 (2005) 288-292.

6000

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Cat-to-Oil ratio

ROT = 538˚C (1000˚F), VGO

ROT = 516˚C (960˚F), VGO

ROT = 516˚C (960˚F), VGO + 20% Canola ROT = 538˚C (1000˚F), VGO + 20% Canola

Figure 1 Total aldehyde content in liquefied petroleum gas (LPG) in Grace’s DCR pilot plant testing of vacuum gas oil (VGO) with and without the addition of canola oil, plotted vs reactor outlet temperature (ROT)¹

PTQ Q3 2026

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A Major FCC Catalyst Iron Tolerance Advancement

Grace Iron Deactivation Protocol (Grace-IDP™)

In an era when traditional value drivers such as flexibility of feedstock are essential to the refining industry, Grace brings you the culmination of decades of R&D: the Grace Iron Deactivation Protocol or Grace-IDP™. Commercially substantiated, Grace-IDP™ extends Grace’s leadership in iron tolerant FCC catalyst technologies, unlocking the capability to explore novel treatments and catalyst formulations that enhance iron tolerance. Talk to your Grace partner today about our long history of looking ahead and how our portfolio of products can help you process heavier feedstocks, creating more flexibility and more opportunity in the FCCU.

Q What alternatives to rare earth-based catalysts can petroleum refiners consider? A Mark Schmalfeld, Global Marketing Manager, Refining Catalyst, BASF, mark.schmalfeld@basf.com Rare earth oxides (REOs), particularly lanthanum, con- tinue to play a critical role in modern fluid catalytic cracking (FCC) catalysts. They provide hydrothermal stability to Y zeolite under severe operating conditions while support - ing an effective balance of activity, selectivity, and metals tolerance. At present, there is no direct, full replacement for rare earths that can deliver equivalent performance across the broad range of commercial FCC applications. That said, refiners do have options to reduce, though not fully eliminate, rare earth usage, depending on feedstock quality, operating severity, and product objectives. One approach involves the increased use of shape-selec - tive zeolites, such as ZSM-5, in combination with lower REO base catalysts. These additives are particularly effec - tive in petrochemical-oriented FCC operations, where shift - ing product yield toward light olefins is a priority. However, ZSM-5 functions as a secondary catalyst and does not replace zeolite-Y’s role in providing total conversion or long-term hydrothermal stability. Another pathway is the use of higher matrix, lower zeo - lite-Y catalyst formulations, which inherently reduce total rare earth demand by shifting some cracking functionality from zeolite to matrix components. These systems can be attractive for resid or metals-rich feeds, but they typically involve trade-offs such as reduced gasoline selectivity, higher bottoms yield, or narrower operating flexibility. Rare-earth-free FCC catalysts have been commercially available for decades, yet their adoption has remained lim - ited. In most applications, the operational benefits derived from rare earth chemistry, particularly stability and selectivity control, outweigh the advantages of their complete removal. Additional strategies include the use of alternative metals traps (for example, magnesium or calcium-based systems) and alternative stabilising ions in zeolite-Y, such as phospho - rus or manganese. While these approaches can contribute to reduced rare earth usage, they are associated with well- understood trade-offs in acidity control, coke selectivity, metals tolerance, or long-term stability. As a result, they have complemented rather than displaced rare earth chemistry. In summary, while several technical strategies exist to reduce rare earth content in FCC catalysts, rare earths remain the most cost-effective and reliable means of stabi - lising zeolite-Y and controlling selectivity under modern FCC conditions. For the foreseeable future, rare earth reduction will remain an exercise in optimisation rather than wholesale substitution within commercially proven FCC technology. A Herb Telidetzki, FCC and Alkylation Advisor, htelidetzki@becht.com, and Scott Sayles, Manager, Renewable Fuels and Alternate Feeds, ssayles@becht. com, Becht Rare earth is used to hydrothermally stabilise zeolite. Removing zeolite increases olefin yields but also leads to more rapid deactivation.

