-
Improving the distillation energy network
Oct-2013
Energy-efficient design applied to the refit of a distillation unit was achieved through optimisation between the distillation column and heat network ...
-
Choosing a neutralising amine corrosion inhibitor
Jul-2004
A review of physical and chemical properties of commonly used amine-based corrosion inhibitors. The authors highlight the relative strengths and weaknesses ...
-
Crude overhead system design considerations
Jul-2007
Proper crude unit overhead system design is important when building a new unit or revamping an existing one to process different crudes
-
Flue gas heat recovery through the acid dew point
Jul-2019
Polymer based heat exchange technology enables more heat recovery from flue gas by addressing acid corrosion issues.
-
Operating vacuum distillation ejector systems
Oct-2016
Best practices and opportunities to deliver reliable ejector system performance and reduce performance risk.
-
Oct-2005
Fundamental design considerations influencing diesel and vacuum gas oil (VGO) recovery when revamping existing or designing grassroots crude units. By ...
-
Preventing ammonium salt fouling and corrosion
Jan-2018
Best practices and opportunities to reduce the risk of salt deposition and damage
-
Why vacuum unit fired heaters coke
Oct-2004
A description of the internal workings of vacuum heaters and the causes of coke formation within them
-
Maximisation of VGO through deep-cut distillation for refinery margins
Jan-2011
Appropriate choice of crude and/or crude oil blends as feedstock and a vacuum tower revamp enable higher production of vacuum gas oil
-
An atmospheric crude tower revamp
Jul-2005
Overall gas oil yield was maintained with heavier crudes due to a crude tower revamp. The revamp allowed for a crude heater outlet temperature reducti ...
-
Entrainment issues in vacuum column flash zones
Jan-2010
For a vacuum tower to operate effectively, the flash zone and the wash section must work together to provide the best possible feed quality to the sections ...
-
Oct-2004
Installation of vortex tube clusters in crude unit preflash drums has eliminated foam carry-over, increasing diesel and atmospheric gasoil product yie ...
-
Reducing vacuum tower pressure
Apr-2015
To create a better vacuum the vapour load to the ejector has to be reduced
-
Designing the CDU/VDU for opportunity crudes
Oct-2012
New units for processing heavy crudes should not be designed using conventional practices or run length will be short, and product yields and quality ...
-
Jan-2006
Cost-effective exchanger network solutions need to rely on more than just pinch technology if they are to be successful
-
Identifying poor heat exchanger performance
Sep-2007
Identifying root causes of poor crude unit debutaniser reboiler performance and low-cost solutions that help meet exchanger original design conditions
-
Nov-2017
Thorough tank cleaning means removing all of the sludge and restoring the vessel’s full storage capacity.
-
Sep-2003
Case studies show how accurate field-measured differential pressure can be interpreted incorrectly when troubleshooting refinery vacuum columns
-
Simulating crude units with preflash
Nov-2016
Process simulation offers a cost effective way of testing ideas to improve yield and energy performance.
-
Future of opportunity crudes processing
Oct-2011
Five critical drivers help refiners remain profitable and sustain long-term business goals while processing relatively inexpensive, low-quality crudes
-
Evaluating opportunity crude processing
Oct-2006
Is processing opportunity crudes for every refiner? Technical challenges and economic benefits from processing high-acid crudes and bottom-of-the-barrel ...
-
Improved conceptual process design avoids revamp scope growth
Mar-2002
For grassroots design, defining project scope is a straightforward exercise. Grassroots projects can follow optimum execution procedures for engineering ...
-
Oct-2012
Inaccurate feed characterisation and process modelling errors are major contributors to poor performance in a vacuum unit as refiners switch to heavier ...
-
Consider retrofits to handle high-viscosity crudes
Mar-2004
In 2000, ConocoPhillips’ refinery in Sweeny, Texas, began processing 16° API gravity blends of extra-heavy crude oils, including Merey 16 and BCF 1 ...
-
Revamping crude towers for quality and yield
Nov-2016
A successful revamp of distillation towers for increased diesel quality and yield depended on reliable design and accurate assembly
-
Revamping atmospheric crude heaters
Sep-2007
Revamp of an atmospheric crude unit heater suffering from coking caused by asphaltene precipitation resulted in an increased heater run length
-
Sep-2006
Operational issues such as higher heater duty and column pressure must be weighed against avoiding residue entrainment in HVGO
-
Bitumen processing: crude unit revamps
Jul-2011
The ability to process bitumen offers a competitive advantage, but revamps of crude and vacuum units to process bitumen require significant changes
to ...
-
Myth of high cutpoint in dry 
vacuum units
Apr-2014
Accurate measures of true boiling point cutpoints are essential to correctly evaluate vacuum unit performance
-
Revamp process design — optimum crude unit product yields
Jul-1997
Designing a new crude unit is an unconstrained process, limited only by capital
investment targets, while revamping an existing unit to optimise ... -
Stabilisation 
of asphaltenes
Jan-2009
Asphaltenes can plug refinery equipment and can decrease or stop production. Stabilisation of asphaltene particles is an efficient and cost-effective way ...
-
Dividing wall technology in distillation columns
Feb-2020
Increased throughput required the revamp of a gasoline unit. Space constraints and strict product requirements led to dividing wall column technology as ...
-
Crude unit start-ups: the results of a 
high liquid level
Sep-2003
Pressure-measurement techniques can avoid the dangers of rapidly changing flow rates and levels during start-up
-
Strategies for improved naphtha processing
Oct-2013
To take advantage of dilbit from Alberta and light oils from shale formations, refiners must develop a strategy for processing additional naphthas and ...
-
Troubleshooting crude column constraints
Jul-2017
Multiple limitations to operating capacity were identified and resolved during a column turnaround
-
Optimising preflash for light tight oil processing
Jul-2015
For a crude unit handling light tight oil feedstock, a semi-preflash column can deliver significant advantages in energy saving, capacity gain and revamp ...
-
Designing a crude unit heat 
exchanger network
Oct-2012
Preheat train design for heavy Canadian crudes can be very challenging, requiring an approach not normally required with other crudes
-
Enhancing energy efficiency in the CDU
Apr-2015
Revisiting your crude distillation unit may expose hidden potential for major energy savings
-
A balanced approach to vacuum tower flash zone/wash section design
Sep-2010
Revamping an existing vacuum column to operate at a higher feed rate, higher flash zone temperature, lower pressure, and different feed stock characterisation ...
-
Vacuum pressure control: impact on profitability
Jul-2001
Optimisation of flash zone pressure and temperature can improve feedstock quality to downstream units
-
Oct-2005
Process modelling and equipment know-how are needed to design deep-cut vacuum units that operate reliably at high temperature and low pressure
-
Jan-2013
Revamping a VDU’s vacuum system delivered operational improvements in a refinery, but also led to safer and more efficient handling of non-condensed ...
-
Troubleshooting vacuum systems
Oct-2016
Case histories of refinery vacuum tower problems solved are gleaned from five decades of experience.
-
Canadian crude processing challenges
Jan-2008
Vacuum unit design influences liquid volume yields, run length, product 
yield and product quality when processing bitumen crude oils
-
Online cleaning of an integrated distillation unit
Oct-2013
Online cleaning technology was validated during a scheduled turnaround at the second largest refinery in Poland.
-
Heat integration projects for 
refining processes
Oct-2013
Heat integration projects can deliver substantial savings, but they require detailed simulation and case-specific heat integration analysis
-
Flow metering vacuum tower bottoms
Oct-2011
A clamp-on ultrasonic flow meter can make flow measurement at the bottom of vacuum distillation towers more reliable
-
Towards a zero gasoline production refinery: part 2
Oct-2013
Refinery configurations can suit various processing objectives, such as variations to the propylene-to-ethylene ratio and production of middle distillates ...
-
CFD study of a VDU feed inlet device and wash bed
Oct-2009
Analysis of vapour velocity profiles at the entry to the wash zone of a VDU column enables a higher feed rate and improved output quality
-
Energy-efficient vacuum systems
Apr-2013
Case analysis of the techniques available to reduce energy consumption in vacuum systems reveals the potential for cost savings
-
High octane isomerates from light naphtha
Feb-2020
Dividing wall column distillation is an energy efficient, cost effective alternative to conventional distillation for delivering high octane products from ...
-
Crude column relief mitigation
Oct-2011
Mitigation of plant-wide relief loads can greatly improve the safety of the plant, reduce flaring and be used as the basis for building smaller relief ...
-
High performance trays for a fractionator in an aromatics plant
May-2015
Distillation is a very important separation technology in refineries and downstream chemical processing. Mass transfer internals in distillation columns ...
-
Mar-2018
Scalable simulation of crude unit operations enables refineries to build increasingly rigorous models to enhance performance
-
Jan-2011
A process review, including the improvement of atmospheric and vacuum distillation columns, for the reformulation of the diesel pool
-
Revamping conceptual process design
Jan-2002
With the desirability of getting the maximum use out of existing equipment when revamps are planned a rigorous approach to CPD is required to avoid scope ...
-
Sep-2007
Primary goals of a lube vacuum column revamp were to increase lube product fractionation and minimise HVGO product contaminants
-
Revamping crude and vacuum units to process bitumen
Apr-2015
Revamping crude and vacuum units to process dilbit can involve extensive equipment replacement as well as major changes to the crude preheating scheme
-
Increasing vacuum tower performance
Oct-2004
Advantages of using gravity flow liquid distributors in services where, historically, spray nozzles have been used, specifically in refinery vacuum tower ...
-
Oil/water interface control for desalters
Oct-2007
Profiling instrument provides vertical real-time phase density measurement in desalter vessels. Benefits include reduced process upsets from interface ...
-
Unlocking current 
refinery constraints
Apr-2008
When processing heavy feeds, technology based on residuum supercritical solvent extraction provides higher volumes of gas oil and DAO for conversion units. ...
-
Silencing hammering in a condenser system
Dec-2017
Detailed analysis leading to correct diagnosis meant that only minor equipment changes were needed to cure severe hammering in a naphtha splitter.
-
Revamping a crude distillation unit
Feb-2020
A revamp project aimed to increase process safety and reduce high energy consumption in a CDU. It also delivered better product separation and higher diesel ...
-
Dealing with desalter cleaning challenges
Aug-2016
How to overcome lengthy and potentially dangerous challenges when cleaning a crude unit desalter.
-
Light tight oil crude unit fouling root causes and troubleshooting
Mar-2015
Fouling in preheaters, crude furnace and atmospheric tower bottoms exchangers directly impacts throughput and profitability, requiring rigorous evaluation ...
-
Improving crude unit operation
Jan-2011
Most crude and vacuum units present an opportunity for improvement using modern process control systems
-
High-capacity tray for debottlenecking a crude distillation unit
Jan-2013
Use of ultra-high-capacity trays in the most constrained section of a CDU enabled over a 50% increase in throughput at less cost than other debottlenecking ...
