NARTC 2025 Conference Newspaper

21 – 22 January 2025 Houston, Texas

Official newspaper published by PTQ / Digital Refining

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 com- mitment to delivering high-quality industry content aligns with our goals for NARTC. We also extend our thanks to our Advisory Board, our Host Sponsor, Axens, our Knowledge Partner, McKinsey & Co., and all other sponsors and exhibitors, without whom, we couldn’t have run this event. I have been particularly struck by their enthusiasm for what we are trying to achieve here. We are truly grateful for your

Welcome to the North American Refining Tech- nology Conference 2025! We are thrilled to be back in Houston, the energy capital of the world, to host another

support, and I hope you enjoy the confer- ence that you have 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! Himal Munsif Senior Manager, Downstream Strategy Chevron (Contributor)

inside

bon tner & Senior rt o.

Todd Miner Managing Advisor Solomon Associates

exciting edition of our programme. Our goal for the next few days is to create a platform for networking, innovation, and knowledge sharing that will help build resilient, for- ward-thinking business models that can withstand the uncertainties ahead and pro- gress through the energy transition.

Kind regards,

Elizabeth Cannon Portfolio Director – Americas World Refining Association

Topsoe low-carbon SynCOR Ammonia process

Terrill Pitkin Senior Vice President of Commercial & Planning ParPacific (Contributor)

egy gy

Key Advisory Board takeaways

Exploiting ‘old’ refinery assets 5 Challenges in diesel hydrotreating catalyst selection 7 Achieving high efficiency in heat transfer equipment with HTRI digital twin technologies 9 Practical case study: Enhancing diesel hydrotreater capacity and reducing CO₂ emissions 11 Crystaphase optimisation helped refiner achieve up to double runtime and throughput 13 Hydrocracking a wider variety of feedstocks to meet demand while reducing energy costs 15

In preparation for the 2025 North American Refining Technology Conference (NARTC), the World Refining Association gathered its esteemed Advisory Board to delve into the key priorities, pressing challenges, and commercial opportunities refiners are facing today. The conclusions from this two-hour closed-door conversa- tion have formed the basis of the NARTC 2025 agenda. Here is a snippet of the key findings from the discussions: Advisory Board Members Macroeconomic Outlook Throughout The Energy ‘Addition’ Our Advisory Board and network recognise the critical role our industry will play over the next several decades. While energy demand grows and fossil fuel margins remain strong, staying competitive is increasingly chal- lenging. Advisors are concerned that legacy infrastructure may not ensure secure fuel supply or stable revenues. They explored what defines a resilient refining business – be it operating region, energy efficiency, production costs, or other metrics – and dis- cussed strategies for staying competitive. Simultaneously, the Board emphasises the need to invest in future fuels and sus- tainable practices. However, making the energy transition profitable remains a chal- lenge. Proven technologies like hydrogen, CCUS, and SAF pathways face insufficient investment and limited offtake agreements. Advisors discussed ways the industry can better influence investor and buyer deci- sions to support long-term competitiveness despite current risks and uncertainties. Ryan Hanson Director, Strategy Cenovus Energy (Contributor) Industry Expert McKinsey & Co.

Scaling SAF A central focus of the meeting was the need to exponentially increase SAF out- put and adoption. While technologies are proven, high production costs make offtake agreements challenging. The Board empha- sised involving airlines, reserve owners, and financial institutions in SAF’s success, urg- ing airlines to reflect on their role as offtak- ers and consider compromising on price to drive adoption. For refiners to invest in SAF, projects must be commercially viable, but current economics deter investment. The Board seeks economic comparisons of SAF pro- duction pathways (such as biomass gasifi- cation and HEFA) to fossil jet fuel, and there is a need to explore whether digitalisation and AI can reduce costs. Attracting and Retaining New Talent A key concern for many advisors is the industry’s struggle to attract and retain new talent, exacerbated by negative media and misconceptions. How can we better highlight our role in delivering affordable, reliable energy and leading the energy tran- sition? Despite perceptions, hydrocarbons

will remain vital for years, and the industry must communicate the need for a balanced energy transition. To inspire young talent, the Board empha- sised defining the future of refining and iden- tifying critical skillsets, such as expertise in AI and data engineering, to build sustain- able infrastructure. Promoting the indus- try’s innovation and dynamic opportunities is essential to securing its future workforce. Commercial Decarbonisation, Digitalisation, and Applications of AI It is agreed that technology is critical for the industry’s transformation on both ends of the sustainability angle. However, we can- not lose sight of the profitability and com- mercial viability of these technologies. Like SAF, many of these technologies are viable on paper and promise endless opportuni- ties. However, they need to be investable, provide sustainable returns, and act as case studies for the industry. The Board considered the technical and commercial challenges preventing the broad application of these methods. Each refinery has different goals, which may include decarbonisation, improving refin- ery/process optimisation, monitoring, pro- cess safety, or a combination of these goals. However, they often do not have a clear method of application. One advisor found that the latency of their SCADA sys- tems is too high to apply many optimisa- tion techniques. This is especially true of AI, where this refiner is having to investigate replacing their instruments first.

