refining india 2025
Analytical solutions for the oil industry and hydrogen clean energy projects
Jochen Geiger AMETEK Process Instruments
Refinery expansion planning sounds simple, but unfortunately, it is not. Meeting today’s requirements for lower emissions while improving process efficiency also demands a lower carbon footprint. While this chal- lenge may sound like a ‘Mission: Impossible‘ scenario, we can achieve a satisfactory out- come without repeated attempts. Such a task requires expertise from mul- tiple disciplines working as a team; other- wise, it risks becoming a daunting trial. For example, failing to identify a suitable sample point during the piping design phase, includ- ing health and safety aspects, can lead to difficulties throughout the project and later under operational conditions. In this article, the following topics will be discussed: ○ Clean energy trends shaping the adoption of blue hydrogen (H₂) in the oil and gas sector. ○ Various processes involved in blue hydro- gen production. ○ Key measurements critical to each process. The industry is built on mature technolo- gies, emphasising efficiency and flexibil- ity. End users are lowering oxygen levels to reduce fuel consumption and emissions, despite safety risks. Reduced flaring has allowed plants to redirect waste to fuel gas headers. Carbon capture remains the primary long-term emission strategy for oil and gas leaders. While efficiency gains help reduce emissions in the short term using existing assets, further reductions are expected in the future through carbon capture, utilisa- tion, and storage (CCUS). Only the back-end capture of carbon diox- ide (CO₂) makes H₂ blue. To operate such pro- cesses efficiently and achieve the required product quality, process analytical instru- mentation (PAI) is essential. PAI can be quite complex, so expertise and knowledge in this field are a must. Notably, various long-term data collection efforts by a ‘global player’ in refining operations indicate that 70% of all measuring signal downtimes are caused by failures in the sampling system/sample preparation. Thus, only a well-designed ‘fit- for-purpose’ system with instruments and integration will work reliably for a long time. The energy transition focuses on the shift to H₂ fuels and their production. Cross- country and cross-company collaborations are driving efforts to lower H₂ and carbon capture costs. However, the oil industry and H₂ energy projects require high-precision analytical solutions to enhance efficiency, ensure compliance, and uphold safety standards. Tailored solutions such as H₂ pro- duction and carbon capture monitoring, H₂ purity analysis, online flare gas analysis, and combustion control are vital for measuring and controlling processes, enabling plants to operate at peak efficiency. The market requires advanced online ana- lytical solutions from experienced, reliable suppliers who offer application-customised
CANSOLV CO
CO
SMR Large reference base, but requires post-combustion CO capture for >90% capture
CO
Steam
Flue gas
CO capture
Feed gas pretreatment
SMR
Puri cation
CO shift
H
CH
CO
Steam
ATR
CH
Feed gas pretreatment
CO capture
ATR
Puri cation
H
CO shift
Feed pretreatment Steam for reaction Fired heater
O
Flue gas (CO emissions)
Air Power
Air separation
Feed heater
CO
High-pressure steam
CO capture
SGP
Puri cation
H
CO shift
CH or re nery fuel gas
SGP No or minimal feed pretreatment Steam production using waste heat No direct CO emissions from process
Air separation O
Air Power
Key technologies for producing hydrogen
A key takeaway is to ensure that significant
must undergo a thorough safety review. For optimising the combustion process, the con- trol parameters remain the same. However, unburned fuel, known as combustibles, must be continuously monitored. Additionally, carbon monoxide (CO) is an emission ele- ment, but it is not a reliable indicator of combustibles. Summary As described, there are many aspects to consider. A key takeaway is to ensure that significant features, especially innovations, are not overlooked during the initial planning phase. A cornerstone of this approach is the balanced evaluation of innovation. Beyond technological novelty, the focus remains on practical and tangible benefits. This per- spective ensures that innovative solutions not only meet theoretical expectations but also enhance real-world performance. From application-specific analyser designs to tailored sampling systems and strategic technology choices, this holis- tic approach propels operations toward optimal efficiency, safety, and sustainable operations. features, especially innovations, are not overlooked during the initial planning phase
Different models of trace moisture analysers made by AMETEK Process Instruments
none closely match what is required for the reformer application. So, any IR spectrome- ter can only be validated with simulations of approximate process conditions. For most users, this is insufficient. Here, QCM technology has a major advantage due to its built-in calibration device. This is a per- meation device that saturates the real pro- cess gas with a known amount of moisture at the ppmv level. This allows for a linearity check and calibration procedure using a two- point calibration method. The device comes with a National Institute of Standards and Technology (NIST) traceable certificate. Carbon clean CCUS As described at the beginning of this article, carbon clean projects require many different measurement technologies; no single tech- nology can fulfil the needs of such processes. The key is to select the best instruments and integrate them into a complete system. Process heaters using hydrogen as fuel H₂ as fuel is one way to achieve lower carbon emissions, especially when the H₂ is ‘blue.’ The challenge is the fact that H₂ requires dif- ferent safety measures compared to con- ventional fuels. Any equipment utilising H₂
solutions that ensure seamless integration and high-performance gas analytics tai- lored to industry needs. The following case studies illustrate the challenges users are facing today. It is impor- tant to understand how instrumentation packages are planned and executed. These case studies focus on the challenge of ‘sam- ple point utilisation.’ A question to ask dur- ing the initial process control design phase is: even if a historical application review asks only for a single component, are there any new technologies available that could enhance process control?
Case studies Catalytic reforming
Catalytic reforming is a well-known pro- cess, and the most critical measurement here is trace moisture. Today’s standard lies between tunable diode laser spectroscopy (TDLAS) and quartz crystal microbalance (QCM) technology. What sets this measure- ment apart from most other process meas- urement technologies is that no calibration gas is available. For almost every other com- ponent, a suitable calibration gas mixture can be found; however, trace moisture is an exception. A few mixtures are available, but
Contact: jochen.geiger@jg-consultant.com
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