Unit - Exxon Powerformer
Catalyst - Exxon
This unit had short cycles and lower than predicted yields of reformate and hydrogen. There was a higher than predicted coke make on the catalyst that could not be resolved by the licensor, the refiner's consultant, or the refiner. RES was called in to analyze the problem. Through observation of the operating unit and later a detailed mechanical inspection of the unit when it was down and evaluation of all operating procedures, RES was able to define the causes for the performance problems. RES recommended modifications in the reactor internal design and modifications in the operating procedures for normal operation and catalyst regeneration and start up procedures. All of these recommendations were implemented. RES conducted training classes for the operators and the engineers. The results were as follows:

Unit - Catalytic Reformer
This unit had a series of short operating cycles between regenerations. The licensor was consulted but did not make recommendations to solve the problem. The catalyst vendor's catalyst regeneration specialists were called in to direct the catalyst regeneration prior to RES involvement but the short cycles and the high catalyst deactivation rates persisted. RES was called in to analyze the problem. Through observation of the operation of the unit and later a detailed mechanical inspection of the unit when it was down, and evaluation of all operating procedures, RES was able to define the causes for the performance problems. RES recommended modifications in the reactor internals and modifications in the operating procedures for normal operation and catalyst regeneration and start up procedures. These recommendations were implemented and the unit performance was improved to normal.

Unit - Catalytic Reformer
This unit had 2 extremely short cycles back to back. The licensor's catalyst regeneration experts had helped on one of the regenerations and a sulfur removal step was conducted. The following cycle was extremely short. RES was called in to analyze the problem. The unit operation was observed by RES. The procedures were reviewed and the unit piping was traced out. RES recommended changes in the operating procedures and in the catalyst regeneration procedures. RES helped with the catalyst regeneration and the unit start up. During the regeneration, RES discovered a line that had 3 closed block valves without double blocks and bleeds where a leak from the naphtha desulfurizer could leak into the system during regeneration. Testing this line proved that all three valves were leaking and recycle gas from the naphtha desulfurizer was leaking into the system during the catalyst regeneration. This gas contained H2S and the contamination was causing sulfate to form on the catalyst resulting in platinum agglomeration on the catalyst. A blind was installed and a sulfur removal step was conducted. The subsequent cycle was a record on the unit.

Unit - UOP Platformer
Catalyst - Englehard
This unit had a history of short cycles and poor catalyst performance as well as a corrosion problem in the fin fan product condensers. RES was called to investigate the poor catalyst performance as well as the corrosion problem in the back end of the unit. The operation was observed by RES and all of the piping was traced out. The equipment was checked including the recycle compressor. Inspection of the piping arrangement by RES revealed 2 sources of leaks of sour (H2S containing) material into the Platformer reactor circuit during normal operation. These potential problems were eliminated. RES made recommendations to change the design of the neutralizing system used during catalyst regeneration to solve the corrosion problem. These changes were made and the corrosion problems were solved by these changes and other changes recommended by RES concerning the catalyst regeneration procedure. RES recommended changes in the normal operating procedures and the procedures used for catalyst regeneration, catalyst reduction and unit start up. RES conducted catalytic reforming training classes for the engineers and the operators. RES helped with the next catalyst regeneration and start up. The following operating cycle on the catalyst set a record for the unit and the unit was able to achieve high octanes at low catalyst deactivation rates. The cycle length was increased by more than a factor of 2. The C5+ yield increased and the hydrogen production was increased. There was also an increase in the recycle gas hydrogen purity.

Unit - Catalytic Reformer with Continuous Regeneration
Catalyst - Criterion
This unit had had a problem with the production of catalyst fines since its initial start up. RES was asked to help by inspecting the unit during a downtime. RES successfully defined the problem and recommended changes. The refiner subsequently made the changes which resulted in solving the fines make problem on the unit.

Unit - Catalytic Reformer with Continuous Regeneration
Catalyst - Undisclosed
This unit had experienced problems with platinum redistribution in the regeneration section of the unit. RES was asked to help define and solve the problem. RES performed a detailed inspection of the regenerator with the client. RES has defined the cause of the problem and now calculations are being made in preparation for a solution to be proposed to the client.