ADVISORY BOARD REPORT 2025

Tim Fitzgibbon Associate Partner & Senior

Himal Munsif Senior Manager, Downstream

Todd Miner Managing Advisor Solomon Associates

Strategy Chevron (Contributor)

Adapt to survive: How to protect catalysts in the switch to renewable feedstocks 17 Women In Refining 18

Terrill Pitkin Senior Vice President of Commercial & Planning ParPacific (Contributor)

Lifecycle management of precious metal catalysts

Enhancing safety in online fuel blending: Role of advanced leak detection systems

advertisers

Process Consulting Services

2 4 6 8

Topsoe

Crystaphase Products W R Grace & Co Malvern Panalytical

10 12 14 16 21 23 24

ERTC LARTC

Sabin Metal Corporation AMETEK Grabner Instruments LARTC Ask the Experts WRA Global Portfolio

ADVISORY BOARD REPORT 2025

Rethinking Old Problems

New design improves FCC slurry pumparound

Rising global demand for transportation fuels and propylene as a chemical feedstock will require new and revamped FCC units to increase supply. Technology enhancements have historically focused on improved or new catalyst formulations, updated feed nozzles, and reactor/regenerator designs. FCC charge rate and reactor temperature are often limited by performance of the main column and bottoms system. To fully capture benefits associated with tailored catalyst formulation or new reactor/ regenerator designs, the main column and slurry pumparound system must be up to the task. For many refiners, problems in the main column and bottoms section are a common occurrence. Rapid fouling in slurry pumparound exchangers requires frequent cleanings and added maintenance costs. Coking in the slurry pumparound bed leads to poor product quality, increased column pressure drop, and

shortened run length. However, many chronic problems can be mitigated with innovative designs driven by a proper understanding of the root cause. S lurry P umParound B ed Many FCCs are expected to operate 5-7 years between planned maintenance turnarounds. Modern grid packings have been used in this severe service with success. Even so, there have been times when the combination of high temperature, high liquid rate, and high vapor rate have caused severe coking. Trough distributors have been the go-to device to distribute liquid to the slurry pumparound bed. Special design features are used to mitigate risk of catalyst and coke particle accumulation in the troughs. The features that make the distributor more forgiving also make it more sensitive to liquid gradient and out-of- levelness. Even with the most careful design, slurry beds have experienced premature coking and shortened run lengths. In order to solve old problems, sometimes new thinking is needed. The engineers at Process Consulting Services, Inc. have revamped high severity, highly-loaded slurry pumparound sections with innovative solutions. A new twist on a classic distributor design improves reliability while eliminating inherent problems of old designs. Patented solutions to highly loaded grid-beds offer needed breathing room. Contact us today to learn how PCS designs can improve your FCC.

Coked distributor and grid

3400 Bissonnet St. Suite 130 Houston, TX 77005, USA

+1 (713) 665-7046 info@revamps.com www.revamps.com

narTC 2025

Topsoe low-carbon SynCOR Ammonia process

Henrik Rasmussen and Johan Malan Topsoe Inc.

the front end (reforming, shift, and CO₂ removal sections) but also in the back end (ammonia synthesis section), resulting in reduced Capex. The design of the inert-free ammo- nia synthesis loop provides another huge advantage. Where other large-scale designs require multiple pressure lev- els and multiple reactors in the ammo- nia synthesis section, SynCOR Ammonia uses a single S-300 ammonia converter in a standard, well-proven Topsoe ammo- nia synthesis loop with a single pressure level. The required ammonia converter size is already well-referenced industrially, with ammonia converters having a catalyst vol- ume above 150 m³. For comparison, an inert-free 6,000 MTPD ammonia synthesis loop in a SynCOR Ammonia plant will require less than 150 m³ of catalyst volume. In summary, the most important factors enabling the significant benefits from econ- omies of scale of SynCOR Ammonia are: • Attractive scaling factor for single trains. • Operation at 0.6 S/C ratio. • 80% reduced steam throughput. • Inert-free ammonia synthesis loop. • Reduced piping and equipment sizes. • Reduced energy consumption. • Single ammonia converter at a single pressure. • Opex savings of around 3%. • Able to capture more than 99% of the CO₂ as precombustion CO₂. The decrease in production cost result- ing from economies of scale is illustrated in Figure 3 for a conventional SMR-based plant and SynCOR Ammonia. The SynCOR reactor design consists of a Topsoe proprietary burner, a combustion chamber, target tiles, a fixed catalyst bed, a catalyst bed support, a refractory lining, and a reactor pressure shell, as illustrated in Figure 4 . SynCOR Ammonia is designed with two high-temperature shift reactors in series, a nitrogen wash to remove the carbon monoxide (CO), and the recycling of shift byproducts. The process layout has numerous benefits, such as close to zero byproduct formation and elimi-

Topsoe pioneered advanced autothermal reforming (ATR) during the 1990s and successfully commercialised plants oper- ating at a low steam-to-carbon (S/C) ATR technology in 2002, known as Topsoe’s SynCOR™ technology. SynCOR removes the limitations that other technologies have in reaching the optimal syngas composition. This advanced technology provides plant own- ers with a huge leap towards economies of scale in combination with a signifi- cant reduction in operational expenditure (Opex). It ensures high reliability and an on-stream performance of 99.5%, with lower requirements for operators and reduced maintenance. Topsoe has licensed four large-scale gas-to-liquids (GTL) sites globally, sev- eral of which comprise two production units per plant. Each unit produces syngas equivalent to more than 6,000 metric tons per day (MTPD) of ammonia at a low S/C ratio of 0.6. These plants have been in suc- cessful operation for more than 150 accu- mulative operating years. Topsoe’s large-scale SynCOR Ammonia™ plant has a capacity of 6,000 MTPD and is based on industrially proven equipment sizes and catalysts in both the frontend and backend ammonia loop in a single train configuration. The technology reduces the energy consumption gap for ammonia pro- duction by 10%, approaching the mini- mum theoretical levels. With the large production capacity comes a reduced capital expenditure (Capex) per ton of ammonia produced. This technology scales more efficiently than steam methane reforming (SMR)-based plants, having a lower scaling exponent. From a Capex perspective, both plant types can be considered for lower capaci- ties. However, SynCOR Ammonia becomes increasingly competitive compared to conventional SMR plants as production