-
Correcting vacuum column design flaws
Apr-2017
Conventional design practices have been proven inadequate when maximising diesel recovery and gas oil cut point
-
Problems in processing discounted crudes Part 1: definition and crude preheat
Feb-2019
Project costs must be considered to fully understand whether or not an opportunity crude really does deliver on savings.
-
Realities of heat flux in fired heaters
Nov-2020
Uneven radiant heat flux distribution is a major cause of poor reliability in refinery fired heaters.
-
Best practice desalting Part 1: crude flexibility window
Jul-2017
A replacement programme of desalter treatment chemistry transformed the operation of crude units struggling to meet performance targets
-
A two stage approach to controlling fouling on preheat trains at OMV’s Schwechat refinery
Aug-2016
Fouling in heat exchanger preheat trains is a well-known problem in the refining industry. Fouling reduces exchanger performance, increases furnace duty, ...
-
Online cleaning: a mindshift for improving operational excellence
Apr-2013
A patented method of chemical cleaning can reduce downtime arising from severe fouling in process units
-
Flexible upgrading of heavy feedstocks
Feb-2019
Adding tailor-made options for upgrading heavy crudes to existing assets can adapt refineries to changes in market conditions and regulatory demands.
-
Balanced distillation equipment design
Feb-2017
Fouling resistance and efficiency requirements for distillation equipment are balanced and optimised for reliable unit performance.
-
Apr-2006
When designing vacuum units for processing heavy Canadian crudes, reliability costs can be high if the feedstock’s thermal instability is not fully ...
-
Refinery CO2 challenges: part III
Jul-2006
For the prediction of CO2 emissions from a refinery, simple correlations are not always sufficient. A rigorous simulation tool that includes fractionation ...
-
Wastewater treatment for challenging crudes
Jan-2018
A new organic polymer treatment has enabled refiners to more effectively process a variety of opportunity crudes
-
Our desalting rate drops away quickly when we use heavier feeds. What is the problem here?
Feb-2021
Responses to a question in the Q1 2021 issues Q&A Feature
-
Problems in processing discounted crudes Part 2: crude and vacuum columns
May-2019
Project costs must be considered to fully understand whether or not an opportunity crude really does deliver on savings.
-
ULSD production: improved feed stream quality
Apr-2003
Much of hydrotreater revamp investment costs in future will be in dealing with the most difficult-to-remove sulphur species, because of their low reaction ...
-
Cost-effective and reliable revamps
Jul-2009
Test run hydraulic measurements and analysis, together with equipment know-how, can help refiners identify profitable, low-cost revamp opportunities
-
Improving solids handling in a delayed coker
Jul-2011
A reliability model applied to a coke handling system demonstrates the benefits of compliance with a preventive maintenance programme
-
Jan-2007
Gamma scanning is a powerful tool that can be used to determine the cause of flooding and regain column efficiency. Debutaniser capacity and performance ...
-
How dynamic pressure can affect vacuum column readings
Jun-2016
Computational fluid dynamics confirmed field measurements to explain a vacuum unit’s poor quality HVGO and was used to redesign the tower internals
-
Model predictive control of a distillation unit
Jul-2017
In a coordinated plant process, particular attention must be paid to control of individual columns.
-
Troubleshooting vacuum unit revamps
Jul-1998
While vacuum unit revamps increase gasoil yield, management is pushing the intervals between turnarounds to four or five years
-
Enhancing fractionator efficiency
Jul-2016
Properly designed vapour and liquid distribution devices enable more effective distillation column efficiency.
-
Practical considerations for crude unit revamps
Oct-1998
Two examples are used in this article to illustrate how changes in the process flow scheme can increase preheat train heat recovery
-
Avoiding unscheduled shutdowns
Apr-2001
Case studies have demonstrated that correct heater design and consequent performance will determine crude unit run length
-
Maximising the use of process energy
Apr-2014
Integrating a flash drum in an atmospheric and crude distillation unit offers the potential for savings and capacity enhancement
-
Specifications — importance of getting them right
Mar-2003
Faulty equipment specifications sometimes carry unforeseen penalties, with loss of performance. It is the process design engineer’s responsibility to ...
-
Vacuum unit design effect on operating variables
Jul-2002
To revamp vacuum units, process modelling and equipment design know-how are needed, and the understanding of connected equipment performance can lead to ...
-
Asphalt quality prediction and control
Oct-2014
With knowledge of heavy vacuum gasoil cut-point and asphalt density, asphalt quality can be inferred
-
Crude column revamp using radial temperature profiles
Sep-2003
Designers need to be aware of all the factors influencing packed bed performance such as feed zone mixing problems
-
Vacuum unit design for high 
metals crudes
Jan-2007
Vacuum unit design can influence vacuum gas yield, product quality and run length. A wet vacuum unit with residue stripping achieves the highest cutpo ...
-
Integrated monitoring for optimising crude distillation
Jan-2012
On-line process analysers in crude distillation units prevent lost throughput caused by non-conforming process conditions and crude oil switching
-
Turnarounds deliver process improvements
Nov-2016
An extended unit shutdown is relatively rare and an opportunity to take every advantage to improve performance.
-
Controlling contaminants in vacuum gasoil
Nov-2017
How revamps can increase VDU capacity and reliability while controlling contaminant levels to acceptable limits.
-
Troubleshooting a heavy crude topper
Jul-2019
Thorough troubleshooting revealed the primary cause of a heavy crude topper’s poor availability: desalter operation. A comprehensive revamp resolved ...
-
Reducing FCC main fractionator operating risks
Mar-2021
Analysis of an FCC main fractionator upset and follow-up revamp showed that removal of the HCO wash section did not impact operations or product quali ...
-
Savings in exchanger network cleaning (TIA)
Jun-2015
The Super Clean System (SCS), an online heat exchanger cleaning technology, is being used by a major oil refiner in Japan at a refinery equipped with a ...
-
Crude unit revamp to increase diesel yield
Apr-2002
Account of a crude vacuum unit revamp where detailed calculation of the true performance of existing equipment raised diesel production by 14.5 vol% on ...
-
Online cleaning of 
process equipment
Oct-2008
In the interest of time and cost savings, online cleaning prior to shutdown can reduce the duration and complexity of refinery turnarounds, as demonstrated ...
-
Importance of testing for vacuum ejectors in refinery service
Jun-2022
Efforts should be made to identify and avoid errors in the specification, engineering, and manufacturing of vacuum system equipment before they manifest ...
-
Data analytics for hydrocarbon processing
Oct-2016
Advanced data handling techniques are transforming operations in the refining industry at an increasing pace.
-
Fouling and cleaning analysis of a heat exchanger network
Dec-2019
Analysis of a complex heat exchanger network employs a digital twin model to establish a programme for fouling and cleaning.
-
Loss into gain in high capacity trays - Part 1: excursion
Jun-2016
Systematic troubleshooting diagnosed and solved two complex and independent problems that limited the capacity of an atmospheric crude distillation to ...
-
Loss into gain in high-capacity trays Part 2: reverse vapour cross flow chanelling
Aug-2016
Systematic troubleshooting diagnosed two complex problems that limited the capacity of an atmospheric crude distillation tower
-
Revamping a bitumen heating system
Jul-2019
A redesigned oil based heating system for bitumen storage and sales saves energy and eliminates customer complaints.
-
Demystifying the zero entrainment myth for vacuum column flash zones
Apr-2009
One of the recurring questions about refinery vacuum tower operation is the issue of flash zone entrainment and the operation of the wash section.
-
Online real-time optimisation helps identify energy gaps
Oct-2010
Real-time supervision of a refinery’s energy system enables optimisation of its fuel consumption and emissions levels
-
Shale feedstocks fuel ethylene, LNG and petrochemical derivatives expansion
Apr-2014
In spite of the variability in shale composition causing operational challenges for refiners, monetisation opportunities are seen throughout the energy ...
-
The age of turbulence: charting a course for refiners to a profitable future
Nov-2012
Relentless turbulence has profoundly affected the global refining landscape in recent years. Moreover, the turmoil is likely to continue unabated in the ...
-
Increasing distillate production at least capital cost
Apr-2015
Investing in improvements to the atmospheric crude unit can deliver increased distillate yields with short payback times
-
Enhancing flexibility in two-stage hydrocrackers
Aug-2022
Shifting markets and refined product priorities compels refiners to find the flexibility for shifting from middle distillate to naphtha for petrochemical ...
-
Reducing the danger of maintenance exposure
Apr-1998
Maintenance cost overruns result from inadequate cost estimating and the emergence of unidentified work that has to be done
-
Identifying very small 
equipment leaks
Jan-2008
Very small leaks in feed/effluent exchangers can be identified using chemical tracing. This online technique can detect leaks as low as 5.0 ppm, avoiding ...
-
Improving level control in desalters to aid in use of opportunity crudes
Sep-2019
Refineries are a complex set of various operating units designed to process crude oil into refined products such as gasoline, diesel, jet fuels and feedstocks ...
-
De-mystifying vacuum ejector systems
Feb-2023
First-stage inter-condenser design and performance are critical for reliable vacuum system performance.
-
Tray revamp restores crude column performance
Jan-2019
Retrofitting the packed top section of a crude atmospheric tower with high capacity trays improved separation efficiency
-
Mitigating overhead corrosion and reducing downstream costs
Jan-2022
A combination of onstream measurements, closed-loop control, and corrosion measurement enabled significant reductions in caustic addition rates and FCC ...
-
Opening the crude flexibility window: automation manages threats in real time
Sep-2018
By increasing the volume of quality data, refiners can automate the correct addition of chemical additives to respond to variations in unit performanc ...
-
Sustainable technology for cleaning a crude preheat exchanger network
Aug-2019
Mitigating environmental impacts, saving time and reducing costs: cleaning a heat exchanger network using a renewable cleaning agent.
-
Desalting chemistry and monitoring methods to help expand crude basket
Feb-2023
Widening the crude basket increases the challenges of maintaining asset reliability and plant performance, including formation of rag layers.
-
Improving crude vacuum 
unit performance
Mar-2008
When simulating or designing an unconventional heavy oil/bitumen vacuum crude unit, the sharing of operating data on cracked gas make, stripping section ...
-
Apr-2019
With the market for high sulphur fuel oil under pressure, refiners with delayed cokers can instead opt for higher value power and steam generation.
-
Crude to chemicals: Part 1 - The basic concept of crudes
Nov-2023
Reactor platforms with novel heat integration designed around advanced separation techniques and catalyst systems achieve 75% yields from selected cru ...
-
Focused revamp increases diesel and HVGO recovery
Jul-2023
Refiners have the best opportunity to maximise return through identification of creative solutions during a focused capital revamp.