During the last significant price increase in 2010, rare earth prices skyrocketed from $8/kg to $140/k, result - ing in soaring FCC catalyst costs. Current prices are more stable because light rare earths such as lanthanum (La) and cerium (Ce) are relatively abundant. However, the rare earth lanthanum-neodymium (LaNd) is used in lithium ion batteries for EVs, which has caused a large spike in the demand-supply curve for LaNd. The interesting outcome is that La and Ce are co-produced from LaNd production and are in lower demand, which is stabilising pricing. To manage the 2010 spike, rare earth content in FCC catalysts was reduced despite impacts on activity and the need for higher catalyst addition. Catalyst suppliers also found alternatives to rare earths, and catalysts were refor - mulated to these new grades. Although not as effective as rare earths, these new formulations performed significantly better than the zero-rare-earth options. Fortunately, rare earth concentrations in FCC catalysts remain low, and prices are not fluctuating. However, if this should change, catalyst suppliers have alternatives available. A Michael Hawkins, Regional Marketing Manager, Americas, Michael.hawkins@grace.com, and Gary Cheng, Director, FCC Strategic Marketing, gary.cheng@grace.com, W. R. Grace & Co. (Grace) Rare earths became valuable in FCC catalysts because they solved a fundamental problem. Early FCC catalysts were amorphous silica-alumina materials with low activity that struggled to handle heavier, metal-contaminated feeds. The introduction of zeolite-Y in the early 1960s was a break - through, delivering orders of magnitude higher activity and enabling modern FCC unit designs. However, zeolite-Y rap - idly collapsed under FCC hydrothermal conditions, losing aluminum from its framework through dealumination. Researchers discovered that exchanging zeolite-Y with rare earth cations, primarily lanthanum, dramati - cally improved performance. Rare earths anchor frame - work aluminum, suppressing dealumination and zeolite destruction. This preserves acidity, maintains activity, and enables higher severity FCC operation. As crude slates became heavier and higher in contaminants, rare earths also provided a means to trap and passivate metals such as vanadium, helping limit their detrimental impacts on unit operation. Today, rare earth availability is less certain, as persis- tent geopolitical tensions, de-globalisation pressures, and supply chain disruptions continue to interact in unpredict- able ways. In prior rare earth crises and supply-challenged environments, researchers and FCC experts rose to the challenge and developed alternatives, including zero- and low-rare-earth FCC catalysts and additives for both hydrotreated and resid feed applications. These solutions are enabled by proprietary zeolite designs and advanced stabilisation techniques that deliver perfor - mance comparable to conventional rare-earth-based FCC technologies. Non-rare-earth elements can be employed to maintain the zeolite structure and minimise dealumination, even under severe hydrothermal conditions. Despite the

PTQ Q3 2026

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absence of rare earths, these innovative catalysts maintain strong resistance to metal contamination and sustained performance in demanding refinery environments. Today’s flexible catalyst system designs allow refiners to develop and tailor optimal catalyst strategies, including zero- and low-rare-earth alternatives, that meet unit objec - tives regardless of feedstock characteristics. This approach helps maintain catalyst activity, product selectivity, and metals tolerance, maximising overall economic value. Q Are there alternatives to the heavy reliance on naph- tha as a key petrochemical feedstock? A Mel Larson, Strategic Consulting Advisor, Becht, mlarson@becht .com Naphtha accounts for approximately 40% of petrochemical feedstock globally, and in India, it accounts for more than 60% of the feed. Circular processing (including recycling) has the long-term potential to replace 5-20% of naphtha, though full lifecycle analysis may show net negative emis - sions benefits. NGLs (propane, butane) are viable alternatives but com - pete with other high-demand markets. The core issue comes down to cost-effective innovations. Ever-increasing demand for petrochemical products may drive first-gener - ation production shifts to plant-based feedstocks, though these still require fossil fuels for agricultural development. There are alternatives to naphtha; however, all require an energy cycle (cradle-to-grave) analysis to properly evalu - ate their true economic value and sustainability. Reliance on naphtha as a feedstock is unlikely to shift significantly over the next two decades. With greater operational and feedstock flexibility, advantaged economics, and improved carbon footprint, FCC technologies offer a practical alternative to naphtha-centric petrochemical feedstock production A Boheng Ma, Strategic Marketing Manager, FCC Catalysts, W. R. Grace & Co. (Grace), boheng.ma@grace.com The petrochemical industry’s traditional dependence on naphtha steam cracking is increasingly challenged by high energy intensity, capital requirements, and carbon expo - sure. While propane dehydrogenation (PDH) has grown as a propylene source, it remains constrained by equilibrium limits and sensitivity to propane pricing. In this dynamic landscape, FCC units provide several distinct advantages to reduce reliance on naphtha as a key petrochemical feedstock. The first advantage FCC technologies enable is on- purpose light olefins production using existing refinery assets. FCC technologies enable deliberate and flexible