Figure 1 SynCOR unit with an equivalent capacity of more than 6,000 MTPD of ammonia

capacity increases, and it clearly becomes the preferred choice at large capacities. Where oxygen is available over the fence, the technology is preferred even at very low capacities. Detailed studies have shown the fol- lowing additional advantages of SynCOR Ammonia plants:  More than 3% lower Opex.  Up to 50% make-up water savings, which is especially important in areas where water is a scarce resource.  An average availability above 99% of the SynCOR reforming unit.  More than 99% carbon dioxide (CO₂) capture, which is up to 50% higher than an SMR-based plant. The SynCOR Ammonia unit has a sig- nificantly reduced physical footprint due

to the elimination of the tubular reforming unit (SMR) and the use of a single-stage ATR for the entire steam reforming con- version. Figure 1 shows how small the SynCOR reactor is, even though its capac- ity corresponds to 6,000 MTPD of ammo- nia. Figure 2 shows the larger footprint of a tubular SMR and a secondary reformer with a capacity of 1,500 MTPD. In com- parison, the plot sizes of the SynCOR unit and the secondary reformer are very simi- lar and correspond to less than 5% of the plot size of the SMR. The most significant operating differ- ence between a conventional SMR-based plant and a SynCOR Ammonia plant is their S/C ratios. Conventional SMR-based plants operate at an S/C ratio of around 3, while SynCOR Ammonia plants operate at an S/C ratio of around 0.6. Consequently, steam throughput is decreased by 80%, resulting in much lower water consumption. SynCOR Ammonia plants also bene- fit from an inert-free ammonia synthesis, with the required nitrogen admitted just upstream of the ammonia synthesis sec- tion. In contrast, conventional ammonia plants introduce nitrogen in the secondary reforming reactor. These features enable significantly reduced pipe and equipment sizes for the SynCOR Ammonia plants, not only in

Oxygen

Natural gas and steam

CTS burner

Pressure shell

Refractory

HTZR™ target tiles Catalyst Catalyst support

Combustion chamber

Conventional plant

SynCOR Ammonia™

Capacity

Syngas

Figure 2 SMR-based reforming section with secondary reformer, 1,500 MTPD ammonia plant

Figure 3 Comparison of ammonia produc- tion cost using SynCOR Ammonia

Figure 4 Topsoe’s SynCOR

WHAT CAN LOW DO FOR YOUR BUSINESS?

MARENÉ RAUTENBACH Principal Scientist Topsoe

KNOWING YOUR LOW-CARBON POTENTIAL As decarbonization requirements go up, refining companies are looking for cost-efficient ways to bring their carbon intensity down. One way to go is low-carbon hydrogen. Using low-carbon hydrogen has the potential to support refining businesses and the energy transition by reducing the carbon intensity of fossil transportation fuels.

Discover the power of low at www.knowing-low.topsoe.com

narTC 2025

nation of the methanation step, purge gas recovery, ammonia absorption, and hydrogen recovery, resulting in a reduced need for compressor/recycle power and significantly reduced sizes of high- pressure equipment and piping. A standard high-temperature shift uses an iron-chromium (Fe/Cr)-based catalyst that cannot operate at an S/C ratio below 2.6. To overcome this limitation, Topsoe invented SK-501 Flex, an Fe and Cr-free catalyst. This catalyst was installed in the first plant 10 years ago and is now in suc- cessful operation in more than two dozen plants. To date, none of the SK-501 Flex catalyst has ever needed to be replaced. Figure 5 shows the main process steps for the new SynCOR Ammonia plant, and Table 1 provides a comparison of the main differences between a conventional ammonia plant and SynCOR Ammonia. The nitrogen wash removes both the slip of CO from the shift section and the methane slip from the reforming section. The off-gas from the nitrogen wash can be used as fuel without any further treatment. This design generates an inert-free syn- thesis gas, which results in a higher ammo- nia conversion per pass in the ammonia synthesis converter. The CO₂ removal unit in a SynCOR Ammonia plant can be a standard com- mercial amine solution. The CO₂ absorber is smaller than for conventional design because no nitrogen is added to the syn- thesis gas. In the Topsoe low-carbon ammonia pro-

Nitrogen

Air separation unit

Air

High temperature shift

O gases

CO removal

Ammonia conversion S-300

Oxygen

Super heated steam

Feed heater

Sulphur removal

Natural gas

Ammonia product

Separator

Nitrogen wash

Process condensate

Steam Hydrogenation

Prereformer

High temperature shift

Autothermal reforming

Fuel

Figure 5 Simplified process sheet of SynCOR Ammonia plant

cess, more than 99% of the CO₂ from nat- ural gas is captured in the CO₂ removal unit and cleaned up to meet the required purity needed for carbon capture, utilisation, and storage (CCUS). This amount of CO₂ cap- ture is up to 50% higher than what can be achieved in an SMR-based design without the use of post-combustion CO₂ capture, which is uneconomic (see Table 1). Today, Topsoe’s SynCOR technology is by far the preferred technology for the pro- duction of low-carbon hydrogen and ammo- nia in the world. To date, seven low-carbon hydrogen or low-carbon ammonia units are already in construction using SynCOR tech- nology, and many more units are in the pipe- line to help decarbonise the world.