-
Maximising stripping section performance
Aug-2021
The design of a crude unit stripping section affects diesel and gasoil yields, energy usage, and unit reliability.
-
Considerations for crude unit preflash drums and preflash towers
Feb-2024
A guide to debottlenecking, revamping, designing, and operating crude unit preflash facilities based on literature and the authors’ experience.
-
Jun-2021
Upgraded crude scheduling enabled a refiner to increase its use of opportunity crudes for higher margin.
-
Online monitor slashes biocide dosage (TIA)
Nov-2018
In many systems, fouling and deposits are a serious problem which results in shutdowns, cleaning actions and unexpected costs for the customer.
-
Debottlenecking product recovery using product pair distillation: Part I
Apr-2023
Advantages of using a thermodynamically efficient method to debottleneck existing distillation trains using fewer new columns than traditional methods ...
-
Reconfiguration of naphtha splitters using divided wall column technology
Feb-2023
Integration of DWCs into existing refining configurations reduces energy consumption and GHG emissions in distillation systems while also lowering operating ...
-
Identifying the root cause of underperforming ejector systems
Nov-2022
Underperforming ejector systems illustrate the importance of the long air baffle, its proper operation, and how to quickly identify problems when they ...
-
Premature foam-flood in an amine absorber: Part 1
Nov-2021
Troubleshooting and hydraulic analysis identified vapour channelling in fixed valve trays as the root cause of premature foam-flooding in a high pressure ...
-
Amine anomaly in a mild hydrocracker
Jun-2021
Simulation and operational changes help to crack the riddle of frequent amine carry-over from a high pressure amine absorber.
-
Jan-2022
Improvements in performance and energy efficiency were achieved during the turnaround of a crude distillation unit.
-
Column revamp boosts diesel production
Nov-2020
Revamping the internals of a main fractionator column enabled a refinery to increase its diesel throughput.
-
Upgrading a vacuum distillation tower (TIA)
Aug-2021
When a major oil refinery in India was constrained by its vacuum tower, it turned to Sulzer Chemtech to find a solution that would not only solve existing ...
-
Unicracking unit flow scheme optimisation and integration
Nov-2023
How an optimisation and integration approach can assist in maximising refinery margin for a residue upgrading project.
-
Anti-fouling additives to improve heavy oil processing
Apr-2023
A continuous pilot testing evaluation shows how magnesium sulphonated-based nano-additive is highly effective in mitigating and reducing upgrader/refinery ...
-
Front end filtering of unconventional oil
Jan-2019
Processing unconventional oils requires technologies such as electrostatic separation to handle higher amounts of filterable solids.
-
Crude preheat train fouling and fix-up
Nov-2022
Rigorous modelling of crude preheat train exchangers allows for fouling progression of the heat exchangers to be monitored throughout the crude unit run ...
-
Processing lower cost crudes with greater confidence and improved reliability
Dec-2020
For more than 100 years, it has been understood in the petroleum refining industry that certain crude oils or, more accurately, crude oil fractions contain ...
-
High performance internals in severe service
Nov-2020
Application of a severe service grid achieved 10% higher throughput with improved reliability in a vacuum tower revamp.
-
Managing vacuum tower wash beds
Sep-2020
ThruVision™ scans monitor the rate of coking in vacuum tower wash beds to get the most out of bed productivity.
-
Worker safety when entering reactors with an inert atmosphere (TiA)
Feb-2024
The products from petrochemical processing touch almost every aspect of modern living. The importance of these products to industry and society emphasises ...
-
Apr-2022
A vacuum column’s economics can be greatly improved with a low cost modification to the ejector system
-
Feb-2024
Part 1 covered the basics of crude-to-chemicals. Part 2 explains how hydroprocessing technology can be used to convert any crude to chemicals to maximise ...
-
Crude oil processing scheme for reducing operating costs in the CDU
Feb-2023
Development of crude oil distillation processing schemes to significantly reduce external energy and stripping steam demand.
-
Premature foam-flood in an amine absorber: Part 2
Jan-2022
Troubleshooting and hydraulic analysis identified vapour channelling in fixed valve trays as the root cause of premature foam-flooding in a high pressure ...
-
ThruVision™ scans are the next step to investigate liquid maldistribution
Sep-2020
ThruVision™ technology allows for a complete understanding of liquid distribution, saving days of production losses and massive costs of a unit shut ...
-
Fouling in VDU ejector systems
Feb-2023
Review of critical ejector-condenser interplay, with an overview of fouling in VDU ejector systems, including a case study where fouling impacted a refiner's ...
-
Mitigating FCC gas plant impacts when increasing reactor LPG yields
Apr-2023
Increasing FCC reactor LPG yields at the expense of gasoline increases profitability, but equipment downstream of the converter requires modifications ...
-
Pre-turnaround scans enable better critical path planning
Sep-2020
Tru-Scan™ and Tru-Grid™ Scan results help determine whether to enter a particular column during the turnaround outage or remove it from the critical ...
-
Simulation VGO and waste lubricating/cooking oil co-hydroprocessing
Nov-2023
Software used to build a simulation case for industrial hydrocracking of VGO, WCO, and WLO validates predicted values of gasoline and middle distillates ...
-
Sulzer’s VIEC technology provides the solution with single-stage early separation
Nov-2022
The principle of “easiest first” applies as much in the oil industry as in most other enterprises. This in no more evident than in the state of the ...
-
Optimising fouled distillation units
Nov-2023
Case studies discuss optimisation strategies and enhanced distillation unit performance against fouled conditions.
-
Planning to counter economic turbulence
Sep-2020
Synchronising engineering and planning models should be a key aim to support the resilience and agility needed for economic recovery
-
Predictive model for maximum feedstock flexibility (ERTC 2023)
Nov-2023
Challenge of crude oil variability. Current market conditions are driving refineries towards a permanent diversification in crudes. Crude oil is a complex ...
-
Design configurations for lowering quenched coke drum venting pressure
Feb-2023
Compare the advantages when installing either an ejector or a water ring compressor for lowering coke drum venting pressure.
-
Upgrading a vacuum distillation tower (TIA)
Feb-2021
Reliable and efficient vacuum towers are key to ensuring optimal performance and yield.
-
Enhancing profitability using high-efficiency heat exchangers (RI 2023)
Nov-2023
Alfa Laval has been in the refinery industry for more than 40 years, with more than 3,000 high-efficiency heat exchangers installed worldwide. The company’s ...
-
Innovative vessel internals for enhanced safety when changing media beds (TiA)
May-2024
In our previous article (PTQ Q1 2024), we discussed the challenges inherent in performing scheduled inspections within confined spaces of fixed-bed downflow ...
-
Guiding the crude-to-chemicals complex towards a net-zero future (RI 2023)
Nov-2023
In today’s world, the expanding chemical value chain requires superior processing flexibility to shift hydrocarbons from fuels to olefins and aromatics ...
-
Three steps to optimise fractionator performance with plate technology
Oct-2022
The refining industry has dealt with various challenges throughout its history, but the current pressure from a range of factors, such as energy optimisation, ...
-
Solving a tube failure problem due to flow stratification using the Xtend tube-insert
Apr-2024
A vacuum heater located at a major oil refinery experienced tube failures at the top of the radiant section, and inspection showed a substantial layer ...
-
Feb-2024
Part 1 covered the basics of crude-to-chemicals. Part 2 explains how hydroprocessing technology can be used to convert any crude to chemicals to maximise ...
-
Enhancing flexibility in two-stage hydrocrackers
Aug-2022
Shifting markets and refined product priorities compels refiners to find the flexibility for shifting from middle distillate to naphtha for petrochemical ...
-
Crude to chemicals: Part 1 - The basic concept of crudes
Nov-2023
Reactor platforms with novel heat integration designed around advanced separation techniques and catalyst systems achieve 75% yields from selected cru ...
-
Revamping crude towers for quality and yield
Nov-2016
A successful revamp of distillation towers for increased diesel quality and yield depended on reliable design and accurate assembly
-
Maximising stripping section performance
Aug-2021
The design of a crude unit stripping section affects diesel and gasoil yields, energy usage, and unit reliability.
-
Importance of testing for vacuum ejectors in refinery service
Jun-2022
Efforts should be made to identify and avoid errors in the specification, engineering, and manufacturing of vacuum system equipment before they manifest ...
-
Flue gas heat recovery through the acid dew point
Jul-2019
Polymer based heat exchange technology enables more heat recovery from flue gas by addressing acid corrosion issues.
-
Crude oil processing scheme for reducing operating costs in the CDU
Feb-2023
Development of crude oil distillation processing schemes to significantly reduce external energy and stripping steam demand.
-
Premature foam-flood in an amine absorber: Part 1
Nov-2021
Troubleshooting and hydraulic analysis identified vapour channelling in fixed valve trays as the root cause of premature foam-flooding in a high pressure ...
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De-mystifying vacuum ejector systems
Feb-2023
First-stage inter-condenser design and performance are critical for reliable vacuum system performance.
-
Column revamp boosts diesel production
Nov-2020
Revamping the internals of a main fractionator column enabled a refinery to increase its diesel throughput.
-
Jun-2021
Upgraded crude scheduling enabled a refiner to increase its use of opportunity crudes for higher margin.
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Crude preheat train fouling and fix-up
Nov-2022
Rigorous modelling of crude preheat train exchangers allows for fouling progression of the heat exchangers to be monitored throughout the crude unit run ...
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Debottlenecking product recovery using product pair distillation: Part I
Apr-2023
Advantages of using a thermodynamically efficient method to debottleneck existing distillation trains using fewer new columns than traditional methods ...
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An atmospheric crude tower revamp
Jul-2005
Overall gas oil yield was maintained with heavier crudes due to a crude tower revamp. The revamp allowed for a crude heater outlet temperature reducti ...
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Design configurations for lowering quenched coke drum venting pressure
Feb-2023
Compare the advantages when installing either an ejector or a water ring compressor for lowering coke drum venting pressure.
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Managing vacuum tower wash beds
Sep-2020
ThruVision™ scans monitor the rate of coking in vacuum tower wash beds to get the most out of bed productivity.
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Anti-fouling additives to improve heavy oil processing
Apr-2023
A continuous pilot testing evaluation shows how magnesium sulphonated-based nano-additive is highly effective in mitigating and reducing upgrader/refinery ...
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Realities of heat flux in fired heaters
Nov-2020
Uneven radiant heat flux distribution is a major cause of poor reliability in refinery fired heaters.
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Jan-2022
Improvements in performance and energy efficiency were achieved during the turnaround of a crude distillation unit.
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Choosing a neutralising amine corrosion inhibitor
Jul-2004
A review of physical and chemical properties of commonly used amine-based corrosion inhibitors. The authors highlight the relative strengths and weaknesses ...
