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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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(2008) Question 89: What are the typical problem areas for CCR catalyst circulation loops? What are the most reliable valve types? How frequently do you conduct fines surveys and what is a reasonable range for fines make?

GRUBB (Chevron U.S.A., Inc.) My experience here is with the design of a new unit in Pascagoula. So we went to the other CCRs within the Chevron system and asked this question already on how to increase our reliability with that project. This is a roundabout answer arranged from all the different operating ones. On the valve types, I’ll just state that all of Chevron’s experience is with the UOP designs and what we do is we specify soft seat on the “V” notch ball valve wherever the catalyst flow must be stopped. We use a double-seated plug and globe “G” valves on the vents and spring loaded “B” ball valves for the gas tight seal on the catalyst transfer line.
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(2019) Question 2: We have a Selective Hydrogeneration Units (SHU) unit that removes butadiene from the olefin feed to the alkylation unit. What is the typical concentration of hydrogen and light ends in the olefin product leaving the SHU? How do hydrogen and light ends affect alky operations?

THOMAS PORRITT (Chevron U.S.A)
A selective hydrogenation unit or SHU converts diolefins to olefins in a stream before it feeds an alkylation unit.

Below is a basic flow scheme.

Figure Q2 - 1 Selective Hydrogenation Unit Flow Scheme

The typical composition of non-condensable gases and light

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(2019) Question 3: What is your experience with ball valves in feed and make-up gas drier circuits in ISOM Units? What strategies have you adopted for monitoring leaks, regular maintenance and achieving longer run length?

DAVINDER MITTAL (HPCL Mittal Energy)

The gas and liquid dryers perform important task of safeguarding the ISOM catalyst from water vapor and other impurities in the make-up hydrogen and hydrocarbon feed.
The dryer switching valves play an important role of directing the inlet/outlet gas streams

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(2019) Question 4: What are your best practices for controlling caustic strength in an isomerization unit scrubber? How frequently is the caustic refreshed?

It is quite important to optimize PERC injection in feed as guided by technology supplier as otherwise the HCl concentration in off gas can go too high (normal range 1500 - 2500 ppm). This will lead to rapid depletion of caustic strength due to neutralization effect, thereby requiring frequent fresh caustic make-up.
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(2019) Question 5: How will Tier 3 rules impact gasoline-producing units at your facility?

ABIGAIL SLATER (HollyFrontier)
The Tier 3 gasoline regulation partially took effect in 2017 and will be fully implemented in 2020. The Tier 3 gasoline regulation has impacted the refining industry in a myriad of ways as refiners reduce sulfur further. These impacts will be similar to most refineries

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(2019) Question 6: What is your main blending limit for gasoline for both summer and winter specs?

ABIGAIL SLATER (HollyFrontier)
Gasoline blending specifications are vast and different in various geographical areas. The common blending limit that taxes both summer and winter specifications are volatility specifications. Depending on the gasoline blend, Reid Vapor Pressure (RVP), Total vapor over

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Question 7: What are your typical precious metal recoveries from reforming catalysts? What factors impact this?

BILL KOSTKA (AXENS NORTH AMERICA)
Reported platinum recoveries from reforming catalyst following commercial utilization have typically ranged between 90 and 100 wt% and have rarely been less than 80 wt%.  The magnitude of this range is both frustrating and at least somewhat explainable.

How one

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Question 49: In the past year, a sulfuric alkylation unit released a significant amount of sulfur dioxide to atmosphere when light hydrocarbon flowed from the reaction zone through the acid blowdown system and into the spent acid tank. What measures do you recommend for preventing this?

We would recommend ensuring that the acid knockout drum be sized large enough to allow the hydrocarbons to disengage in the drum.
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Question 51: Reforming unit stabilizer column top trays and overhead condensers can experience fouling with ammonium chloride salts, which are commonly removed by online water washing of the column overhead. What practices do you employ to reduce the risk of rapid corrosion and the potential failure associated with this fouling and subsequent water washing procedure?

Ammonium chloride salts are a common problem in both naphtha reforming and naphtha hydrotreating units.
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Question 61: Have you found that you needed to install a methanator upstream of a chlorided catalyst isomerization unit to remove carbon monoxide (CO) from the feed? What is the source of the CO and how much of a difference has the addition of the methanator made to catalyst life? What is the expected payout for the cost of the methanator?

The problem now comes from the oxygen ingress coming in with makeup hydrogen, with the culprit typically being CO and CO2.
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