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These digital transcripts are meant to share information on process safety practices in order to help improve process safety performance and awareness throughout industry. The goal is to capture and share knowledge that could be used by other companies or sites when developing new process safety practices or improving existing ones. The documents being shared have been used by an industry member, but this does not mean it should be used or that it will produce similar results at any other site. Rather, it is an option to consider when implementing or adjusting programs and practices at a site. ​

BY THEMSELVES, THESE DIGITAL TRANSCRIPTS ARE NOT STANDARDS OR RECOMMENDED PRACTICES. THEY ARE NOT INTENDED TO REPLACE SOUND ENGINEERING JUDGMENT. THEY DO NOT PRECLUDE THE USE OF ALTERNATIVE METHODS THAT COMPLY WITH LEGAL REQUIREMENTS. A SUBJECT MATTER EXPERT SHOULD BE CONSULTED PRIOR TO DETERMINING WHETHER A PRACTICE CAN BE USED IN ANY SPECIFIC SITUATION. 

​

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(2018) Question 49: As the demand for higher octane gasoline components increases and lobbying for a 95 RON gasoline standard continues, how are you adjusting your operations to meet the market demand? What FCC specific changes do you make to produce higher octane gasoline components?

Refiners are optimizing their gasoline blend components to maximize high octane components. Alkylate and reformate yields are becoming increasingly important, as well as minimizing low octane component yields. The emergence of tight oil feeds has created an increase in low octane natural gasoline and LPG saturate production.
Read more

(2018) Question 50: Butylene demand and prices in relation to other refined products reached a record level in 2017. What caused it and what can we do in the FCC to produce more butylenes?

Higher demand for butylene is result of octane shortage in the gasoline market stemming from several main causes.
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(2018) Question 55: With new challenges presented by the Refinery Sector and Maintenance Venting Rules oil circuits are taking longer to prepare for maintenance; what successes and challenges have you had in staging shutdown operations to allow for safe entry to the FCC reactor/regenerator section prior to clearing other sections of the unit?

With new challenges presented by the Refinery Sector and Maintenance Venting Rules oil circuits are taking longer to prepare for maintenance; what successes and challenges have you had in staging shutdown operations to allow for safe entry to the FCC reactor/regenerator section prior to clearing other sections of the unit?
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(2018) Question 56: Excluding nickel passivation. How does antimony use in the reactor riser impact the FCC operations and equipment?

Antimony functions by attaching to a fresh Nickel molecule in the FCC feed and preventing it from laying down on the surface of the catalyst. Efficiency of antimony in passivating Nickel and tendency to have side effects is highly dependent on the carrier and distribution method. Antimony can be water based or oil based, with oil-based antimony having a higher lay down efficiency (approx. 85% typical) as compared to water based (approx. 65%).
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(2018) Question 57: How are you optimizing the use of wet gas scrubbers caustic use and SOx additives?

You can utilize a SOx additive in addition to a Wet Gas Scrubber system in order to reduce caustic consumption and minimize cost. Utilizing a SOx additive can be optimized by calculating the caustic savings + value of additional liquid sulfur produced - the cost of the Sox additive.
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(2017) Question 20: What is your Best Practice for handling temperature excursions for hydrocrackers? Is a manual or automatic control system best?

Automatic depressuring on a “defined” temperature excursion is the procedure considered to be Best Practice and can be used to prevent the potential failure of the reactor outlet elbow or line. Automatic depressuring retrofits to existing units continues in industry.
Read more

(2017) Question 21: What are some of your typical examples of integrity operating window (IOW) types which are specific to hydroprocessing? What technique do you use to determine severity level of IOW alarms? How do you coordinate operator response to IOW alarms?

Hydroprocessing is an area that is somewhat unique in refining in the sense that it has everything that you do not want for mechanical integrity: high temperature, high pressure, and a process that can run away at both, as well as high concentrations of hydrogen sulfide and hydrogen; and just to make things fun, injection of water into the process.
Read more

(2017) Question 22: A) What has been your experience with hydrogen leaks to cooling water systems and the resulting impacts? B) What are your findings and recommendations from major associated incidents?

I have seen an instance where hydrogen leaking to a cooling water system was detected by a local VOC monitor at the cooling tower. The source was isolated as a pinhole leak at the hydrocracker unit’s makeup hydrogen cooler.
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(2017) Question 23: When shutting down a reactor, what is your current Best Practice for measuring CO (carbon monoxide) in a mostly hydrogen/nitrogen atmosphere to assess the carbonyl concentration? Is the steel a potential source of zero-valence metal necessary for carbonyl formation? If so, does that cause a corrosion concern for equipment that normally operates in the temperature range favorable for carbonyl formation?

When shutting down a reactor, what is your current Best Practice for measuring CO (carbon monoxide) in a mostly hydrogen/nitrogen atmosphere to assess the carbonyl concentration? Is the steel a potential source of zero-valence metal necessary for carbonyl formation? If so, does that cause a corrosion concern for equipment that normally operates in the temperature range favorable for carbonyl formation?
Read more

(2017) Question 24: What are you doing to meet the Euro VI/BS VI/China VI fuel quality specifications for gasoline and diesel product streams?

This is a global question, so I will try to give you a broad answer. Looking at the specifications, you will notice that whether it is Euro VI, a Bharat stage VI, or a China VI, the specifications are similar with minor variations. All of them are attempting to get to the 10 ppm (parts per million) level for the sulfur while trying to reduce aromatics and olefins in the fuel. This is the general intent of all the specifications and changes happening globally. 
Read more

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