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Improving the distillation energy network
Oct-2013
Energy-efficient design applied to the refit of a distillation unit was achieved through optimisation between the distillation column and heat network ...
-
Myth of high cutpoint in dry 
vacuum units
Apr-2014
Accurate measures of true boiling point cutpoints are essential to correctly evaluate vacuum unit performance
-
Problems in processing discounted crudes Part 2: crude and vacuum columns
May-2019
Project costs must be considered to fully understand whether or not an opportunity crude really does deliver on savings.
-
Flexible upgrading of heavy feedstocks
Feb-2019
Adding tailor-made options for upgrading heavy crudes to existing assets can adapt refineries to changes in market conditions and regulatory demands.
-
Planning to counter economic turbulence
Sep-2020
Synchronising engineering and planning models should be a key aim to support the resilience and agility needed for economic recovery
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Pre-turnaround scans enable better critical path planning
Sep-2020
Tru-Scan™ and Tru-Grid™ Scan results help determine whether to enter a particular column during the turnaround outage or remove it from the critical ...
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ThruVision™ scans are the next step to investigate liquid maldistribution
Sep-2020
ThruVision™ technology allows for a complete understanding of liquid distribution, saving days of production losses and massive costs of a unit shut ...
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High performance internals in severe service
Nov-2020
Application of a severe service grid achieved 10% higher throughput with improved reliability in a vacuum tower revamp.
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Processing lower cost crudes with greater confidence and improved reliability
Dec-2020
For more than 100 years, it has been understood in the petroleum refining industry that certain crude oils or, more accurately, crude oil fractions contain ...
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Our desalting rate drops away quickly when we use heavier feeds. What is the problem here?
Feb-2021
Responses to a question in the Q1 2021 issues Q&A Feature
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Upgrading a vacuum distillation tower (TIA)
Feb-2021
Reliable and efficient vacuum towers are key to ensuring optimal performance and yield.
-
Reducing FCC main fractionator operating risks
Mar-2021
Analysis of an FCC main fractionator upset and follow-up revamp showed that removal of the HCO wash section did not impact operations or product quali ...
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Amine anomaly in a mild hydrocracker
Jun-2021
Simulation and operational changes help to crack the riddle of frequent amine carry-over from a high pressure amine absorber.
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Premature foam-flood in an amine absorber: Part 2
Jan-2022
Troubleshooting and hydraulic analysis identified vapour channelling in fixed valve trays as the root cause of premature foam-flooding in a high pressure ...
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Sulzer’s VIEC technology provides the solution with single-stage early separation
Nov-2022
The principle of “easiest first” applies as much in the oil industry as in most other enterprises. This in no more evident than in the state of the ...
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Fouling in VDU ejector systems
Feb-2023
Review of critical ejector-condenser interplay, with an overview of fouling in VDU ejector systems, including a case study where fouling impacted a refiner's ...
-
Mitigating FCC gas plant impacts when increasing reactor LPG yields
Apr-2023
Increasing FCC reactor LPG yields at the expense of gasoline increases profitability, but equipment downstream of the converter requires modifications ...
-
Focused revamp increases diesel and HVGO recovery
Jul-2023
Refiners have the best opportunity to maximise return through identification of creative solutions during a focused capital revamp.
-
Optimising fouled distillation units
Nov-2023
Case studies discuss optimisation strategies and enhanced distillation unit performance against fouled conditions.
-
Preventing ammonium salt fouling and corrosion
Jan-2018
Best practices and opportunities to reduce the risk of salt deposition and damage
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Problems in processing discounted crudes Part 1: definition and crude preheat
Feb-2019
Project costs must be considered to fully understand whether or not an opportunity crude really does deliver on savings.
-
Enhancing energy efficiency in the CDU
Apr-2015
Revisiting your crude distillation unit may expose hidden potential for major energy savings
-
Correcting vacuum column design flaws
Apr-2017
Conventional design practices have been proven inadequate when maximising diesel recovery and gas oil cut point
-
Troubleshooting crude column constraints
Jul-2017
Multiple limitations to operating capacity were identified and resolved during a column turnaround
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Loss into gain in high capacity trays - Part 1: excursion
Jun-2016
Systematic troubleshooting diagnosed and solved two complex and independent problems that limited the capacity of an atmospheric crude distillation to ...
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Nov-2017
Thorough tank cleaning means removing all of the sludge and restoring the vessel’s full storage capacity.
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Identifying the root cause of underperforming ejector systems
Nov-2022
Underperforming ejector systems illustrate the importance of the long air baffle, its proper operation, and how to quickly identify problems when they ...
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Mitigating overhead corrosion and reducing downstream costs
Jan-2022
A combination of onstream measurements, closed-loop control, and corrosion measurement enabled significant reductions in caustic addition rates and FCC ...
-
Crude overhead system design considerations
Jul-2007
Proper crude unit overhead system design is important when building a new unit or revamping an existing one to process different crudes
-
Operating vacuum distillation ejector systems
Oct-2016
Best practices and opportunities to deliver reliable ejector system performance and reduce performance risk.
-
Opening the crude flexibility window: automation manages threats in real time
Sep-2018
By increasing the volume of quality data, refiners can automate the correct addition of chemical additives to respond to variations in unit performanc ...
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Oct-2004
Installation of vortex tube clusters in crude unit preflash drums has eliminated foam carry-over, increasing diesel and atmospheric gasoil product yie ...
-
Troubleshooting vacuum systems
Oct-2016
Case histories of refinery vacuum tower problems solved are gleaned from five decades of experience.
-
Consider retrofits to handle high-viscosity crudes
Mar-2004
In 2000, ConocoPhillips’ refinery in Sweeny, Texas, began processing 16° API gravity blends of extra-heavy crude oils, including Merey 16 and BCF 1 ...
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Why vacuum unit fired heaters coke
Oct-2004
A description of the internal workings of vacuum heaters and the causes of coke formation within them
-
Future of opportunity crudes processing
Oct-2011
Five critical drivers help refiners remain profitable and sustain long-term business goals while processing relatively inexpensive, low-quality crudes
-
Model predictive control of a distillation unit
Jul-2017
In a coordinated plant process, particular attention must be paid to control of individual columns.
-
Controlling contaminants in vacuum gasoil
Nov-2017
How revamps can increase VDU capacity and reliability while controlling contaminant levels to acceptable limits.
-
Revamping crude and vacuum units to process bitumen
Apr-2015
Revamping crude and vacuum units to process dilbit can involve extensive equipment replacement as well as major changes to the crude preheating scheme
-
Sep-2003
Case studies show how accurate field-measured differential pressure can be interpreted incorrectly when troubleshooting refinery vacuum columns
-
Revamping a crude distillation unit
Feb-2020
A revamp project aimed to increase process safety and reduce high energy consumption in a CDU. It also delivered better product separation and higher diesel ...
-
Balanced distillation equipment design
Feb-2017
Fouling resistance and efficiency requirements for distillation equipment are balanced and optimised for reliable unit performance.
-
Entrainment issues in vacuum column flash zones
Jan-2010
For a vacuum tower to operate effectively, the flash zone and the wash section must work together to provide the best possible feed quality to the sections ...
-
Oct-2012
Inaccurate feed characterisation and process modelling errors are major contributors to poor performance in a vacuum unit as refiners switch to heavier ...
-
Jan-2013
Revamping a VDU’s vacuum system delivered operational improvements in a refinery, but also led to safer and more efficient handling of non-condensed ...
-
Asphalt quality prediction and control
Oct-2014
With knowledge of heavy vacuum gasoil cut-point and asphalt density, asphalt quality can be inferred
-
Upgrading a vacuum distillation tower (TIA)
Aug-2021
When a major oil refinery in India was constrained by its vacuum tower, it turned to Sulzer Chemtech to find a solution that would not only solve existing ...
-
Apr-2022
A vacuum column’s economics can be greatly improved with a low cost modification to the ejector system
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Reconfiguration of naphtha splitters using divided wall column technology
Feb-2023
Integration of DWCs into existing refining configurations reduces energy consumption and GHG emissions in distillation systems while also lowering operating ...
-
Predictive model for maximum feedstock flexibility (ERTC 2023)
Nov-2023
Challenge of crude oil variability. Current market conditions are driving refineries towards a permanent diversification in crudes. Crude oil is a complex ...
-
Solving a tube failure problem due to flow stratification using the Xtend tube-insert
Apr-2024
A vacuum heater located at a major oil refinery experienced tube failures at the top of the radiant section, and inspection showed a substantial layer ...
-
Enhancing fractionator efficiency
Jul-2016
Properly designed vapour and liquid distribution devices enable more effective distillation column efficiency.
-
Towards a zero gasoline production refinery: part 2
Oct-2013
Refinery configurations can suit various processing objectives, such as variations to the propylene-to-ethylene ratio and production of middle distillates ...
-
Data analytics for hydrocarbon processing
Oct-2016
Advanced data handling techniques are transforming operations in the refining industry at an increasing pace.
-
Improving level control in desalters to aid in use of opportunity crudes
Sep-2019
Refineries are a complex set of various operating units designed to process crude oil into refined products such as gasoline, diesel, jet fuels and feedstocks ...
-
Wastewater treatment for challenging crudes
Jan-2018
A new organic polymer treatment has enabled refiners to more effectively process a variety of opportunity crudes
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Stabilisation 
of asphaltenes
Jan-2009
Asphaltenes can plug refinery equipment and can decrease or stop production. Stabilisation of asphaltene particles is an efficient and cost-effective way ...
-
A balanced approach to vacuum tower flash zone/wash section design
Sep-2010
Revamping an existing vacuum column to operate at a higher feed rate, higher flash zone temperature, lower pressure, and different feed stock characterisation ...
-
High performance trays for a fractionator in an aromatics plant
May-2015
Distillation is a very important separation technology in refineries and downstream chemical processing. Mass transfer internals in distillation columns ...
-
Dividing wall technology in distillation columns
Feb-2020
Increased throughput required the revamp of a gasoline unit. Space constraints and strict product requirements led to dividing wall column technology as ...
-
Evaluating opportunity crude processing
Oct-2006
Is processing opportunity crudes for every refiner? Technical challenges and economic benefits from processing high-acid crudes and bottom-of-the-barrel ...
-
Light tight oil crude unit fouling root causes and troubleshooting
Mar-2015
Fouling in preheaters, crude furnace and atmospheric tower bottoms exchangers directly impacts throughput and profitability, requiring rigorous evaluation ...
-
Silencing hammering in a condenser system
Dec-2017
Detailed analysis leading to correct diagnosis meant that only minor equipment changes were needed to cure severe hammering in a naphtha splitter.