control for the production of these petrochemical feedstocks. Through catalyst and additive design, and particularly with the use of high-activity ZSM-5-based technologies like the proprietary Zavanti or OlefinsUltra MZ, refiners can selec - tively crack gasoline-range olefins into valuable light olefins products with little to no capital investment. This flexibility allows FCC units to shift from fuels-focused production to on-purpose petrochemical feedstock production as market conditions change and evolve. In contrast, steam crackers and PDH units are largely locked into single-product opti - misation strategies and require substantial capital to alter product slates. From economic and decarbonisation perspectives, FCC- derived propylene is an important petrochemical feedstock, offering the lowest cash cost of production and lowest carbon footprint among commercial propylene pathways. PDH units require high reactor temperatures to overcome equilibrium limitations, resulting in high energy consump- tion and associated carbon emissions. Steam cracking is even more energy and carbon-intensive, operating at extreme temperatures to drive the thermal cracking reac - tions that produce petrochemical feedstocks. In contrast, an FCC unit’s catalytic pathway for propylene production operates at lower reactor temperatures and derives most of its process energy internally through coke combustion. This translates into lower operating costs, fewer processing steps, and reduced carbon intensity. Another advantage of FCC units is their feedstock and transition flexibility. PDH technologies rely almost exclu - sively on high-purity propane, while steam crackers are highly sensitive to naphtha composition and availability. FCC units can process a broad range of fossil, renewable, and circular feeds, including bio-derived oils and plastic- derived feedstocks, enabling the production of bio-circular propylene. This flexibility positions FCC as a practical bridge between today’s refining system and a lower-carbon petro - chemical future. Beyond these benefits, FCC units offer additional options to extend and upgrade petrochemical value within existing refinery configurations through incremental olefin recovery and upgrading routes. For example, FCC units operating in petrochemical mode also produce meaningful quantities of ethylene and butylenes. Ethylene, a typical constituent in the fuel gas system, can be valorised when routed to an integrated petrochemical complex. For non-integrated FCC units, targeted investments in ethylene recovery and purification may also be economi - cal to capture incremental value from this product stream. Additionally, co-processing bioethanol can leverage the high dehydration activity of FCC catalysts to generate additional bio-derived ethylene, creating potential economic upside through ‘green premiums’.1 Alternatively, FCC-derived eth - ylene and butylenes can be converted to additional propyl- ene via olefin metathesis. Finally, petrochemically focused FCC operation results in a lower naphtha yield that is richer in aromatic content, which can enhance the economics of benzene, toluene, and xylenes (BTX) recovery from FCC- derived naphtha. With greater operational and feedstock flexibility,