Technology

Conventional NH 3

plant

SynCOR Ammonia

Desulphurisation section

Standard

S/C ratio

3.0

0.6

Reforming section

Tubular stream reformer and air-blown secondary reformer

Prereformer and oxygen-blown ATR

Shift section

High-temperature shift followed by

Two high-temperature shifts in series with recirculation of byproducts

low-temperature shift

CO 2 removal % for CCUS Synthesis gas cleaning

60-65

>99

Methanation

Nitrogen wash with purge and nitrogen addition

Ammonia synthesis

Ammonia synthesis loop with purge

Inert-free synthesis loop with no purge

Purge gas treatment

Ammonia wash followed by hydrogen recovery

No treatment required

Relative SNEC

100

Relative make-up water consumption

100

40-50

Contact: hwr@topsoe.com

Table 1

Exploiting ‘old’ refinery assets

Rene Gonzalez Editor, PTQ

waste fats, oils, and greases into refinery products. Margins opportunities for the more com- plex refiners ensure continued investment in complexity and capacity. These invest- ments are reflected by recent data show- ing that the total FCC cracking propylene capacity across US refineries is estimated to range between 6.5 and 7.5 million met- ric tons annually. This capacity has ben- efited from refiners’ ability to optimise assets, such as FCC units for olefins pro- duction, using advanced catalysts and oper- ating conditions tailored for future gasoline blends and higher yields of petrochemical feedstock like propylene. Legislation such as the proposed Next Generation Fuels Act aims to establish a minimum research octane number (RON) of 98 for future gasoline blends, support- ing advanced internal combustion engine (ICE) technologies while reducing carbon emissions through ethanol blending. These higher-octane fuels would enable more effi- cient engine performance and could become standard as automakers increasingly align engine design with these advancements, starting as early as the model year 2026. Meanwhile, rising cobalt costs will not make EVs cheaper anytime soon. EVs may fill the role as the ‘second car’, but ICE-powered vehicles will keep refiners competitive.

Although North America, as a major transit route, is well positioned for building refiner- ies, no new facilities have been built since 1977. It is no secret that government policy supersedes market forces and other advan- tages such as large crude resources, engi- neering expertise, and an efficient supply chain and service infrastructure. Instead, refineries are closing in the US and Europe. However, there appear to be opportunities for repurposing assets. In 2025, two significant US refineries are expected to close. The LyondellBasell Houston Refinery, with a capacity of 263,776 bpd, is scheduled to shut down in the first quarter. Additionally, Phillips 66’s Los Angeles refinery, which processes 139,000 bpd, is planned to close by the end of 2025. These closures will result in a combined loss of more than 400,000 bpd in refining capacity, possibly provid- ing higher margins opportunities for the remaining high-complexity facilities. Environmental, social, and governance (ESG) practices, CO₂ footprint mandates, renewable identification numbers (RINs), and other regulatory and policy factors continue to temper a refining organisation’s market- ability. However, the US Energy Information Administration (EIA) projects 2025 US gas- oline consumption will remain at the same level as 2024, estimated at 9 million bpd. Refiners will likely benefit from robust Gulf Coast margins due to feedstock accessibil-

The LyondellBasell Houston Refinery is due to close this year

ity (such as West Texas Intermediate [WTI], low-sulphur shale crudes) and strong export opportunities to Latin America and Europe, predicating the need for extending the life of gasoline-producing units such as the cata- lytic reformer and FCC unit. According to the US EIA, US fossil fuel production rose over the last four years, from 76 quads in 2020 to a record high of 86 quads in 2023, more than ten times the amount of total renewable energy produc- tion. Less than expected EV demand is par- tially why modest refinery investments will continue. Depending on which expert you favour, margins could range from $7-15 per barrel for complex refineries, based on the crude and product mix. US distillate con- sumption is also expected to grow by 4% in 2025 due to an increase in industrial, min- ing, and manufacturing activities.

In any case, water and higher hydrogen demand to meet clean fuels specifications is less expensive than in other regions. For example, hydrogen is five times more expensive in China than in the US. Against this backdrop, the more carbon-intensive and less efficient facilities may reconsider closing and instead reconfigure themselves as biorefineries for the production of sus- tainable aviation fuel (SAF), renewable die- sel, and similar products. These ‘old’ facilities can leverage exist- ing utilities, including desulphurisation capacity, boiler house, flare, and other offsites (such as tank storage, product blending, loading and receiving, and water effluent treatment). Having this infrastruc- ture in place is necessary when investing in supporting hydroprocessing assets that can catalytically process a wide range of

Contact: editor@petroleumtechnology.com

It’s the“aha”moment when a client realizes what Crystaphase brings to any challenge.Deep-dive analysis by expert teams. Highly advanced filtration technologies.Carefully tailored solutions that bring out the best in your reactor. Active collaboration throughout every step of the process. That’s the Crystaphase Experience.

crystaphase.com

narTC 2025

Challenges in diesel hydrotreating catalyst selection

Tiago Vilela and Nattapong Pongboot AVANTIUM

During the proposal stage, Catalyst scheme F was conservatively estimated to be 9°C lower than that of Catalyst scheme B. However, in reality, Catalyst scheme F was by far the best performer, with 25°C better activity than Catalyst scheme B, which is also among the poorest per- formers. The same observation applies to Catalyst schemes E and G to a certain extent, where their actual activity is top tier while being underestimated on paper. Case Study 2: Benchmarking four catalyst systems In this case, four catalyst schemes were tested with the objective of processing 5 vol% LCO. According to all the cata- lyst vendors, the catalysts could handle this amount of LCO for the intended cycle duration. After the first test results with 5 vol% LCO + 95 vol% SR diesel, a very high catalyst deactivation rate was observed. It became clear that none of the catalyst schemes could handle the LCO and would not last the 36-month cycle in the com- mercial unit. As seen in Figure 2 , although there were activity gaps between catalyst systems, the relative differences were not that large. The differences in WABT between catalyst systems will be a matter of cycle months, not years. More importantly, based on the test data, no catalyst system would meet the required cycle length with this operating scenario. In this case, the most conserv- ative catalyst scheme on paper, Catalyst scheme D, turns out to be the best per- former in real life. On the contrary, a seemingly attrac- tive catalyst scheme on paper, Catalyst scheme A is a poor choice, as it required the highest WABT to achieve 10 ppm product sulphur based on the actual test results. Conclusion Without independent catalyst testing, it is extremely difficult to select the right die- sel hydrotreating catalyst for your appli- cation. Real-world catalyst testing reveals the true catalyst performance and pro- vides refiners with reliable data for their economic evaluation. A parallel catalyst testing system bene- fits both refiners and catalyst vendors by allowing one catalyst vendor to offer/test more than one catalyst loading scheme, increasing the chance of getting bet- ter catalyst loading schemes. The data obtained from pilot plant testing can also be used for kinetic modelling to gain more insights into actual catalyst performance. Reference 1 Flowrence is a registered trademark for Avantium’s high-throughput catalyst testing systems. Contact: Tiago.Vilela@avantium.com