-
Sustainable technology for cleaning a crude preheat exchanger network
Aug-2019
Mitigating environmental impacts, saving time and reducing costs: cleaning a heat exchanger network using a renewable cleaning agent.
-
Best practice desalting Part 1: crude flexibility window
Jul-2017
A replacement programme of desalter treatment chemistry transformed the operation of crude units struggling to meet performance targets
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Revamp process design — optimum crude unit product yields
Jul-1997
Designing a new crude unit is an unconstrained process, limited only by capital
investment targets, while revamping an existing unit to optimise ... -
Crude unit revamp to increase diesel yield
Apr-2002
Account of a crude vacuum unit revamp where detailed calculation of the true performance of existing equipment raised diesel production by 14.5 vol% on ...
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Vacuum unit design for high 
metals crudes
Jan-2007
Vacuum unit design can influence vacuum gas yield, product quality and run length. A wet vacuum unit with residue stripping achieves the highest cutpo ...
-
Heat integration projects for 
refining processes
Oct-2013
Heat integration projects can deliver substantial savings, but they require detailed simulation and case-specific heat integration analysis
-
Reducing vacuum tower pressure
Apr-2015
To create a better vacuum the vapour load to the ejector has to be reduced
-
Simulating crude units with preflash
Nov-2016
Process simulation offers a cost effective way of testing ideas to improve yield and energy performance.
-
Mar-2018
Scalable simulation of crude unit operations enables refineries to build increasingly rigorous models to enhance performance
-
Maximisation of VGO through deep-cut distillation for refinery margins
Jan-2011
Appropriate choice of crude and/or crude oil blends as feedstock and a vacuum tower revamp enable higher production of vacuum gas oil
-
Revamping atmospheric crude heaters
Sep-2007
Revamp of an atmospheric crude unit heater suffering from coking caused by asphaltene precipitation resulted in an increased heater run length
-
Maximising the use of process energy
Apr-2014
Integrating a flash drum in an atmospheric and crude distillation unit offers the potential for savings and capacity enhancement
-
Tray revamp restores crude column performance
Jan-2019
Retrofitting the packed top section of a crude atmospheric tower with high capacity trays improved separation efficiency
-
Canadian crude processing challenges
Jan-2008
Vacuum unit design influences liquid volume yields, run length, product 
yield and product quality when processing bitumen crude oils
-
Improving solids handling in a delayed coker
Jul-2011
A reliability model applied to a coke handling system demonstrates the benefits of compliance with a preventive maintenance programme
-
Sep-2007
Primary goals of a lube vacuum column revamp were to increase lube product fractionation and minimise HVGO product contaminants
-
The age of turbulence: charting a course for refiners to a profitable future
Nov-2012
Relentless turbulence has profoundly affected the global refining landscape in recent years. Moreover, the turmoil is likely to continue unabated in the ...
-
Savings in exchanger network cleaning (TIA)
Jun-2015
The Super Clean System (SCS), an online heat exchanger cleaning technology, is being used by a major oil refiner in Japan at a refinery equipped with a ...
-
Online cleaning: a mindshift for improving operational excellence
Apr-2013
A patented method of chemical cleaning can reduce downtime arising from severe fouling in process units
-
Strategies for improved naphtha processing
Oct-2013
To take advantage of dilbit from Alberta and light oils from shale formations, refiners must develop a strategy for processing additional naphthas and ...
-
Oil/water interface control for desalters
Oct-2007
Profiling instrument provides vertical real-time phase density measurement in desalter vessels. Benefits include reduced process upsets from interface ...
-
Shale feedstocks fuel ethylene, LNG and petrochemical derivatives expansion
Apr-2014
In spite of the variability in shale composition causing operational challenges for refiners, monetisation opportunities are seen throughout the energy ...
-
How dynamic pressure can affect vacuum column readings
Jun-2016
Computational fluid dynamics confirmed field measurements to explain a vacuum unit’s poor quality HVGO and was used to redesign the tower internals
-
Troubleshooting vacuum unit revamps
Jul-1998
While vacuum unit revamps increase gasoil yield, management is pushing the intervals between turnarounds to four or five years
-
Avoiding unscheduled shutdowns
Apr-2001
Case studies have demonstrated that correct heater design and consequent performance will determine crude unit run length
-
Vacuum pressure control: impact on profitability
Jul-2001
Optimisation of flash zone pressure and temperature can improve feedstock quality to downstream units
-
Crude column revamp using radial temperature profiles
Sep-2003
Designers need to be aware of all the factors influencing packed bed performance such as feed zone mixing problems
-
Oct-2005
Fundamental design considerations influencing diesel and vacuum gas oil (VGO) recovery when revamping existing or designing grassroots crude units. By ...
-
Apr-2006
When designing vacuum units for processing heavy Canadian crudes, reliability costs can be high if the feedstock’s thermal instability is not fully ...
-
Refinery CO2 challenges: part III
Jul-2006
For the prediction of CO2 emissions from a refinery, simple correlations are not always sufficient. A rigorous simulation tool that includes fractionation ...
-
Cost-effective and reliable revamps
Jul-2009
Test run hydraulic measurements and analysis, together with equipment know-how, can help refiners identify profitable, low-cost revamp opportunities
-
Bitumen processing: crude unit revamps
Jul-2011
The ability to process bitumen offers a competitive advantage, but revamps of crude and vacuum units to process bitumen require significant changes
to ...
-
Flow metering vacuum tower bottoms
Oct-2011
A clamp-on ultrasonic flow meter can make flow measurement at the bottom of vacuum distillation towers more reliable
-
Integrated monitoring for optimising crude distillation
Jan-2012
On-line process analysers in crude distillation units prevent lost throughput caused by non-conforming process conditions and crude oil switching
-
Increasing distillate production at least capital cost
Apr-2015
Investing in improvements to the atmospheric crude unit can deliver increased distillate yields with short payback times
-
Revamping a bitumen heating system
Jul-2019
A redesigned oil based heating system for bitumen storage and sales saves energy and eliminates customer complaints.
-
High octane isomerates from light naphtha
Feb-2020
Dividing wall column distillation is an energy efficient, cost effective alternative to conventional distillation for delivering high octane products from ...
-
Designing the CDU/VDU for opportunity crudes
Oct-2012
New units for processing heavy crudes should not be designed using conventional practices or run length will be short, and product yields and quality ...
-
Troubleshooting a heavy crude topper
Jul-2019
Thorough troubleshooting revealed the primary cause of a heavy crude topper’s poor availability: desalter operation. A comprehensive revamp resolved ...
-
Increasing vacuum tower performance
Oct-2004
Advantages of using gravity flow liquid distributors in services where, historically, spray nozzles have been used, specifically in refinery vacuum tower ...
-
Jan-2006
Cost-effective exchanger network solutions need to rely on more than just pinch technology if they are to be successful
-
Crude column relief mitigation
Oct-2011
Mitigation of plant-wide relief loads can greatly improve the safety of the plant, reduce flaring and be used as the basis for building smaller relief ...
-
Turnarounds deliver process improvements
Nov-2016
An extended unit shutdown is relatively rare and an opportunity to take every advantage to improve performance.
-
A two stage approach to controlling fouling on preheat trains at OMV’s Schwechat refinery
Aug-2016
Fouling in heat exchanger preheat trains is a well-known problem in the refining industry. Fouling reduces exchanger performance, increases furnace duty, ...
-
Considerations for crude unit preflash drums and preflash towers
Feb-2024
A guide to debottlenecking, revamping, designing, and operating crude unit preflash facilities based on literature and the authors’ experience.
-
Dealing with desalter cleaning challenges
Aug-2016
How to overcome lengthy and potentially dangerous challenges when cleaning a crude unit desalter.
-
Online cleaning of 
process equipment
Oct-2008
In the interest of time and cost savings, online cleaning prior to shutdown can reduce the duration and complexity of refinery turnarounds, as demonstrated ...
-
Energy-efficient vacuum systems
Apr-2013
Case analysis of the techniques available to reduce energy consumption in vacuum systems reveals the potential for cost savings
-
Online cleaning of an integrated distillation unit
Oct-2013
Online cleaning technology was validated during a scheduled turnaround at the second largest refinery in Poland.
-
Loss into gain in high-capacity trays Part 2: reverse vapour cross flow chanelling
Aug-2016
Systematic troubleshooting diagnosed two complex problems that limited the capacity of an atmospheric crude distillation tower
-
Front end filtering of unconventional oil
Jan-2019
Processing unconventional oils requires technologies such as electrostatic separation to handle higher amounts of filterable solids.
-
Unlocking current 
refinery constraints
Apr-2008
When processing heavy feeds, technology based on residuum supercritical solvent extraction provides higher volumes of gas oil and DAO for conversion units. ...
-
CFD study of a VDU feed inlet device and wash bed
Oct-2009
Analysis of vapour velocity profiles at the entry to the wash zone of a VDU column enables a higher feed rate and improved output quality
-
Designing a crude unit heat 
exchanger network
Oct-2012
Preheat train design for heavy Canadian crudes can be very challenging, requiring an approach not normally required with other crudes
-
Improved conceptual process design avoids revamp scope growth
Mar-2002
For grassroots design, defining project scope is a straightforward exercise. Grassroots projects can follow optimum execution procedures for engineering ...
-
Reducing the danger of maintenance exposure
Apr-1998
Maintenance cost overruns result from inadequate cost estimating and the emergence of unidentified work that has to be done
-
Revamping conceptual process design
Jan-2002
With the desirability of getting the maximum use out of existing equipment when revamps are planned a rigorous approach to CPD is required to avoid scope ...
-
Specifications — importance of getting them right
Mar-2003
Faulty equipment specifications sometimes carry unforeseen penalties, with loss of performance. It is the process design engineer’s responsibility to ...
-
ULSD production: improved feed stream quality
Apr-2003
Much of hydrotreater revamp investment costs in future will be in dealing with the most difficult-to-remove sulphur species, because of their low reaction ...
-
Crude unit start-ups: the results of a 
high liquid level
Sep-2003
Pressure-measurement techniques can avoid the dangers of rapidly changing flow rates and levels during start-up
-
Oct-2005
Process modelling and equipment know-how are needed to design deep-cut vacuum units that operate reliably at high temperature and low pressure
-
Jan-2007
Gamma scanning is a powerful tool that can be used to determine the cause of flooding and regain column efficiency. Debutaniser capacity and performance ...
-
Identifying very small 
equipment leaks
Jan-2008
Very small leaks in feed/effluent exchangers can be identified using chemical tracing. This online technique can detect leaks as low as 5.0 ppm, avoiding ...
-
Improving crude vacuum 
unit performance
Mar-2008
When simulating or designing an unconventional heavy oil/bitumen vacuum crude unit, the sharing of operating data on cracked gas make, stripping section ...
