refining india 2023
the entire fleet, enabling the identification of critical compressors. Its Zoom-In Mode investigates deeper, analysing DCS trends for detailed insights. By harmonising both modes, Hoerbiger crafts strategies that optimise performance and reduce opera- tional expenditures. A Roadmap to Sustainability As the refining industry navigates a rapidly evolving landscape, the need for sustaina- ble practices grows paramount. Hoerbiger’s approach offers a comprehensive roadmap towards a more environmentally responsi- ble future (see Figure 4 ). By optimising the compressor’s maintenance and operating strategies, the company empowers plants to balance operational efficiency with reduced carbon footprints. The advance- ment of cutting-edge technologies helps prevent vented and fugitive emissions, and diminish energy-related emissions, estab- lishing novel industry benchmarks. Conclusion Hoerbiger’s participation in Refining India 2023 conference marks a significant
milestone in the journey toward sustain- able practices in the oil industry. The REE concept, combined with innovative digital tools, forms the bedrock of the company’s mission. As the industry grapples with the challenges of the present, Hoerbiger sets new standards in sustainability, offering pragmatic solutions that drive both profit- ability and environmental responsibility. technologies helps prevent vented and fugitive emissions, and diminish energy-related emissions The advancement of cutting-edge
Figure 4 Emission reduction strategies
Empowering Sustainable Decisions The intersection of technology and sustain- ability forms the core of Hoerbiger’s con- tributions. Through data-driven insights, the company empowers operators to make informed decisions that align with decar- bonisation goals. By balancing conflict- ing priorities, Hoerbiger bridges the gap
between operational needs and environ- mental responsibility.
Optimising with the Fleet Performance Platform Hoerbiger’s proprietary Fleet Performance Platform is the cornerstone of its strategy. This platform provides a bird’s eye view of
Contact: nikolaus.lubega@hoerbiger.com
Hybrid loading of regenerated and fresh catalyst for a lower carbon footprint
Siddharth Sagar eurecat
Catalysts are typically one of the larg- est controllable costs for a refiner. Reusing properly regenerated catalysts avoids unnecessary spending and com- plements environmental sustainability. A pool of reusable catalysts is a valuable resource for refiners to manage their fill costs and precious foreign exchange. The reuse of catalyst does not only reduce the cost, but also reduces the CO₂ footprint significantly. Hybrid loading is a practice followed by many refiners in which the reactor is loaded with fresh catalyst (at the bot- tom) and regenerated/rejuvenated cata- lyst (at the top). Hybrid loading renders almost similar performance with signifi- cant cost savings and very negligible/no performance. Sulphur Reactivity The idea of hybrid loading is to combine regenerated catalyst at the top of the reac- tor and fresh catalyst at the bottom. In the top bed, no complex reactions occur, so catalyst activity does not hamper the per- formance of the unit. The highly reactive sulphur species with high reaction rates of removal at the top of the reactor are not limited by catalyst activity. Therefore, regenerated catalysts are good enough to provide the needed activity at the top of the reactor. Higher activity is required as the feed progresses through the unit, so fresh catalyst is loaded in the bottom beds (see Figure 1 ).
Reactive sulphur Low activity required
Unreactive sulphur High activity required
R
R SH
R
S
R’
S
R
R
R
R’
R
R’
R
R’
R
S
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CH
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Figure 1 Sulphur reactivity
overall activity is that one does not need a 100% new-generation active catalyst in the entire reactor system. As mentioned earlier, in the top bed of the reactor, a sim- ple reaction occurs. So, a little lower active catalyst is good enough to act there. In the bottom part of the reactor, a difficult reac- tion occurs, so one needs a highly active catalyst there. So, Case 2 does not have any impact on cycle length and unit perfor- mance but results in cost saving and CO₂ footprint saving. economical and sustainable Hybrid loading is well-proven practice through years of experience by many refin- ers, which cost-effectively maximises the performance of the unit. Hybrid loading is also supported/guaranteed by catalyst manufacturers. Hybrid catalyst loading is an economical and sustainable approach to drive profitability and promoting circu- lar economy.
Case 1
Case 2
Calculated RVA Measured RVA Relative fill cost
120 120
110 120
60% FRESH CAT 40% REJUV CAT
100% 100%
<85% 100%
Relative cycle length
100% FRESH CAT
Relative CO₂ footprint 100%
76%
Prior gen catalyst = 100 RVA Latest gen catalyst = 120 RVA Prior gen rejuvenated catalyst = 95 RVA Case 1 is for 100% fresh catalyst is loading having no usage of regenerated. Case 2 is hybrid loading of 40% rejuvenated catalyst (at the top) and 60% fresh catalyst (at the bottom).
Case 1
Case 2
Figure 2 Hybrid catalyst loading
Hybrid Loading Figure 2 will help in understanding the benefits of hybrid loading. In hybrid load- ing (Case 2), one is likely to save total cost by >15% and able to reduce CO₂ by 24% reduction in carbon footprint. When calcu-
lated mathematically for Case 2, it might appear that there is a loss of activity (10 units). However, when actual RVA is actu- ally measured in a simulation plant, it is observed that RVA remains the same for both cases. The reason for this unchanged
Contact: ssagar@eurecat.in
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