Yes, sealless pumps have been successfully used in both HF and sulfuric alkylation processes, typically in the acid rerun system for the HF process and fresh acid service for the sulfuric process. However, the API-610 sealed pump is, by far, the most commonly used pump based on the fact that API 610 pumps are familiar within the refinery for the Maintenance and Projects groups and also because of their robust design and relatively low initial cost.

As you can see on the slide, there is a big variation in the design HF-to-alkylate ratios. The order of older units, as denoted by old Heritage-Phillips and old Heritage-UOP types, has fairly high ratios. The more modern ones were designed with lower ratios.

We have quite a few refineries that use oxygen enrichment. One of them uses it in very high concentration. None of the sites – and I spoke with them specifically about this – say that they have seen an increase in particulate emissions as a result of increasing their oxygen enrichment.

We have extensive experience with the use of ammonia in the FCC flue gas line in order to improve the conductivity of the particles and improve the operation of the ESP. We inject ammonia at the target level of 10 parts per million or less.

Our main problem with the ESP is fines accumulation in both the ESP hoppers and the transfer line from the hoppers to the fine's storage bin. We have incorporated some design improvements that have helped us minimize, but not completely eliminate, the main problems of condensation in the system and plugging.

As I mentioned briefly in an earlier question, most of our FCCs with CO boilers start-up with the CO boilers bypassed. If we run partial-burn on any of these FCCs, we tend to start-up in full-burn at reduced rates. Once the feed is in the unit and considered stable, most sites will cut into their CO boiler with the process flow.

KBR’s Best Practice is to fabricate the main catalyst loading and unloading lines with carbon steel. To protect the carbon steel lines against elevated regenerator temperatures, KBR recommends that Operations personnel only de-inventory the converter after the catalyst has been cooled below 650°F.

We have quite a few units that use valves in the vapor line and others with just simple blocked valves in that service. Two more units now have a newer style: a double disc valve which relies, in part, on a steam purge to provide positive isolation. Because that valve was very successful, two more valves are going to be installed soon.

At KBR, we specify design parameters that will allow the operator to achieve extended regenerator cyclone life for several turnaround intervals. Based on our experience, it was shown that most cyclone problems are attributed to operating above the maximum recommended velocities. KBR recommends that Operations maintain a cyclone inlet velocity below 70 fps and 80 fps for the first- and second-stage cyclones respectively.

Most sites replace the internals of the expander during every turnaround. The stator veins are thoroughly inspected and replaced on as-needed basis.