-
Demystifying the zero entrainment myth for vacuum column flash zones
Apr-2009
One of the recurring questions about refinery vacuum tower operation is the issue of flash zone entrainment and the operation of the wash section.
-
Online real-time optimisation helps identify energy gaps
Oct-2010
Real-time supervision of a refinery’s energy system enables optimisation of its fuel consumption and emissions levels
-
Jan-2011
A process review, including the improvement of atmospheric and vacuum distillation columns, for the reformulation of the diesel pool
-
Improving crude unit operation
Jan-2011
Most crude and vacuum units present an opportunity for improvement using modern process control systems
-
High-capacity tray for debottlenecking a crude distillation unit
Jan-2013
Use of ultra-high-capacity trays in the most constrained section of a CDU enabled over a 50% increase in throughput at less cost than other debottlenecking ...
-
Optimising preflash for light tight oil processing
Jul-2015
For a crude unit handling light tight oil feedstock, a semi-preflash column can deliver significant advantages in energy saving, capacity gain and revamp ...
-
Online monitor slashes biocide dosage (TIA)
Nov-2018
In many systems, fouling and deposits are a serious problem which results in shutdowns, cleaning actions and unexpected costs for the customer.
-
Apr-2019
With the market for high sulphur fuel oil under pressure, refiners with delayed cokers can instead opt for higher value power and steam generation.
-
Fouling and cleaning analysis of a heat exchanger network
Dec-2019
Analysis of a complex heat exchanger network employs a digital twin model to establish a programme for fouling and cleaning.
-
Three steps to optimise fractionator performance with plate technology
Oct-2022
The refining industry has dealt with various challenges throughout its history, but the current pressure from a range of factors, such as energy optimisation, ...
-
Desalting chemistry and monitoring methods to help expand crude basket
Feb-2023
Widening the crude basket increases the challenges of maintaining asset reliability and plant performance, including formation of rag layers.
-
Enhancing profitability using high-efficiency heat exchangers (RI 2023)
Nov-2023
Alfa Laval has been in the refinery industry for more than 40 years, with more than 3,000 high-efficiency heat exchangers installed worldwide. The company’s ...
-
Worker safety when entering reactors with an inert atmosphere (TiA)
Feb-2024
The products from petrochemical processing touch almost every aspect of modern living. The importance of these products to industry and society emphasises ...
-
Sep-2006
Operational issues such as higher heater duty and column pressure must be weighed against avoiding residue entrainment in HVGO
-
Practical considerations for crude unit revamps
Oct-1998
Two examples are used in this article to illustrate how changes in the process flow scheme can increase preheat train heat recovery
-
Vacuum unit design effect on operating variables
Jul-2002
To revamp vacuum units, process modelling and equipment design know-how are needed, and the understanding of connected equipment performance can lead to ...
-
Identifying poor heat exchanger performance
Sep-2007
Identifying root causes of poor crude unit debutaniser reboiler performance and low-cost solutions that help meet exchanger original design conditions
-
Simulation VGO and waste lubricating/cooking oil co-hydroprocessing
Nov-2023
Software used to build a simulation case for industrial hydrocracking of VGO, WCO, and WLO validates predicted values of gasoline and middle distillates ...
-
Guiding the crude-to-chemicals complex towards a net-zero future (RI 2023)
Nov-2023
In today’s world, the expanding chemical value chain requires superior processing flexibility to shift hydrocarbons from fuels to olefins and aromatics ...
-
Unicracking unit flow scheme optimisation and integration
Nov-2023
How an optimisation and integration approach can assist in maximising refinery margin for a residue upgrading project.
-
Innovative vessel internals for enhanced safety when changing media beds (TiA)
May-2024
In our previous article (PTQ Q1 2024), we discussed the challenges inherent in performing scheduled inspections within confined spaces of fixed-bed downflow ...
-
Innovative vessel internals for enhanced safety when changing media beds (TiA)
May-2024
In our previous article (PTQ Q1 2024), we discussed the challenges inherent in performing scheduled inspections within confined spaces of fixed-bed downflow ...
-
Solving a tube failure problem due to flow stratification using the Xtend tube-insert
Apr-2024
A vacuum heater located at a major oil refinery experienced tube failures at the top of the radiant section, and inspection showed a substantial layer ...
-
Feb-2024
Part 1 covered the basics of crude-to-chemicals. Part 2 explains how hydroprocessing technology can be used to convert any crude to chemicals to maximise ...
-
Worker safety when entering reactors with an inert atmosphere (TiA)
Feb-2024
The products from petrochemical processing touch almost every aspect of modern living. The importance of these products to industry and society emphasises ...
-
Considerations for crude unit preflash drums and preflash towers
Feb-2024
A guide to debottlenecking, revamping, designing, and operating crude unit preflash facilities based on literature and the authors’ experience.
-
Unicracking unit flow scheme optimisation and integration
Nov-2023
How an optimisation and integration approach can assist in maximising refinery margin for a residue upgrading project.
-
Predictive model for maximum feedstock flexibility (ERTC 2023)
Nov-2023
Challenge of crude oil variability. Current market conditions are driving refineries towards a permanent diversification in crudes. Crude oil is a complex ...
-
Enhancing profitability using high-efficiency heat exchangers (RI 2023)
Nov-2023
Alfa Laval has been in the refinery industry for more than 40 years, with more than 3,000 high-efficiency heat exchangers installed worldwide. The company’s ...
-
Guiding the crude-to-chemicals complex towards a net-zero future (RI 2023)
Nov-2023
In today’s world, the expanding chemical value chain requires superior processing flexibility to shift hydrocarbons from fuels to olefins and aromatics ...
-
Crude to chemicals: Part 1 - The basic concept of crudes
Nov-2023
Reactor platforms with novel heat integration designed around advanced separation techniques and catalyst systems achieve 75% yields from selected cru ...
-
Simulation VGO and waste lubricating/cooking oil co-hydroprocessing
Nov-2023
Software used to build a simulation case for industrial hydrocracking of VGO, WCO, and WLO validates predicted values of gasoline and middle distillates ...
-
Optimising fouled distillation units
Nov-2023
Case studies discuss optimisation strategies and enhanced distillation unit performance against fouled conditions.
-
Focused revamp increases diesel and HVGO recovery
Jul-2023
Refiners have the best opportunity to maximise return through identification of creative solutions during a focused capital revamp.
-
Debottlenecking product recovery using product pair distillation: Part I
Apr-2023
Advantages of using a thermodynamically efficient method to debottleneck existing distillation trains using fewer new columns than traditional methods ...
-
Mitigating FCC gas plant impacts when increasing reactor LPG yields
Apr-2023
Increasing FCC reactor LPG yields at the expense of gasoline increases profitability, but equipment downstream of the converter requires modifications ...
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Anti-fouling additives to improve heavy oil processing
Apr-2023
A continuous pilot testing evaluation shows how magnesium sulphonated-based nano-additive is highly effective in mitigating and reducing upgrader/refinery ...
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De-mystifying vacuum ejector systems
Feb-2023
First-stage inter-condenser design and performance are critical for reliable vacuum system performance.
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Fouling in VDU ejector systems
Feb-2023
Review of critical ejector-condenser interplay, with an overview of fouling in VDU ejector systems, including a case study where fouling impacted a refiner's ...
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Desalting chemistry and monitoring methods to help expand crude basket
Feb-2023
Widening the crude basket increases the challenges of maintaining asset reliability and plant performance, including formation of rag layers.
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Design configurations for lowering quenched coke drum venting pressure
Feb-2023
Compare the advantages when installing either an ejector or a water ring compressor for lowering coke drum venting pressure.
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Reconfiguration of naphtha splitters using divided wall column technology
Feb-2023
Integration of DWCs into existing refining configurations reduces energy consumption and GHG emissions in distillation systems while also lowering operating ...
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Crude oil processing scheme for reducing operating costs in the CDU
Feb-2023
Development of crude oil distillation processing schemes to significantly reduce external energy and stripping steam demand.
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Sulzer’s VIEC technology provides the solution with single-stage early separation
Nov-2022
The principle of “easiest first” applies as much in the oil industry as in most other enterprises. This in no more evident than in the state of the ...
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Identifying the root cause of underperforming ejector systems
Nov-2022
Underperforming ejector systems illustrate the importance of the long air baffle, its proper operation, and how to quickly identify problems when they ...
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Crude preheat train fouling and fix-up
Nov-2022
Rigorous modelling of crude preheat train exchangers allows for fouling progression of the heat exchangers to be monitored throughout the crude unit run ...
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Three steps to optimise fractionator performance with plate technology
Oct-2022
The refining industry has dealt with various challenges throughout its history, but the current pressure from a range of factors, such as energy optimisation, ...
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Enhancing flexibility in two-stage hydrocrackers
Aug-2022
Shifting markets and refined product priorities compels refiners to find the flexibility for shifting from middle distillate to naphtha for petrochemical ...
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Importance of testing for vacuum ejectors in refinery service
Jun-2022
Efforts should be made to identify and avoid errors in the specification, engineering, and manufacturing of vacuum system equipment before they manifest ...
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Apr-2022
A vacuum column’s economics can be greatly improved with a low cost modification to the ejector system
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Mitigating overhead corrosion and reducing downstream costs
Jan-2022
A combination of onstream measurements, closed-loop control, and corrosion measurement enabled significant reductions in caustic addition rates and FCC ...
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Premature foam-flood in an amine absorber: Part 2
Jan-2022
Troubleshooting and hydraulic analysis identified vapour channelling in fixed valve trays as the root cause of premature foam-flooding in a high pressure ...
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Jan-2022
Improvements in performance and energy efficiency were achieved during the turnaround of a crude distillation unit.
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Premature foam-flood in an amine absorber: Part 1
Nov-2021
Troubleshooting and hydraulic analysis identified vapour channelling in fixed valve trays as the root cause of premature foam-flooding in a high pressure ...
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Maximising stripping section performance
Aug-2021
The design of a crude unit stripping section affects diesel and gasoil yields, energy usage, and unit reliability.
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Upgrading a vacuum distillation tower (TIA)
Aug-2021
When a major oil refinery in India was constrained by its vacuum tower, it turned to Sulzer Chemtech to find a solution that would not only solve existing ...
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Jun-2021
Upgraded crude scheduling enabled a refiner to increase its use of opportunity crudes for higher margin.
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Amine anomaly in a mild hydrocracker
Jun-2021
Simulation and operational changes help to crack the riddle of frequent amine carry-over from a high pressure amine absorber.
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Reducing FCC main fractionator operating risks
Mar-2021
Analysis of an FCC main fractionator upset and follow-up revamp showed that removal of the HCO wash section did not impact operations or product quali ...
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Upgrading a vacuum distillation tower (TIA)
Feb-2021
Reliable and efficient vacuum towers are key to ensuring optimal performance and yield.