Unit - UOP Platformers (2)
Catalyst - Undisclosed
This refiner was experiencing low yields and low hydrogen makes on both Platformers in the refinery. RES was asked to investigate the problems. RES traced out the piping in both units, reviewed the unit design and observed the operation of both units. RES helped with the turnarounds on both units including planning the turnarounds, mechanical inspection, catalyst loading and repairs made on the units due to problems identified during the inspection. RES recommended changes in the unit operating procedures, the catalyst regeneration procedures, the catalyst reduction procedures and the unit start up procedures. These procedures save time and result in improved performance of the units. RES conducted catalytic reforming training classes for the operators and the engineers and helped with the catalysts regenerations and the unit start ups. Subsequent operation has shown an improvement in C5+yields and an improvement in hydrogen production. Catalyst cycle lengths have also improved.

Unit - Catalytic Reformer
Catalyst - Criterion
This unit had a problem of high catalyst deactivation rates resulting in short catalyst operating cycles. RES was asked to investigate the problems. RES was also asked to investigate ways to improve the unit performance. RES observed the unit operation and reviewed the unit design. RES was asked to help with the unit turnaround including the mechanical inspection of the unit, catalyst loading, catalyst regeneration, catalyst reduction and unit start up. Mechanical inspection by RES revealed some discrepancies between the as built unit and the intended design of the unit. These discrepancies had resulted in improper catalyst loading which in turn had resulted in a blown seal at the top of the reactors. This flaw had likely imposed significant financial losses to the refiner due to bad flow distribution through the catalyst beds and the resulting decrease in C5+yields. RES recommended changes to the reactor internals and the catalyst loading were made during the turnaround. RES recommended changes in the normal operating procedures, the catalyst regeneration procedures, catalyst reduction procedures and the start up procedures after regeneration. RES conducted training classes on catalytic reforming for the operators, supervisors, and the engineers. By using the RES procedures, significant improvements were made in catalyst cycle length as measured in barrels processed per pound of catalyst. Improvements were also achieved in C5+yields and hydrogen production.

Unit - UOP Platformer
The first reactor in this unit was a cold wall design. Because of high maintenance cost, the refiner replaced the reactor with a used hot wall design vessel. The used vessel came with no reactor internals. RES designed the new radial flow internals and the performance has been excellent since the reactor has been put on line.

Unit - Catalytic Reformer
Catalyst - Englehard
This unit had a history of short cycles. The design separator pressure was below 200 psig and the design H2/HC ratio was lower than similar units. The unit was run at relatively high octane. The longest cycle since the unit was built was 6 months. The catalyst suppliers had helped in the past with the catalyst regeneration and start up. The catalyst suppliers, the unit designers, the refiner's consultant and the refiner were unable to resolve these problems. RES was called in because of a corrosion problem on the fin fan product condensers. RES observed the unit operation and traced out all the piping and reviewed the equipment including the recycle compressor. A problem was identified in the seal oil system of the centrifugal recycle compressor which was causing seal oil to leak into the process during normal operation. This problem was corrected. The corrosion problem was identified. It was caused by an improper design of the neutralizing system used during the catalyst regeneration operations. The catalyst regeneration procedure being used also contributed to the corrosion problem. A new system was designed by RES and this system was installed. The corrosion problem was solved.

RES analyzed the lack of proper performance on this unit. Recommendations were made to change the normal operating procedures as well as the procedures used in catalyst regeneration and start up. RES conducted training classes for the operators and the engineers on catalytic reforming and hydrocracking. RES helped with the following catalyst regeneration and start up. The following cycle was a record for the unit. The C5+ yield increased by more than 1 liquid volume percent and the hydrogen production increased by about 200 scfb. The recycle gas hydrogen purity increased about 2%. The catalyst operating cycle length on the unit was increased by a factor of more than 2.5.