PTQ Q3 2026

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• Reduce waste first through operational discipline. • Build flexibility through smarter system design and connectivity. • Align the organisation so execution matches strategy. Every drop counts, but success comes when the struc - ture is built to manage it. A sustainable and effective water strategy does not require perfection, and it often does not require major capital. What it does require is focus, sequencing, and accountability. When those elements are in place, water management becomes a driver of reliability, cost reduction, risk control, and long-term resilience. Q What technological advances can be leveraged to accelerate the next wave of SAF projects? A Scott Sayles, Manager, Renewable Fuels and Alternate Feeds, ssayles@becht.com, Becht Emerging technologies for SAF are being announced at a rapid pace, though implementation remains slower. Hydrotreating is still the primary upgrading technology in use today. Examples of developing pathways include: • Ethanol to SAF. • Bamboo and other biomass to SAF. • Methanol to SAF. • CO₂ to SAF. • Other options. The basic concept across these approaches is the use of alternative carbon sources to produce SAF. These pro - cesses are technologically complex and typically yield a lower volume of SAF than the feed to the unit. SAF pro - duction can be increased, but doing so requires significant capital investment and higher operating costs. Competition with fossil fuels limits the likelihood of large-scale expan - sion, meaning that government funding or changes in crude pricing would be required to accelerate production. A Natalia Krupkin, Technical Service Manager, Biofuels Applications, W. R. Grace & Co. (Grace), natalia.v.krupkin@ grace.com As the production of SAF expands, the next wave of proj - ects will depend not only on new catalytic technologies but also on technological advances, such as advanced feed - stock pretreatment innovations that help producers reduce cost, risk, and their environmental footprint. Synthetic amorphous silica adsorbents can offer a critical technologi - cal lever that can be implemented to help improve feedstock quality, simplify pretreatment processes, and materially reduce solid waste generation, which is an increasingly important constraint for large-scale SAF deployment. A fundamental challenge of SAF production is the high impurity content and variability of renewable and waste- based lipid feedstocks, which can include waste/used cook - ing oil, animal fats, and distillers’ corn oil. These feedstocks often contain phospholipids, soaps, trace metals, and other polar contaminants that can deactivate hydrotreating cata - lysts, increase hydrogen consumption, and shorten operat - ing cycles. Technologically advanced products like Grace’s proprietary Trisyl silica adsorbent, unlike natural silica, are engineered

advantaged economics, and improved carbon footprint, FCC technologies offer a practical alternative to naphtha-centric petrochemical feedstock production. These pathways, coupled with incremental value extension opportunities, allow refiners to adapt existing assets to changing market and carbon constraints without reliance on new, capital- intensive routes. ZAVANTI and OlefinsUltra MZ are marks of W. R. Grace & Co. (Grace). 1 Petrobras and Braskem complete tests for renewable content chemi - cal product, Hydrocarbon Processing , August 2024. Q What innovative strategies can refiners consider for securing long-term fresh water supply? A Carlos Cavalca, Vice President, Technical & Performance, Innovation Leader, Sustainable Industries & Buildings, Charles.cavalca@veolia.com, Veolia North America, Eric Ye, Process Group Lead, eye@becht.com, Becht, and Karen Green, Sustainability Technologist, KGreen1@Marathonpetroleum.com, Marathon Petroleum Securing long-term fresh water supplies for refining opera - tions is not necessarily a matter of adopting the latest inno - vative technologies or strategies, but rather developing a deliberate, well-designed, and carefully planned water use strategy that starts with understanding the source(s) and quality of the water consumed and what purposes the water consumption serves the refinery. In addition, an understand - ing of the drivers for water reduction and the real investment required to implement the actions or projects is needed. The first step in the development of an effective and sus - tainable water strategy, if not already done, is to conduct a comprehensive water use audit. This audit accounts for the sources of water and all types and uses of water consump - tion. It is more than a simple accounting of the volume of the water consumed and where it is being used. Instead, the audit is an overview of how the water is being used. Following this audit, a structured water use reduction programme should be developed. This programme starts with benchmarking water usage against industry norms and conducting a brainstorming workshop to identify capi - tal and non-capital water reduction measures. These initia - tives and projects are then prioritised and implemented in a manner consistent with the refinery’s needs, budget, and overall strategy. The implementation of this strategy is a concerted effort between the people who run the units every day and those who maintain and optimise them. The most durable gains in water consumption are realised when water becomes part of daily operational thinking rather than by implement - ing the latest technology. Alignment and commitment are essential. Leadership commitment is necessary, but day-to-day results depend on the decisions made by operators, engineers, and super - visors, with clear priorities, transparency, and consis - tent performance tracking that build trust and reinforce accountability. The strongest water reduction programmes consistently follow three principles:

