PTQ Q3 2026 Issue

comprising light vacuum gas oil (LVGO), heavy vacuum gas oil (HVGO), and heavy coker gas oil (HCGO). Following incremental upgrades, the unit now operates at 110% of design capacity while sustaining nearly 99.0 LV% conversion. Middle distillates are typically recovered in the 150-370°C boiling range. Catalyst evolution and technology advancements A key enabler of high MD yield has been CLG’s ongoing innovation in hydrocracking catalyst technology. Over time, hydrocracking catalysts have evolved from amorphous cogel catalysts to zeolite-containing formulations, deliver- ing improved activity, stability, and heavier feed handling capability. CLG’s current catalyst portfolio continues this progression by offering refiners a range of selectivity and robustness options to maximise profitability across differ - ent hydrocracking objectives. A recent addition to CLG’s catalyst portfolio is the ICR 252 catalyst, a next-generation base-metal, second-stage hydrocracking catalyst that surpasses its predecessor, ICR 250. Installed during the most recent catalyst changeout, ICR 252 significantly improved MD selectivity as compared to prior catalyst systems. Pilot-plant data indicate a 6.7 wt% increase in second-stage MD yield with ICR 252 versus ICR 250, primarily driven by shifting product distribution from heavy naphtha toward diesel-range material (see Figure 2 ). In addition to improved selectivity, ICR 252 enhances management of heavy polynuclear aromatics (HPNA), reducing fouling propensity and enabling lower uncon- verted oil (UCO) bleed rates. This allows operation at higher conversion severity without compromising catalyst stabil- ity or cycle length. Since its commercialisation in 2021, ICR 252 has been adopted in multiple global installations, dem- onstrating consistent performance benefits. Complementary improvements were also made in the first-stage catalyst system. Relative to the previous oper - ating cycle, the updated catalyst combination contributed to an overall MD yield increase of approximately 6.4 wt%, with the second-stage catalyst delivering the largest share of the improvement. Process optimisation and fractionation enhancements While catalyst selection Recycle gas

and payback measured in months. Higher available through- put, lower energy consumption, reduced maintenance demand, and avoided lost production all contributed to the return. This case shows how operators can intensify a process without installing a new vessel or redesigning an entire unit. By replacing a restrictive outlet component with an engi- neered full-diameter support grid, the customer converted a chronic reliability constraint into a stable, low-pressure- drop system. WMP now offers the OSG for new-build and retrofit axial-flow reactors across refining, petrochemical, chemical, and oil and gas applications. 1 Customer blinded for confidentiality.

Woven Metal Products (WMP) Russell Hillenburg Contact: rrh@wovenmetal.com

Chevron Lummus Global (CLG), in collaboration with a refining company, has demonstrated a sustained improve - ment in middle distillate (MD) yield of more than 6 wt% above the highest levels achieved over more than 10 years of operation – an exceptional result rarely seen in the industry for a large, two-stage hydrocracking unit (HCU) processing heavy gas oil feeds. This performance mile- stone was achieved through a combination of advanced catalyst technology, targeted fractionation upgrades, and disciplined post-turnaround optimisation. The results high- light how integrated process design and ongoing technical collaboration can significantly enhance product selectivity while maintaining high throughput and conversion. Unit overview The HCU is a CLG-licensed two-stage recycle hydrocracker (see Figure 1 ). Originally designed to process a high fresh feed rate (>100 MBPD) and maximum MD produc- tion at near-full conversion, the unit handles a feed slate Enhancing middle distillate production through improved catalyst system and HPNA management

Make-up hydrogen

Product gas

Fresh feed

played a central role, expert technical support was a key enabler of the record MD yield. Following the catalyst turnaround, CLG worked closely with the site team to monitor HCU performance and guide operating changes. Following unit restart, CLG and refinery engineers imple - mented a structured opti- misation programme over a five-month period.

Recycle gas

Light naphtha

Heavy naphtha

Kerosene

Diesel

First-stage product

Second-stage product

Figure 1 Standard two-stage recycle hydrocracking unit configuration

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PTQ Q3 2026