Selecting the best diesel hydrotreating catalyst is complex due to several factors: • Diesel hydrotreating net conversion is typically less than 5.0 wt% without dewax- ing, making it difficult to distinguish the best catalyst based on yield gaps alone. • Hydrogen consumption is considerably lower than that of hydrocracking, making the assessment more challenging because the differences between vendors can be minimal. • Predicting product properties with dif- ferent estimators makes direct compari- sons less useful, particularly in terms of volume swell. • Catalyst activity is estimated using kinetic models, but each vendor has their own models and assumptions, leading to comparison biases. Economic Importance of Catalyst Selection Catalyst loading strategies for light cycle oil (LCO) processing must consider factors like olefin saturation, metal loading/disper- sion, and pore structure to handle contam- inants and ensure reactor stability. Choosing the optimal catalyst can increase refining profits, extend unit cycle lengths, improve product quality, and reduce energy consumption. Some spe- cific economic benefits include: • Increasing refining profit by processing more refractory and less expensive feed components. • Maximising unit cycle length to avoid unplanned shutdowns. • Improving product quality and yield by lowering product sulphur, nitrogen, den- sity, and total aromatics, and increasing cetane number. • Reducing energy consumption by min- imising the energy required to initiate chemical reactions and maximising heat recovery. High-Throughput Catalyst Testing Avantium’s high-throughput parallel test- ing technology allows for efficient and accurate testing of multiple catalyst sys- tems, providing high-quality data with minimal waste. Single pellet single string reactors (SPSRs) help minimise axial dis- persion and ensure reproducible reac- tor loading. Avantium’s micro-pilot plant allows for highly efficient testing of cata- lysts for fixed-bed processes, producing the highest data quality with low amounts of feed. Realistic scaling down of diesel hydro- treaters for lab testing involves adjusting parameters like hydrogen partial pressure and hydrogen-to-oil ratio and including demetallisation catalysts when neces- sary. The first step in designing an effec- tive catalyst testing programme involves a comprehensive review of the commercial operation. Independent testing is essential to accu- rately determine catalyst performance,

+26.0˚C

+25.0˚C

Prediction Actual

+24.0˚C

+22.5˚C

+19.5˚C

+17.0˚C

+14.0˚C

+12.0˚C

+9.0˚C

+8.0˚C

+7.0˚C

+2.0˚C

Catalyst scheme

Figure 1 WABT requirements for 8 ppm product sulphur

The project was executed in accord- ance with protocols from catalyst vendors, ensuring good mass balance and data con- sistency. For quality assurance, Avantium used duplicate reactors for the catalyst systems to ensure good repeatability. The key highlight here is to find the cat- alyst system that can process the feed blend of 25% LCO over the 60-month cat- alyst cycle length and, at the same time, stay within the hydrogen consumption limit (dictated by the size of the make-up hydro- gen compressor). This amount of LCO is relatively high compared to standard die- sel hydrotreating units. Since the refinery had never processed this high percentage of LCO before, this study can also be considered proof of con- cept for whether the economic drive from the linear programming (LP) planning tool can be implemented in the real world. The predicted weight-averaged bed temperatures (WABTs) were based on dif- ferent kinetic models and assumptions. While some catalyst vendors offered attractive catalyst activity on paper, with others being more conservative (such as higher WABT), the reality turned out to be quite different, as demonstrated in Figure 1 . DID you know? Avantium’s high- throughput parallel testing technology allows for efficient and accurate testing of multiple catalyst systems, providing high-quality data with minimal waste

+17.0˚C

Prediction Actual

+8.0˚C

+7.0˚C

+3.5˚C

+2.0˚C +2.0˚C

Catalyst scheme

Figure 2 WABT requirements for 10 ppm product sulphur

avoiding reliance on vendor predictions and ensuring reliable data for economic evaluations. This article summarises two recent case studies illustrating how our independent catalyst testing was utilised to identify the most effective diesel hydrotreating catalyst. Case Study 1: Benchmarking nine catalyst systems Testing often reveals discrepancies between predicted and actual catalyst performance, emphasising the need for independent testing to uncover true cata- lyst efficiency. In the first case study, catalyst vendors offered various combinations of base met- als and stacking strategies. Some ven- dors proposed 100% nickel-molybdenum (NiMo) for the maximum hydrodesulphuri- sation (HDS)/ hydrodearomatisation (HDA) activity, while others used combinations of cobalt-molybdenum (CoMo)/NiMo to balance the hydrogen consumption and provide more HDS stability over the oper- ating cycle. In total, nine catalyst loading schemes (including the incumbent loading scheme) were compared. In a conventional catalyst test system, it will take much longer to finalise the results as only a few catalyst systems can be tested at the same time. With 16 par- allel reactors in Avantium’s proprietary Flowrence¹ system, the whole study was conducted in less than two months with comparable results to the commercial- scale unit.

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 2025

Achieving high efficiency in heat transfer equipment with HTRI digital twin technologies

Simon Pugh, Hans Zettler, James Kennedy and Edward Ishiyama Heat Transfer Research, Inc.