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Unit - Hydrocracker Unicracker
Catalyst - Union/Criterion
This unit had reliability problems with the reciprocating hydrogen make up and recycle compressors. A corrosion problem was also being experienced in the back end of the plant. The unit capacity was also limited by heater limitations. RES was contacted to investigate these problems. RES made recommendations on the compressors to improve the reliability. These recommended changes were made and the compressor reliability was improved. RES simulated the entire hydrocracker circuit. A charge heater limitation problem was identified. RES recommended a two step change approach to improve the performance of the unit and to increase the unit capacity. The first change was implemented which allowed the unit to run at record capacity. The complete revamp modification has not yet been made.

RES helped with new RES catalyst manual dense loading techniques. RES also wrote new operating procedures for sulfiding and start up as well as emergency procedures on the unit. RES conducted training classes for the engineers and the operators on hydrocracking.

Unit - Hydrocracker
Catalyst - Chevron/Criterion/UOP
This unit had a histroy of poor flow distribution across the catalyst beds in both reactors since the original start up in the 1960's. The licensor had redesigned the trays in a unit revamp but the distribution problem persisted. The unit was difficult to control and temperature runaways were frequent. Because of the distribution problem, high zeolite catalysts could not be used in this unit. RES was asked to investigate this problem. RES traced out the piping and analyzed the design of the reactor internals. Recommendations were made to change the design of the reactor internals. The RES recommended changes were made and the subsequent run proved that the unit was quite easily controlled because of the good flow distribution across the catalyst beds. Before the reactor internals modification, the radial differential temperature profile in the reactor was as high as 50 degrees F. After the modification, the radial profile is normally 5 degrees F or less. High zeolite catalyst was put in the unit and the performance is excellent. The modifications resulted in lowering the amount of quench gas necessary to control the bed temperatures. The yields of valuable products increased and the gas make decreased.

Unit - Hydrocracker
Catalyst - AKZO/UOP/Criterion
This large hydrocracker had a history of poor flow distribution across the catalyst beds in both reactors since the original start up in the early 70's. The licensor had redesigned the trays in a reactor internals revamp, but the redistribution problem persisted. RES was asked to investigate the reactor after a run with Akzo Catalyst. RES inspected the reactor internals and made recommendations. The catalyst type was changed but all of the recommendations were not followed. The following cycle RES was asked to evaluate and redesign the reactor internals. RES redesigned the reactor internals, including the mixing arrangement and the catalyst support grid as well as other components. The catalyst was changed and the flow distribution across the catalyst beds as indicated by traverse temperature profile mesurements are better than they have ever been.

Unit - Hydrocracker
Catalyst - Union/Criterion
This unit had a history of low yields of high value products. RES was asked to investigate the problems and help with a unit turnaround and catalyst change. RES observed the operation and traced out the piping. RES recommended a change in catalyst type that resulted in an increase in jet fuel production of more than 10 liquid volume percent and an increase in the overall conversion. RES helped in planning the turnaround and inspecting the equipment. RES wrote the start up and sulfiding procedures as well as unit emergency procedures. The refiner adapted these procedures to the unit.

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Unit - Naphtha Hydrotreater
Catalyst - Criterion
For approximately one year of operation, this unit had experienced excessive fouling in the feed-effluent exchangers. The run lengths were typically in the range of 3 to 5 weeks before high pressure drops necessitated shutdowns. Downtime was approximately 5 to 7 days per occurrence for exchanger cleaning and corollary problems associated with the reactor heater restart. A costly complete unit revamp of the heat exchange system including buying new exchangers had been planned by the refiner. RES was called in to analyze the problem. RES observed the operation and properly defined the root cause of the problem. RES recommended minor changes in the piping and processing and the moving of one piece of existing equipment. These changes were implemented and the run length is now completely normal for this operation. The average run length was increased by more than one year. There is essentially no excessive pressure drop or fouling problem. Significant savings were realized by the refiner by avoiding the cost of the expensive exchanger revamp that had been proposed. The savings in capital investment alone are estimated to be more than $.75MM.