PTQ Q3 2026

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to selectively adsorb these polar impurities to trace levels, stabilising feed quality upstream of catalytic processing. By enabling feedstock flexibility while also reducing waste and operating complexity, synthetic amorphous silica adsorbents support faster, more resilient SAF scale-up. Beyond impu- rity removal efficiency, this engineered silica adsorbent can improve SAF project economics and speed to market by streamlining the pretreatment process. In many instances, Trisyl silica can partially or fully replace the water washing and caustic refining steps necessary with conventional bleaching earth. This minimises equip - ment needs, lowers water and chemical consumption, and simplifies permitting and wastewater handling. For SAF producers looking to accelerate timelines and lower the capital intensity of future projects, particularly retrofits of existing renewable diesel or refinery assets, this is a major advantage. Through technological advancements in silica engineering, the silica can enable producers to dramatically reduce their solid waste generation during pretreatment. Due to its high surface area, engineered pore structure, Ultimately, leveraging advanced feedstock pretreatment technologies, such as silica adsorbents, represents a practical and scalable pathway for SAF producers and strong affinity for polar contaminants, the engineered silica often requires significantly lower dosing rates than activated bleaching earth. Unlike clay-based adsorbents, it does not retain large volumes of oil within its structure. Together, these properties can reduce pretreatment solid waste volumes by up to ~85% compared to bleaching earth, based on manufacturer and industry application data. For SAF producers, this translates directly into lower disposal costs, smaller waste handling systems, reduced truck traffic, and improved lifecycle sustainability metrics – factors that increasingly influence offtake agreements and policy incentives. Synthetic amorphous silica contains no detectable crys- talline silica and is chemically inert; using it avoids the auto-ignition risks and oxidative side reactions sometimes

associated with bleaching earth and diatomaceous earth. These attributes align with the stricter safety expectations placed on new SAF facilities and support improved refinery operability at scale. Ultimately, leveraging advanced feedstock pretreatment technologies, such as silica adsorbents, represents a prac- tical and scalable pathway for SAF producers to improve feedstock quality, reduce pretreatment waste, simplify operations, and protect downstream catalysts, delivering both economic and sustainability benefits at a commercial scale today. TRISYL is a mark of W. R. Grace & Co. (Grace). A Danny Verboekend, Founder and CSO, Zeopore Technologies, danny.verboekend@zeopore.com The most opportune way to boost the industrialisation and commercialisation of SAF may be to evaluate technological advances in catalytic conversions involved in the hydro- carbon synthesis. Moreover, ideally, one focuses on the reactions most widely employed to produce SAF: hydro - processing (see Figure 2 ). In hydroprocessing, the length and shape of the hydro- carbons are conditioned to meet the stringent specifica - tions of SAF. In hydrocracking, the molecules are reduced to the right size, whereas isomerisation is performed to branch the typically very linear alkanes and thereby reduce the cold flow properties. Importantly, the key criterion is feedstock retention: losses to byproducts (typically lights) directly lower the efficiency of all preceding steps. The performance of hydroprocessing can be significantly boosted by using catalysts based on pre - mium accessible zeolites. Accessible zeolites are those that facilitate the access and transport of reactants and product molecules to and from the intrinsic zeolitic active sites. As compared to standard zeolite-based catalysts, the benefits of accessible zeolites are significant: boosting conversion, selectivity, and lifetime.1 This implies that per kg of SAF, less energy, less feedstock, and therefore less CO₂ emissions are required.2 The enhanced hydroprocess - ing performance provides a clear economic benefit, yielding more SAF for the same input of precious feedstock. However, other secondary benefits are not to be under - estimated in terms of economic and environmental impact. For example, accessible zeolites typically reduce the out -

put of undesired lights (C 1 - C₄). These species often find application for heat generation via combus- tion and therefore directly contribute to the emissions of CO₂. Fewer lights also relates to a reduced hydro- gen consumption, which is a costly and environmentally demanding resource. When combining reduced lights, reduced hydrogen consumption, and increased

Hydrogen

Hydroprocessing

Isomerisation

Cracking

Pretreatment

Removal S, N, O and other elements

Circular feedstocks

Renewable fuels

Z eopore

Fats, oils and grease (FOGs)

Heavy-duty trucks, shipping and aviation

Byproducts (lights)