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Our desalting rate drops away quickly when we use heavier feeds. What is the problem here?
Feb-2021
Responses to a question in the Q1 2021 issues Q&A Feature
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Processing lower cost crudes with greater confidence and improved reliability
Dec-2020
For more than 100 years, it has been understood in the petroleum refining industry that certain crude oils or, more accurately, crude oil fractions contain ...
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High performance internals in severe service
Nov-2020
Application of a severe service grid achieved 10% higher throughput with improved reliability in a vacuum tower revamp.
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Column revamp boosts diesel production
Nov-2020
Revamping the internals of a main fractionator column enabled a refinery to increase its diesel throughput.
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Realities of heat flux in fired heaters
Nov-2020
Uneven radiant heat flux distribution is a major cause of poor reliability in refinery fired heaters.
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ThruVision™ scans are the next step to investigate liquid maldistribution
Sep-2020
ThruVision™ technology allows for a complete understanding of liquid distribution, saving days of production losses and massive costs of a unit shut ...
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Pre-turnaround scans enable better critical path planning
Sep-2020
Tru-Scan™ and Tru-Grid™ Scan results help determine whether to enter a particular column during the turnaround outage or remove it from the critical ...
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Managing vacuum tower wash beds
Sep-2020
ThruVision™ scans monitor the rate of coking in vacuum tower wash beds to get the most out of bed productivity.
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Planning to counter economic turbulence
Sep-2020
Synchronising engineering and planning models should be a key aim to support the resilience and agility needed for economic recovery
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High octane isomerates from light naphtha
Feb-2020
Dividing wall column distillation is an energy efficient, cost effective alternative to conventional distillation for delivering high octane products from ...
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Dividing wall technology in distillation columns
Feb-2020
Increased throughput required the revamp of a gasoline unit. Space constraints and strict product requirements led to dividing wall column technology as ...
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Revamping a crude distillation unit
Feb-2020
A revamp project aimed to increase process safety and reduce high energy consumption in a CDU. It also delivered better product separation and higher diesel ...
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Fouling and cleaning analysis of a heat exchanger network
Dec-2019
Analysis of a complex heat exchanger network employs a digital twin model to establish a programme for fouling and cleaning.
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Improving level control in desalters to aid in use of opportunity crudes
Sep-2019
Refineries are a complex set of various operating units designed to process crude oil into refined products such as gasoline, diesel, jet fuels and feedstocks ...
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Sustainable technology for cleaning a crude preheat exchanger network
Aug-2019
Mitigating environmental impacts, saving time and reducing costs: cleaning a heat exchanger network using a renewable cleaning agent.
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Flue gas heat recovery through the acid dew point
Jul-2019
Polymer based heat exchange technology enables more heat recovery from flue gas by addressing acid corrosion issues.
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Troubleshooting a heavy crude topper
Jul-2019
Thorough troubleshooting revealed the primary cause of a heavy crude topper’s poor availability: desalter operation. A comprehensive revamp resolved ...
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Revamping a bitumen heating system
Jul-2019
A redesigned oil based heating system for bitumen storage and sales saves energy and eliminates customer complaints.
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Problems in processing discounted crudes Part 2: crude and vacuum columns
May-2019
Project costs must be considered to fully understand whether or not an opportunity crude really does deliver on savings.
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Apr-2019
With the market for high sulphur fuel oil under pressure, refiners with delayed cokers can instead opt for higher value power and steam generation.
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Problems in processing discounted crudes Part 1: definition and crude preheat
Feb-2019
Project costs must be considered to fully understand whether or not an opportunity crude really does deliver on savings.
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Flexible upgrading of heavy feedstocks
Feb-2019
Adding tailor-made options for upgrading heavy crudes to existing assets can adapt refineries to changes in market conditions and regulatory demands.
-
Front end filtering of unconventional oil
Jan-2019
Processing unconventional oils requires technologies such as electrostatic separation to handle higher amounts of filterable solids.
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Tray revamp restores crude column performance
Jan-2019
Retrofitting the packed top section of a crude atmospheric tower with high capacity trays improved separation efficiency
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Online monitor slashes biocide dosage (TIA)
Nov-2018
In many systems, fouling and deposits are a serious problem which results in shutdowns, cleaning actions and unexpected costs for the customer.
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Opening the crude flexibility window: automation manages threats in real time
Sep-2018
By increasing the volume of quality data, refiners can automate the correct addition of chemical additives to respond to variations in unit performanc ...
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Mar-2018
Scalable simulation of crude unit operations enables refineries to build increasingly rigorous models to enhance performance
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Preventing ammonium salt fouling and corrosion
Jan-2018
Best practices and opportunities to reduce the risk of salt deposition and damage
-
Wastewater treatment for challenging crudes
Jan-2018
A new organic polymer treatment has enabled refiners to more effectively process a variety of opportunity crudes
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Silencing hammering in a condenser system
Dec-2017
Detailed analysis leading to correct diagnosis meant that only minor equipment changes were needed to cure severe hammering in a naphtha splitter.
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Controlling contaminants in vacuum gasoil
Nov-2017
How revamps can increase VDU capacity and reliability while controlling contaminant levels to acceptable limits.
-
Nov-2017
Thorough tank cleaning means removing all of the sludge and restoring the vessel’s full storage capacity.
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Model predictive control of a distillation unit
Jul-2017
In a coordinated plant process, particular attention must be paid to control of individual columns.
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Best practice desalting Part 1: crude flexibility window
Jul-2017
A replacement programme of desalter treatment chemistry transformed the operation of crude units struggling to meet performance targets
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Troubleshooting crude column constraints
Jul-2017
Multiple limitations to operating capacity were identified and resolved during a column turnaround
-
Correcting vacuum column design flaws
Apr-2017
Conventional design practices have been proven inadequate when maximising diesel recovery and gas oil cut point
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Balanced distillation equipment design
Feb-2017
Fouling resistance and efficiency requirements for distillation equipment are balanced and optimised for reliable unit performance.
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Turnarounds deliver process improvements
Nov-2016
An extended unit shutdown is relatively rare and an opportunity to take every advantage to improve performance.
-
Revamping crude towers for quality and yield
Nov-2016
A successful revamp of distillation towers for increased diesel quality and yield depended on reliable design and accurate assembly
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Simulating crude units with preflash
Nov-2016
Process simulation offers a cost effective way of testing ideas to improve yield and energy performance.
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Operating vacuum distillation ejector systems
Oct-2016
Best practices and opportunities to deliver reliable ejector system performance and reduce performance risk.
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Data analytics for hydrocarbon processing
Oct-2016
Advanced data handling techniques are transforming operations in the refining industry at an increasing pace.
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Troubleshooting vacuum systems
Oct-2016
Case histories of refinery vacuum tower problems solved are gleaned from five decades of experience.
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Dealing with desalter cleaning challenges
Aug-2016
How to overcome lengthy and potentially dangerous challenges when cleaning a crude unit desalter.
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A two stage approach to controlling fouling on preheat trains at OMV’s Schwechat refinery
Aug-2016
Fouling in heat exchanger preheat trains is a well-known problem in the refining industry. Fouling reduces exchanger performance, increases furnace duty, ...
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Loss into gain in high-capacity trays Part 2: reverse vapour cross flow chanelling
Aug-2016
Systematic troubleshooting diagnosed two complex problems that limited the capacity of an atmospheric crude distillation tower
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Enhancing fractionator efficiency
Jul-2016
Properly designed vapour and liquid distribution devices enable more effective distillation column efficiency.
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Loss into gain in high capacity trays - Part 1: excursion
Jun-2016
Systematic troubleshooting diagnosed and solved two complex and independent problems that limited the capacity of an atmospheric crude distillation to ...
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How dynamic pressure can affect vacuum column readings
Jun-2016
Computational fluid dynamics confirmed field measurements to explain a vacuum unit’s poor quality HVGO and was used to redesign the tower internals
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Optimising preflash for light tight oil processing
Jul-2015
For a crude unit handling light tight oil feedstock, a semi-preflash column can deliver significant advantages in energy saving, capacity gain and revamp ...
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Savings in exchanger network cleaning (TIA)
Jun-2015
The Super Clean System (SCS), an online heat exchanger cleaning technology, is being used by a major oil refiner in Japan at a refinery equipped with a ...
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High performance trays for a fractionator in an aromatics plant
May-2015
Distillation is a very important separation technology in refineries and downstream chemical processing. Mass transfer internals in distillation columns ...
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Enhancing energy efficiency in the CDU
Apr-2015
Revisiting your crude distillation unit may expose hidden potential for major energy savings
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Increasing distillate production at least capital cost
Apr-2015
Investing in improvements to the atmospheric crude unit can deliver increased distillate yields with short payback times
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Reducing vacuum tower pressure
Apr-2015
To create a better vacuum the vapour load to the ejector has to be reduced
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Revamping crude and vacuum units to process bitumen
Apr-2015
Revamping crude and vacuum units to process dilbit can involve extensive equipment replacement as well as major changes to the crude preheating scheme
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Light tight oil crude unit fouling root causes and troubleshooting
Mar-2015
Fouling in preheaters, crude furnace and atmospheric tower bottoms exchangers directly impacts throughput and profitability, requiring rigorous evaluation ...
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Asphalt quality prediction and control
Oct-2014
With knowledge of heavy vacuum gasoil cut-point and asphalt density, asphalt quality can be inferred
-
Shale feedstocks fuel ethylene, LNG and petrochemical derivatives expansion
Apr-2014
In spite of the variability in shale composition causing operational challenges for refiners, monetisation opportunities are seen throughout the energy ...
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Maximising the use of process energy
Apr-2014
Integrating a flash drum in an atmospheric and crude distillation unit offers the potential for savings and capacity enhancement
-
Myth of high cutpoint in dry 
vacuum units
Apr-2014
Accurate measures of true boiling point cutpoints are essential to correctly evaluate vacuum unit performance
-
Heat integration projects for 
refining processes
Oct-2013
Heat integration projects can deliver substantial savings, but they require detailed simulation and case-specific heat integration analysis
-
Strategies for improved naphtha processing
Oct-2013
To take advantage of dilbit from Alberta and light oils from shale formations, refiners must develop a strategy for processing additional naphthas and ...
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Towards a zero gasoline production refinery: part 2
Oct-2013
Refinery configurations can suit various processing objectives, such as variations to the propylene-to-ethylene ratio and production of middle distillates ...
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Improving the distillation energy network
Oct-2013
Energy-efficient design applied to the refit of a distillation unit was achieved through optimisation between the distillation column and heat network ...
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Online cleaning of an integrated distillation unit
Oct-2013
Online cleaning technology was validated during a scheduled turnaround at the second largest refinery in Poland.