Attendees at the COP29 conference in Baku, Azerbaijan, reiterated critical pledges to accelerate climate actions across various industrial sectors. Among these, improving energy efficiency in the process industry emerged as a pivotal area of focus. While heat transfer efficiency is just one contributor to overall sustaina- bility goals, its role cannot be overlooked. Achieving high efficiency in heat transfer equipment is integral to reducing energy consumption and emissions, aligning directly with the ambitious climate action targets. In this context, the adoption of digital twin technologies has evolved from a luxury to an operational necessity. Role of Digital Twins in Heat Transfer Efficiency A digital twin should be a highly accurate virtual representation of a physical sys- tem that is directly connected to real-time monitoring data. By creating a near-real- time replica of a heat transfer system, digi- tal twins enable detailed forensic analysis, providing critical insights into system per- formance. They answer pressing opera- tional questions, such as the following: • How well or poorly is the equipment performing? • When might it move outside safe opera- tional ranges? • How can operations be optimised to main- tain safety, reduce emissions, and maxim- ise profitability? Through these capabilities, high-fidelity digital twins empower operators to proac- tively manage equipment, ensuring peak performance and reliability. HTRI: Innovating Heat Transfer Research and Solutions Heat Transfer Research, Inc. (HTRI) is at the forefront of developing solutions to advance predictive and preventive maintenance. At our advanced research facility in Navasota, Texas, we conduct real-world applied research using pilot-scale units designed in collaboration with industry members. These units replicate the conditions of operat- ing refineries and process plants, providing unparalleled insights into the performance of heat transfer equipment. Complementing our physical experiments, we leverage advanced computational tools such as computational fluid dynamics (CFD) and laser anemometry for detailed visuali- sation and analysis. Our experimental data represent the largest repository of heat transfer expertise globally, supporting rig- orous evaluations of thermal and hydraulic performance, vibration analysis, flow mald- istribution, two-phase flow regimes, and their impact on overall performance.

Database including more than 60 years of HTRI knowledge and research

Micro level

Meso level

Macro level

Vibration Corrosion Fouling

0 0.006 0.004 0.002 0.008

Integration of physical models and AI-based digital twin models

Two-way data transfer

Facilitating knowledge transfer and conducting digital experiments to

support informed decision-making

Data historian

Physical assets

Work groups

Figure 1 HTRI heat exchanger ecosystem

from HTRI software to data historians and automates performance analysis (see Figure 2 ). HTRI connect provides the following benefits: • Organising and tagging HTRI files with metadata for streamlined management. • Generating detailed performance reports using precision analytics. • Linking rigorous HTRI exchanger models to data historians for real-time monitoring. • Harnessing parallel processing for effi- cient computation of hundreds of digital twins. HTRI SmartPM™: Performance Monitoring, Predictive and Precision Maintenance HTRI’s SmartPM models are dynamic dig- ital twins that offer predictive capabili- ties. These models integrate advanced AI-driven analytics to deliver high-defi- nition insights into fouling behaviour and system performance. This advanced methodology enables plant operators to optimise maintenance sched- DID YOU KNOW? HTRI’s SmartPM models are dynamic digital twins that offer predictive capabilities delivering high-definition insights into fouling behaviour and system performance

Bind HTRI models to databases holding plant data

Run HTRI models, view any/all calculated data and publish results back to databases

Figure 2 Views from HTRI connect illustrating X changer Suite files for a specific plant and links to a data historian

• Macro level: Total network economics. HTRI’s flagship software, X changer Suite ® , supports the design, simulation, and rating of a wide variety of heat trans- fer equipment, including shell-and-tube exchangers, air coolers, economisers, and fired heaters. This suite is integrated with HTRI connect ™, which serves as a bridge

tools enable users to assess heat trans- fer performance across micro, meso, and macro scales (see Figure 1 ): • Micro level: Tube bundle vibration and skin temperature monitoring linked to cor- rosion and creep. • Meso level: Individual heat exchanger performance.

Integrating Research Insights into Digital Solutions

HTRI incorporates research results into proprietary software solutions. These

Protect your processes Protecting your catalysts in the switch to renewable feedstocks

Renewable feedstocks are the future, transforming plastic and food oil waste into fuel for aviation, innovation, and day-to-day living. However, it is a challenge for many refineries to incorporate them effectively because they contain a higher concentration of the detrimental elements that exist in traditional feedstocks, plus new ones, like silicon and chlorine. Even traces of these

elements risk poisoning your catalysts and grinding operations to a costly halt – but the right analysis methods can prevent this. Our Epsilon 1 Ultra-Low Sulfur instrument can detect even trace levels of catalyst- killing elements, helping you act fast to protect your catalyst materials – and your bottom line.

Read more here!

nartc 2025

entire networks, aiding in operational plan- ning and turnaround activities.

ules, extend equipment run times, and enhance operational efficiency. Figure 3 illustrates the predictive analytic capabili- ties of SmartPM, specifically how past and future performance metrics are tracked and used to inform decision-making. Proven Success of Digital Twin Modelling HTRI tools have been successfully applied across numerous real-world scenarios. Several case studies, available on https:// www.htri.net/software/smartpm/case- studies, highlight the tangible results: u Monitoring fouling and slagging in fired heaters: SmartPM identified critical links between furnace fuel types and oper- ational lifespan, enabling energy efficiency improvements. v Optimising cleaning and energy savings: Strategically implementing exchanger bypasses and optimising clean- ing schedules resulted in significant fuel savings and reduced CO₂ emissions. w Maximising productivity across refin- eries: Adopting SmartPM within digital

FC0004.PV

Furnace

Driving the Future of Heat Transfer Innovation As industries embrace digital transfor- mation, tools like HTRI’s X changer Suite , HTRI connect , and SmartPM provide a solid foundation for achieving climate goals while enhancing operational effi- ciency. These innovations not only sup- port COP29 pledges but also establish a framework for sustainable practices in the process industry. Leveraging digital twin technologies makes a company’s jour- ney toward reducing emissions and opti- mising energy usage both attainable and profitable. HTRI remains committed to leading this transformation through rigorous research, advanced software, and practical solutions for the process industry. Together, these efforts position us to make meaningful con- tributions to global climate action, one heat exchanger at a time.

TI0021.PV

TI0020.PV

EX4 A Resid-ashed crude

EX4B Resid-ashed crude

LGO

Resid.