Figure 2 Hydroprocessing flow diagram

PTQ Q3 2026

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output of SAF, the CO₂ savings are in the order of 0.25 kg per kg of SAF. In an average hydroprocessing unit, this implies that, compared to a standard zeolite benchmark, the accessible zeolites generate CO₂ savings of about 50 metric tonnes per kg of zeolite. These benefits, combined with more than $500 of increased output per kg of zeo - lite, make accessible zeolites a technological smart play for advancing SAF technology. That is, if developers can scale and manufacture the accessible zeolite-based catalysts in a commercially relevant manner. Q How is AI being applied to enhance predictive mainte- nance for refinery and petrochemical equipment? A Mark Fronek, Manager, Digital Solutions, Becht, mark. fronek@becht.com On a scale of 0 to 7 of AI maturity (0 = no AI; 1 = descriptive analytics; 2 = diagnostic analytics; 3 = predictive analytics; 4 = prescriptive analytics; 5 = augmented intelligence, 6 = autonomous systems; and 7 = transformative AI), predic - tive maintenance is being explored at a ‘Level 3’ by nearly all mid-major and larger organisations. Many have a goal of automated work order generation at a fractional level of accuracy, which pushes into ‘Level 4’ maturity. A key difference between these efforts and long-estab - lished predictive models for rotating equipment is that the analysis looks at maintenance, inspection, and operational data. This introduces a significant challenge to success, as maintenance data sets are not easily audited for validity and have only more recently been leveraged in AI-driven systems. As a result, they have a shorter history of data clean-up and institutional emphasis on data quality. In general, inspection data is more robust than mainte - nance repair history, and AI-driven results based on this data are more likely to be accurate and require less human clean-up. However, the lengthy periods of data needing review and the likely changes in methodologies and sys - tems over those time periods create additional challenges. 1 Siters, K. Alkegen Fiber based specialty catalyst material maximises surface area and catalyst contact. PTQ Catalysis 2022 , pp.45-49. 2 Verboekend, D. Economic and environmental versatile technologies in refining. PTQ Q4 2025 , pp.45-48. A Doug Cooper, Product Management Director, Emerson’s Aspen Technology business, douglascooper@ emerson.com AI is being applied to predictive maintenance in refinery and petrochemical operations in several ways, ranging from model development and alerting strategy to diag - nostics and workflow support. The objective is to improve how early issues are detected, interpreted, and addressed before equipment problems affect production, cost, or safety. In these environments, AI helps identify early deg - radation patterns to predict likely failure before traditional alarms or maintenance intervals indicate a problem. One important application is in the development of pre - dictive models themselves. AI can be used to determine training ranges for machine learning agents, identify sensor

requirements, and establish alerting ranges that are more representative of actual operating behaviour. This is par - ticularly relevant for refinery and petrochemical equipment because operating conditions are variable and asset response is dependent on process context. In these environments, static thresholds alone are often not sufficient to detect early degradation or support reliable failure prediction. AI is also being used to improve diagnostic quality. Rather than only indicating that abnormal behaviour exists, it can help determine the likely failure mode so that more prescriptive guidance can be provided for remediation. This supports a more actionable maintenance programme, especially for assets such as pumps, compressors, heat exchangers, and distillation-related equipment where multiple process and mechanical factors can contribute to failure. Supporting technologies may include failure, anomaly, and process agents, depending on the type of asset and monitoring objective. When linked to an embedded Failure Modes and Effects Analysis (FMEA) library, the system can map likely causes, effects, and recommended corrective actions, making predictive alerts more practical for main - tenance teams. A further application is in the design and scaling of asset health strategies. AI can support the creation of asset tem - plates for refinery and petrochemical equipment; help define asset health KPIs across rule-based, condition monitoring, and first-principles approaches; and improve consistency across similar asset classes. When combined with domain expertise and physical properties data, this can provide a more complete view of asset condition than conventional monitoring methods alone. AI is also being applied to reduce inefficiency in main - tenance workflows. For example, it can help prevent alert fatigue by grouping multiple alerts associated with a single underlying issue. This allows teams to focus on the most rel - evant root cause, instead of spending time sorting through secondary symptoms. AI is also enhancing predictive main - tenance by operationalising workflows through enterprise asset management (EAM) software and computerised maintenance management system (CMMS) integration. Rather than leaving predictive insights in a dashboard, the objective is to connect maintenance intelligence directly into business processes so alerts can be reviewed, priori - tised, and translated into recommended corrective actions or work orders. This supports faster review, better prioriti - sation, and a closed-loop workflow from prediction to exe - cution. Overall, AI is making predictive maintenance more practical and scalable for industrial operators. AI helps identify early degradation patterns to predict likely failure before traditional alarms or maintenance intervals indicate a problem

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