Unit - Diesel Hydrotreater
Catalyst - Criterion
RES was asked to provide consulting serivces on this unit with process design and the reactor internals design and installation. Prior to the reactor internals installation, RES helped the refiner in the reactor internal design and catalyst loading review. Later when the trays were installed in the reactors, RES helped with the tray installation and inspection. Because RES tray installation techniques were used, the tray levelness easily exceeded the licensor's specified levelness requirements. Significant cost savings and time savings were realized by the refiner due to RES working with the contractor during the tray installation process rather than conducting a post installation inspection which would have resulted in much rework.

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Unit - 1950's Generic Catalytic Reformer (Revamped to a licensed unit.)
Catalyst - Undisclosed
This unit had a problem with high coke make, low C5+yields, low hydrogen production and short catalyst operating cycles. The operation was limited to low octane because of these factors. RES was asked to investigate these problems. RES traced out the unit piping, observed the unit operation, and reviewed the reactor internal designs. RES recommended that changes be made to the reactor internal designs and that a modification be made in the reactor circuit to improve the measurement of the recycle gas. RES made a detailed mechanical inspection of the unit during the turnaround. Based on the inspection, more changes were recommended to the reactor internal design. All of the RES recommended changes to the reactor internals were implemented. RES also recommended changes in the catalyst regeneration, catalyst reduction and unit start up procedures that save time and result in improved performance of the unit. RES conducted operator and engineer training classes on catalytic reforming. The enhanced unit performance since implementing these changes has resulted in an increase in C5+yields of more than 1% and an increase in hydrogen production of about 200 scfb. The cycle length as measured by barrels per pound of catalyst had more than doubled. The unit is no longer octane limited and high octanes can be achieved at will.

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Unit - UOP Fluid Catalytic Cracker
Over a period of approximately one month the refiner had experienced a number of operational and mechanical upsets on this unit. These upsets resulted in excessive downtime, large catalyst losses, high maintenance costs and complaints from environmental authorities. RES was called in to analyze the problems and make appropriate recommendations to improve operation. RES reviewed Incident Analyses and other reports and data relative to the upsets to help confirm the accuracy of the analyses. Additionally, the refiner's recommendations as to corrective future actions were evaluated and commented upon. RES reviewed startup and operations procedures and made recommendations. RES participated in the inspection of the regenerator, made suggestions as to repairs and assisted in making plans for future operator training. Recommendations regarding mechanical improvements during future turnarounds were developed and submitted to the refiner. RES observed and assisted with the successful re-startup of the unit.

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Unit - Englehard Magnaformer
This unit was revamped for lower reactor pressure operation. A Pakinox exchanger was installed in the reactor section. Problems were encountered with pressure drops in the Pakinox exchanger. RES was asked to investigate the problem. The problem was correctly defined. RES simulated the unit for several cases each of which involved changes in equipment location to optimize the operation at the present time. Modifications to the recycle compressor were also evaluated. RES recommended two options on the solution to the problem. The refinery is presently evaluating these options with the help of RES.

Unit - Englehard Magnaformer
This unit had internal refractory insulation in the reactors. One of the reactors had frequent failures of the internal lining resulting in hot spots on the outside vessel wall. RES was asked to investigate the problem and made recommendations for a permanent solution to the problem.

Unit - Englehard Magnaformer
This was an old unit with internal refractory insulation in the reactors. The performance of the unit indicated lower than expected yields. RES was asked to investigate the problem. RES recommended to modify the reactor internals. RES designed the new internals. They were built and installed in the reactors and the performance of the unit improved. The yields improved and the run length between regenerations also improved.

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Unit - Complete Refinery Flare Evaluation and Design
To comply with PSM rules the refinery was required to document the design of the flare system in the as built refinery. RES was the successful bidder on this job. RES identified the problem areas and then recommended changes in the relief system to minimize the cost of the required changes. RES designed a new flare system. While tracing out the piping in the units to identify locations of the required relief valves, RES identified a significant energy savings project in one of the units. RES made recommendations to modify the system in order to save significant energy. The recommended changes were made and the project had a 6 month payout. Subsequent to this flare design evaluation, RES has performed other extensive evaluations of flare designs.

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