TI0022.PV

EX3 (Heat exchanger) Filtered - average ( m onitoring/reconciliation data only +/– 2.5σ

0 0.006 0.004 0.002 0.008

Date

Fouling resistance (overall) - Reconciliation Fouling resistance (overall) - Tracking

Fouling resistance (overall) - Simulation Fouling resistance (overall) - Cleaning

Figure 3 Snapshot of performance monitoring and predictive maintenance capabilities of SmartPM

transformation programs allowed opera- tors to maximise energy recovery and vali- date in-house research.

x Forensic analysis of heat exchanger networks: SmartPM facilitated detailed analysis of individual exchangers and

Contact: simon.pugh@htri.net

Practical case study: Enhancing diesel hydrotreater capacity and reducing CO 2 emissions

SINDY STONE and THIERRY TISON Heurtey Petrochem solutions JAN RENETEAU NECTIS

Introduction In the pursuit of emission reductions and sustainable growth, the Axens Group, through its business lines Heurtey Petrochem Solutions and Nectis (a joint venture between ZPJE and Axens), offers a flow scheme with advanced technology equipment. For process unit heat integra- tion, traditional shell-and-tube exchang- ers are replaced by high-efficiency spiral tube heat exchangers (STHE) distributed by Nectis. This reduces heat consumption in fired heaters and decreases energy use in compressors and pumps thanks to its low-pressure drop. Additionally, in facilities with access to an electrical source, replac- ing process fired heaters with electric tubu- lar radiant heaters from Heurtey Petrochem Solutions enables zero carbon emissions at unit level. The diesel hydrotreater (DHT) revamp project is an excellent example of how this advanced technology scheme can be applied to achieve both operational and environmental improvements. The goal of the project was to increase the DHT unit’s capacity from 30,000 to 40,000 BPSD while reducing CO₂ emissions. The project faced several constraints, including a fired heater operating at maximum capacity, a hot approach temperature (HAT) of 81ºF (45ºC) in the heat exchangers, and limited space for new equipment. Despite these challenges, two solutions were identified and evaluated. Project Objective and Constraints The key objectives were increasing capac- ity and reducing CO₂ emissions. The main constraints included:

• Fired heater operating at maximum capacity: Limited thermal energy available for increased processing. • HAT of 81ºF (45ºC): Poor heat transfer efficiency. • Limited plot plan: Restricted space for new equipment. Given these constraints, two identified solutions were evaluated and are outlined below as Option 1 and Option 2. Option 1: Stripper reboiler and heat exchanger modification Option 1 proposed replacing seven tradi- tional shell-and-tube heat exchangers with three STHEs. These exchangers could recover all available heat, enabling the unit to operate without the fired heater dur- ing normal operations. The fired heater would only be needed for start-up and tran- sient operation, reducing CO₂ emissions DID YOU KNOW? replacing fired heaters with electric tubular radiant heaters from Heurtey Petrochem Solutions enables zero carbon emissions at unit level

Water Injection

Reactor 1

Hex A/B

Hex C/D

Hex E/F

Reactor 2

Feed

Heater

1 Fired Heater

Air cooler Water injection

Stripper

Makeup

7 Horizontal Shell & Tube Heat Exchangers

HP separator

Diesel

BP separator

Hex Reboiler

Existing flow scheme

STHE-1

STHE-3

Reactor 2

Feed

Heater

Reactor 1

1 Fired Heater

STHE-2

Stripper

Water injection Air cooler

3 Spiral Tube Heat Exchangers

Makeup H

Stripping steam

HP separator

BP separator

Diesel

Advanced technology equipment flow scheme: Option 1

17 - 20 NOVEMBER 2025 CANNES, FRANCE

Empowering the Downstream Industry with Technological Solutions for a Resilient and Sustainable Future

Expert Speakers 100

of Networking 3 DAYS

Attendees 900+

Ref iners 350+

Connect with Leading Refiners

Apply to speak at ERTC 2025! Submit your papers

nartc 2025

and achieving a net-zero emissions solu- tion during normal operation. The proposal for Option 1 also included the following modifications: • Simplified system: Fewer exchangers reduced complexity. • Reduced flanges and piping: Led to cost savings and easier installation. • Increased complexity: Additional equipment in the low-pressure section of the unit made the implementation more difficult. • Reactor #1 inlet control: A bypass of the heat exchangers was proposed for tem- perature control during normal operation. Additionally, a bypass of the fired heater would optimise the reaction section loop overall differential pressure in normal operations, allowing a lower recycle gas compressor utility consumption. Although Option 1 offered numerous advantages, it was ultimately not selected due to its impact on the stripper reboiler caused by the introduction of stripping steam, which would result in: • Higher capital and operational costs: The addition of a vacuum dryer system and utilities would significantly increase both capital and operational expenditures. • Increased complexity: The inclusion of additional equipment in the low-pressure section of the unit would make implemen- tation more challenging. Option 2: Optimised heat exchanger and heater solution Option 2 was chosen for its simpler design and greater cost-effectiveness: • Heat exchanger replacement: Six con- ventional heat exchangers were replaced by two STHEs, reducing the HAT from

• Simplified design: Fewer exchangers and piping led to reduced costs and easier implementation and maintenance. • Operational similarity: The design main- tained process continuity, allowing for seam- less integration into the existing operation. Cost Considerations In both options, the heat exchangers’ costs were similar, but Option 2 offered lower overall costs due to its simpler design. By eliminating the vacuum dryer and related equipment, Option 2 avoided significant capital expenditure. The electrical radi- ant heater further reduced fuel consump- tion and CO₂ emissions, making it the more cost-effective solution. Conclusion Axens Group’s offering for the DHT revamp project positions it to successfully increase capacity to 40,000 BPSD while target- ing CO₂ emissions reduction. Although Option 1 offers net zero emissions, its complexity and high costs make it less via- ble. Option 2 involves replacing traditional heat exchangers with STHEs distributed by Nectis and transitioning the heating source from a fired heater to a unique elec- tric tubular radiant heater designed by Heurtey Petrochem Solutions. This option provides an efficient, cost-effective solu- tion that aligns with both operational and environmental goals. This practical case study demonstrates the value of integrat- ing advanced technology with careful cost considerations to enhance refinery perfor- mance and sustainability.