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Energy-efficient vacuum systems
Apr-2013
Case analysis of the techniques available to reduce energy consumption in vacuum systems reveals the potential for cost savings
-
Online cleaning: a mindshift for improving operational excellence
Apr-2013
A patented method of chemical cleaning can reduce downtime arising from severe fouling in process units
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Jan-2013
Revamping a VDU’s vacuum system delivered operational improvements in a refinery, but also led to safer and more efficient handling of non-condensed ...
-
High-capacity tray for debottlenecking a crude distillation unit
Jan-2013
Use of ultra-high-capacity trays in the most constrained section of a CDU enabled over a 50% increase in throughput at less cost than other debottlenecking ...
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The age of turbulence: charting a course for refiners to a profitable future
Nov-2012
Relentless turbulence has profoundly affected the global refining landscape in recent years. Moreover, the turmoil is likely to continue unabated in the ...
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Designing a crude unit heat 
exchanger network
Oct-2012
Preheat train design for heavy Canadian crudes can be very challenging, requiring an approach not normally required with other crudes
-
Oct-2012
Inaccurate feed characterisation and process modelling errors are major contributors to poor performance in a vacuum unit as refiners switch to heavier ...
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Designing the CDU/VDU for opportunity crudes
Oct-2012
New units for processing heavy crudes should not be designed using conventional practices or run length will be short, and product yields and quality ...
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Integrated monitoring for optimising crude distillation
Jan-2012
On-line process analysers in crude distillation units prevent lost throughput caused by non-conforming process conditions and crude oil switching
-
Future of opportunity crudes processing
Oct-2011
Five critical drivers help refiners remain profitable and sustain long-term business goals while processing relatively inexpensive, low-quality crudes
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Crude column relief mitigation
Oct-2011
Mitigation of plant-wide relief loads can greatly improve the safety of the plant, reduce flaring and be used as the basis for building smaller relief ...
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Flow metering vacuum tower bottoms
Oct-2011
A clamp-on ultrasonic flow meter can make flow measurement at the bottom of vacuum distillation towers more reliable
-
Bitumen processing: crude unit revamps
Jul-2011
The ability to process bitumen offers a competitive advantage, but revamps of crude and vacuum units to process bitumen require significant changes
to ...
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Improving solids handling in a delayed coker
Jul-2011
A reliability model applied to a coke handling system demonstrates the benefits of compliance with a preventive maintenance programme
-
Improving crude unit operation
Jan-2011
Most crude and vacuum units present an opportunity for improvement using modern process control systems
-
Maximisation of VGO through deep-cut distillation for refinery margins
Jan-2011
Appropriate choice of crude and/or crude oil blends as feedstock and a vacuum tower revamp enable higher production of vacuum gas oil
-
Jan-2011
A process review, including the improvement of atmospheric and vacuum distillation columns, for the reformulation of the diesel pool
-
Online real-time optimisation helps identify energy gaps
Oct-2010
Real-time supervision of a refinery’s energy system enables optimisation of its fuel consumption and emissions levels
-
A balanced approach to vacuum tower flash zone/wash section design
Sep-2010
Revamping an existing vacuum column to operate at a higher feed rate, higher flash zone temperature, lower pressure, and different feed stock characterisation ...
-
Entrainment issues in vacuum column flash zones
Jan-2010
For a vacuum tower to operate effectively, the flash zone and the wash section must work together to provide the best possible feed quality to the sections ...
-
CFD study of a VDU feed inlet device and wash bed
Oct-2009
Analysis of vapour velocity profiles at the entry to the wash zone of a VDU column enables a higher feed rate and improved output quality
-
Cost-effective and reliable revamps
Jul-2009
Test run hydraulic measurements and analysis, together with equipment know-how, can help refiners identify profitable, low-cost revamp opportunities
-
Demystifying the zero entrainment myth for vacuum column flash zones
Apr-2009
One of the recurring questions about refinery vacuum tower operation is the issue of flash zone entrainment and the operation of the wash section.
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Stabilisation 
of asphaltenes
Jan-2009
Asphaltenes can plug refinery equipment and can decrease or stop production. Stabilisation of asphaltene particles is an efficient and cost-effective way ...
-
Online cleaning of 
process equipment
Oct-2008
In the interest of time and cost savings, online cleaning prior to shutdown can reduce the duration and complexity of refinery turnarounds, as demonstrated ...
-
Unlocking current 
refinery constraints
Apr-2008
When processing heavy feeds, technology based on residuum supercritical solvent extraction provides higher volumes of gas oil and DAO for conversion units. ...
-
Improving crude vacuum 
unit performance
Mar-2008
When simulating or designing an unconventional heavy oil/bitumen vacuum crude unit, the sharing of operating data on cracked gas make, stripping section ...
-
Identifying very small 
equipment leaks
Jan-2008
Very small leaks in feed/effluent exchangers can be identified using chemical tracing. This online technique can detect leaks as low as 5.0 ppm, avoiding ...
-
Canadian crude processing challenges
Jan-2008
Vacuum unit design influences liquid volume yields, run length, product 
yield and product quality when processing bitumen crude oils
-
Oil/water interface control for desalters
Oct-2007
Profiling instrument provides vertical real-time phase density measurement in desalter vessels. Benefits include reduced process upsets from interface ...
-
Revamping atmospheric crude heaters
Sep-2007
Revamp of an atmospheric crude unit heater suffering from coking caused by asphaltene precipitation resulted in an increased heater run length
-
Identifying poor heat exchanger performance
Sep-2007
Identifying root causes of poor crude unit debutaniser reboiler performance and low-cost solutions that help meet exchanger original design conditions
-
Sep-2007
Primary goals of a lube vacuum column revamp were to increase lube product fractionation and minimise HVGO product contaminants
-
Crude overhead system design considerations
Jul-2007
Proper crude unit overhead system design is important when building a new unit or revamping an existing one to process different crudes
-
Jan-2007
Gamma scanning is a powerful tool that can be used to determine the cause of flooding and regain column efficiency. Debutaniser capacity and performance ...
-
Vacuum unit design for high 
metals crudes
Jan-2007
Vacuum unit design can influence vacuum gas yield, product quality and run length. A wet vacuum unit with residue stripping achieves the highest cutpo ...
-
Evaluating opportunity crude processing
Oct-2006
Is processing opportunity crudes for every refiner? Technical challenges and economic benefits from processing high-acid crudes and bottom-of-the-barrel ...
-
Sep-2006
Operational issues such as higher heater duty and column pressure must be weighed against avoiding residue entrainment in HVGO
-
Refinery CO2 challenges: part III
Jul-2006
For the prediction of CO2 emissions from a refinery, simple correlations are not always sufficient. A rigorous simulation tool that includes fractionation ...
-
Apr-2006
When designing vacuum units for processing heavy Canadian crudes, reliability costs can be high if the feedstock’s thermal instability is not fully ...
-
Jan-2006
Cost-effective exchanger network solutions need to rely on more than just pinch technology if they are to be successful
-
Oct-2005
Fundamental design considerations influencing diesel and vacuum gas oil (VGO) recovery when revamping existing or designing grassroots crude units. By ...
-
Oct-2005
Process modelling and equipment know-how are needed to design deep-cut vacuum units that operate reliably at high temperature and low pressure
-
An atmospheric crude tower revamp
Jul-2005
Overall gas oil yield was maintained with heavier crudes due to a crude tower revamp. The revamp allowed for a crude heater outlet temperature reducti ...
-
Increasing vacuum tower performance
Oct-2004
Advantages of using gravity flow liquid distributors in services where, historically, spray nozzles have been used, specifically in refinery vacuum tower ...
-
Oct-2004
Installation of vortex tube clusters in crude unit preflash drums has eliminated foam carry-over, increasing diesel and atmospheric gasoil product yie ...
-
Why vacuum unit fired heaters coke
Oct-2004
A description of the internal workings of vacuum heaters and the causes of coke formation within them
-
Choosing a neutralising amine corrosion inhibitor
Jul-2004
A review of physical and chemical properties of commonly used amine-based corrosion inhibitors. The authors highlight the relative strengths and weaknesses ...
-
Consider retrofits to handle high-viscosity crudes
Mar-2004
In 2000, ConocoPhillips’ refinery in Sweeny, Texas, began processing 16° API gravity blends of extra-heavy crude oils, including Merey 16 and BCF 1 ...
-
Crude column revamp using radial temperature profiles
Sep-2003
Designers need to be aware of all the factors influencing packed bed performance such as feed zone mixing problems
-
Crude unit start-ups: the results of a 
high liquid level
Sep-2003
Pressure-measurement techniques can avoid the dangers of rapidly changing flow rates and levels during start-up
-
Sep-2003
Case studies show how accurate field-measured differential pressure can be interpreted incorrectly when troubleshooting refinery vacuum columns
-
ULSD production: improved feed stream quality
Apr-2003
Much of hydrotreater revamp investment costs in future will be in dealing with the most difficult-to-remove sulphur species, because of their low reaction ...
-
Specifications — importance of getting them right
Mar-2003
Faulty equipment specifications sometimes carry unforeseen penalties, with loss of performance. It is the process design engineer’s responsibility to ...
-
Vacuum unit design effect on operating variables
Jul-2002
To revamp vacuum units, process modelling and equipment design know-how are needed, and the understanding of connected equipment performance can lead to ...
-
Crude unit revamp to increase diesel yield
Apr-2002
Account of a crude vacuum unit revamp where detailed calculation of the true performance of existing equipment raised diesel production by 14.5 vol% on ...
-
Improved conceptual process design avoids revamp scope growth
Mar-2002
For grassroots design, defining project scope is a straightforward exercise. Grassroots projects can follow optimum execution procedures for engineering ...
-
Revamping conceptual process design
Jan-2002
With the desirability of getting the maximum use out of existing equipment when revamps are planned a rigorous approach to CPD is required to avoid scope ...
-
Vacuum pressure control: impact on profitability
Jul-2001
Optimisation of flash zone pressure and temperature can improve feedstock quality to downstream units
-
Avoiding unscheduled shutdowns
Apr-2001
Case studies have demonstrated that correct heater design and consequent performance will determine crude unit run length
-
Practical considerations for crude unit revamps
Oct-1998
Two examples are used in this article to illustrate how changes in the process flow scheme can increase preheat train heat recovery
-
Troubleshooting vacuum unit revamps
Jul-1998
While vacuum unit revamps increase gasoil yield, management is pushing the intervals between turnarounds to four or five years
-
Reducing the danger of maintenance exposure
Apr-1998
Maintenance cost overruns result from inadequate cost estimating and the emergence of unidentified work that has to be done
-
Revamp process design — optimum crude unit product yields
Jul-1997
Designing a new crude unit is an unconstrained process, limited only by capital
investment targets, while revamping an existing unit to optimise ...