Is there scope for significantly reducing fractionation furnace energy consumption for FCC and hydrocracker product recovery sections?

Currently we are facing problem of higher CO (Carbon Monoxide) and CO2 contents in the Net Gas (Net Gas is H2, produced in CCR Platforming Unit). This CO is affecting UOP's Penex Unit Catalyst. Please help finding out the source of CO & CO2 and guide how to reduce both in the Net Gas (our main focus is on reduction of Carbon Monoxide as it is a permanent poison for Penex Catalyst).

How can we recover heat from boiler flue gas by maintaing dewpoint temperature?

How can we control the undesirable reactions in catalytic naphtha reforming (SRR Unit) (fixed bed reactors) in order to enhance the Octane Number and Hydrogen Purity?

Crude Tank (Floating Double Deck Pontoon) is preparing to take crude oil (API29) for the first time. Is it safe to put crude directly in to the tank without Oxygen freeing? If water is first taken into the tank up to the floating level and then charge the crude, is it more safer?

Considering that new catalyst formulations play a significant role in successful reactor performance, what else is necessary for optimal reactor/catalyst performance?

In the transition to digital worker and enablement solutions using predictive analytics and remote monitoring, how much input does the end-user have in creating the ‘dashboard’?

What do you see necessary for successful implementation of plant-wide AI and machine learning (ML) in the refinery and petrochemical complex? Can AI/ML strategies provide additional benefits beyond APC?

With the enormous potential for reducing the refinery carbon footprint by increasing direct fired heater efficiency, what successful cases provide an example of increased efficiency and reduced emissions?

In our DHDT unit stripper bottom doctor test result is positive while after taking sample test from vacuum drier bottom result is negative, what could be possible reasons. Stripper feed is heat exchanged with stripper bottom and then stripper bottom routed to drier. We are maintaining stripper inlet temperature around 260deg C. HP steam temperature at stripper inlet is 280 degC.

Considering more stringent NOx reduction requirements in the refining and petrochemical industry, what are the optimal strategies for reducing NOx emissions from process heaters and SMR/PSA heaters?

In my sulphur unit we had pollution of the pit, the sulphur is ok in quality but its colour is between green and yellow. Do you have any idea of ​​the possible origin of this colour?

What are impurities in alkylation spent sulphuric acid? Is there Chloride or Flouride in such spent acid?

I am currently looking after mechanical maintenance of Delayed Coker unit (DCU). We are witnessing frequent leakage issues in our plant due cyclic loading and unloading of Coke drums. Please suggest concrete solution either to resolve the issue or to mitigate the same and increase MTBF.

Our (SRR) reforming catalyst (Pt/Re) experience high moisture (water content) in feed, we inject chlorine as PDC ( C3 H5 Cl2 ) (sp.gr=1.13) for that. Our reforming unit with capacity 40 m³/hr (Heavy Naphtha, sp.gr=0.745) and the moisture = 100 ppm, 30 ppm respectively, how much PDC must be injected per hour? What's the concentration of chlorine (Cl) ppm ?

There are many possible methods for process cost allocation. How do your refineries allocate costs for calculating the production costs of the final products?

Crude unit is usually seeing water shots due to insufficient tank settling time, However, as soon as DCS operator notices increase in Desalter amps he first suspects high water carryover from Crude. Therefore, he reduces wash water make up to Desalter to reduce net incoming water to Desalter. As per our refinery Desalter control philosophy, Desalter water level is controlled by outgoing brine and wash water flow set point has been given as per requirement. So whenever there is water carryover with crude is occurring, manual intervention is required to control wash water make up. The query is, has any refinery tried to change the control philosophy of desalter to control desalter interface level with wash water addition rate and fixing the outgoing brine flow based on wash water flow requirement% basis. This is to reduce operator intervention during water shot upset.

At our refinery we recently observed damage on the top of the radiant roof tubes of our VDU fired heater (2 parallel cabin radiant sections and 1 common convection section), clearly caused by long term operation at too high tube wall temperature. This is different from the issues we had in the past, where hotspots were mainly located on the bottom of the radiant tubes.

During the run we can't monitor this location with IR camera, thus the high temperatures could not be detected.

After restarting the unit the newly installed skin temperatures confirmed this area of the furnace is running at ca. 100 degC above the rest. Possible contributing factors are the presence of roof tiles just above the interested 8" and 10" tubes and the fact that the furnace was revamped to low-NOx burners 2 TARs ago.

Do you have any experience of high temperatures on the top side of the radiant tubes and possible mitigation measures / modifications to be carried out?

How can catalyst circulation rate and feed rate be related for promoting Naphthene dehydrogenation and paraffin dehydro cyclization reactions, desired reactions in CCR?

In our Regenerative Caustic Treatment System, a naphtha current is added to aid in disulfide removal. Thus, the residual gas stream from the three-phase separation vessel of the oxidation section has the presence of hydrocarbons (Oxygen, nitrogen, and HC's). Which is the best destination for this stream in the refinery (Coking furnace firebox, flare, knockout fuel gas and knockout centrifugal compressor knockout drum, others)?

In Crude Distillation Unit CDU, we inject caustic soda (NaOH) for treating salts in crude oil (<= 20ppm ), but if the concentration of the salt in crude became too high (e.g 40ppm), desalter (desalting system) is required for that. The query is, if the desalter is out of service, what procedures are to be taken for treating salts? And what are the disadvantages of increasing the injection of caustic soda (NaOH)?

New constructed crude tank (Double Deck Pontoon Floating Roof) is going receive crude oil (29 API). What should be the status of the tank? Filled with water just up to floating level or keep the tank empty?

In catalytic reforming Process:
- increasing the initial boiling point leads to increasing in hydrogen production. Any Explanation ?
- How can we increase the purity of the hydrogen (recycle gas) ?
- What is the maximum allowable moisture (ppm) in the feed (Heavy Naphtha) ?

We have taken recently two shutdowns of DHDT unit due to HHPS overhead exchanger leak (CLPS HC to stripper vs HHPS overhead gases), leading to sudden increase in stripper overhead pressure. What can be possible reasons?

What is your experience with utilisation of internals in Riser? What are the expected benefits in delta pressure and yields?