Water injection

STHE-2

STHE-1

Reactor 2

Feed

1 Electric Tubular Radiant Heater

Reactor 1

2 Spiral Tube Heat Exchangers

Stripper

Air cooler

Makeup

Diesel

HP separator

Hex reboiler

BP separator

Advanced Technology equipment flow scheme: Option 2

Existing ow scheme

2 18 ˚F (10˚C) 16.3 MMBTU/h (e-heater) (4.8 MW) Advanced technology equipment ow scheme – Option 2

6 81 ˚F (45˚C) 51.6 MMBTU/h (15.1 MW)

No of exchangers: Hot approach Heaters duty Electricity cost : (1)

-2.4 MM USD/year 3.1 MM USD/year 1.8 MM USD/year 2.5 MM USD/year

– – – –

(2) Fuel savings :

Emission savings : (3)

Total savings

(1) Considering an electricity cost of 17.7 USD/MMBTU (2) Considering a fuel cost of USD/MMBTU (3) Considering CO emission cost of 70 USD/ton

CO savings ≈ 25,000 tons/year Zero emissions at Process Unit

Petrochem Solutions. This is presently the only proven electrical technology available on the market for hydrocarbon processing, enabling the achievement of net zero emis- sions at the unit level.

81ºF (45ºC) to 18ºF (10ºC) and reducing heater duty by 68%. • Fired heater replacement: The fired heater was replaced with an electrical tubular radiant heater, supplied by Heurtey

Contacts: Sindy.STONE@heurtey.net Jan.RENETEAU@nectis.net

Crystaphase optimisation helped refiner achieve up to double runtime and throughput

Austin Schneider Crystaphase

tor’s foulant profile, the Crystaphase team could turn to their data modelling capabil- ities for a projection of the pressure drop over the next year. The customer received some good news: the system would likely continue to perform without dP limitations over an extended cycle. The projection from Crystaphase was accurate, and when Cycle 1 completed, the hydrocracker’s runtime and through- put doubled with the Crystaphase optimi- sation. Since the completion of Cycle 1, other successful cycles have followed, with Crystaphase optimisations assisting. The most recently completed run was a full cycle without a pressure drop increase, shutting down at approximately 80% of the Cycle 1 runtime. The current cycle is on track to repeat the performance of Cycle 1, once again doubling the cumulative throughput. Conclusion With the guidance and technology of Crystaphase, operation has become much more stable over the long term, and pres- sure is no longer an imminent threat to the refinery’s cycle goals.

mid-cycle skim of the hydrocracker pre- treat reactor, Crystaphase installed an ActiPhase ® TRANS solution designed with enough capacity to reach the next sched- uled changeout, about one year later, with- out dP limitations. With the system installed, the cus- tomer met that goal. When the reactor was shut down for a scheduled full cata- lyst changeout, the customer installed an optimised ActiPhase system designed, together with Crystaphase, to extend the cycle length even further. Over the duration of that cycle, the reactor suffered several unrelated setbacks, including equipment failures. Despite all of these events, the pressure drop remained virtually flat after each restart. Through the mid-point of the hydroc- racker’s first complete cycle (Cycle 1) with the Crystaphase solution, the pressure drop appeared to remain effectively flat. Given the impressive results, the customer approached Crystaphase to see if the sys- tem could continue past its next sched- uled shutdown. Due to their work with the customer and understanding of the reac-

Not long after a summer turnaround, a major Gulf Coast refinery had a problem. The engineering team noticed a pressure drop (dP) increase in bed 1 of their hydro- cracker pretreat reactor shortly after start- up, all but guaranteeing they would not meet their cycle length goal without per- forming a mid-cycle skim. The site’s chal- lenges did not end there. A year later, they experienced an unexpected two-hour equipment shutdown. Upon restart, the team observed a dP increase in bed 2 while the state of bed 1 continued to worsen. The engineers had little time to dream about extending the cycle length; they needed just to keep the reactor online and running at the required rates. As in most refineries, the hydrocracker needed to deliver consistently high throughput for stable operations and to meet demand. The refinery’s engineers knew that the increased pressure drop could limit the hydrocracker’s performance. With their standard configuration, which utilised tra- ditional grading, the runtimes were short. Downtime from mid-cycle skims reportedly ranged from 20 to 60 days. At high-com-

plexity facilities, disruptions like these can seriously impact availability, profitability, and risk associated with turnaround and maintenance operations. Having worked with Crystaphase to solve tough challenges at other locations, the engineers turned to the company‘s filtra- tion technologies to deliver results with a novel, empirically based solution to a com- mon reactor problem: pressure drop due to crust layer formation. Working with the site’s process engi- neer, Crystaphase collected samples from two previous cycles to analyse and better understand the reactor’s foulant profile. After lab analysis of these samples, the Crystaphase team identified the foulants that appeared most likely to be contribut- ing to pressure drop. tailored solution From this detailed analysis, Crysta- phase’s process and development engi- neer, Umakant Joshi, and director of tech- nology, Austin Schneider, developed a tailored solution that could optimise the reactor’s configuration. Following the next

Page 1 Page 2 Page 3 Page 4 Page 5 Page 6 Page 7 Page 8 Page 9 Page 10 Page 11 Page 12 Page 13 Page 14 Page 15 Page 16 Page 17 Page 18 Page 19 Page 20 Page 21 Page 22 Page 23 Page 24