STEAM DRUM AND

INTERNALS CAN BE
CUSTOMIZED FOR
FAST REACTION TIME.

STEEL COMPONENTS
PREFITTED FOR
QUICK FIELD
INSTALLATION.
HEAT TRANSFER
SURFACES DESIGNED
FOR OPTIMAL POWER
CONSUMPTION.

TEXAS HERITAGE.
RENTECH BOILERS. AS TOUGH AS TEXAS.
At RENTECH, every boiler’s custom built. The conditions, demands and specs
of your application are unique – and mission critical to success. Our expert
engineers will analyze your needs and design an integrated, cost-effective
solution. Then we’ll construct and deliver a boiler that’s durable, energy efficient
and clean running. Always the best – and never off the shelf.
WWW.RENTECHBOILERS.COM
 NOVEMBER 2019 | HydrocarbonProcessing.com

INSTRUMENTATION
AND AUTOMATION
The future of digital transformation
and smart manufacturing

Process engineering, optimization

and advanced process control

DIGITALIZATION
Maximize assets with a digital
investment framework for oil and gas

HP AWARDS
The winners of the third-annual
awards honoring the best
of the HPI are announced
 STEAM DRUM AND
INTERNALS CAN BE
CUSTOMIZED FOR
FAST REACTION TIME.

STEEL COMPONENTS
PREFITTED FOR
QUICK FIELD
INSTALLATION.
HEAT TRANSFER
SURFACES DESIGNED
FOR OPTIMAL POWER
CONSUMPTION.

TEXAS HERITAGE.
RENTECH BOILERS. AS TOUGH AS TEXAS.
At RENTECH, every boiler’s custom built. The conditions, demands and specs
of your application are unique – and mission critical to success. Our expert
engineers will analyze your needs and design an integrated, cost-effective
solution. Then we’ll construct and deliver a boiler that’s durable, energy efficient
and clean running. Always the best – and never off the shelf.
WWW.RENTECHBOILERS.COM
 NOVEMBER 2019 | Volume 98 Number 11
HydrocarbonProcessing.com

25

20

SPECIAL FOCUS: INSTRUMENTATION AND AUTOMATION DEPARTMENTS

21 The future of digital transformation and smart manufacturing 4 Industry Perspectives
Y. Abualsoud and E. A. Buhulaiga 8 Construction
25 Building industrial networks to serve IIoT and digitalization 80 Advertiser Index
C. Logue
81 Marketplace
31 Process engineering, optimization and advanced process control
A. Kern 82 Events

33 The future of wireless control COLUMNS

H. Boger
7 Editorial Comment
CYBERSECURITY Honoring the industry’s best … take 2!
36 Pay attention: LockerGoga and Trisis/Triton demand
an improved cybersecurity strategy 11 Reliability
Improve condition monitoring
J. Brajkovich
with shock pulse technology
HYDROCARBON PROCESSING AWARDS 13 Process Safety
39 This special section details all the winners for the third annual HP Awards. Process safety in a connected world

CATALYST 14 Inspection
46 Unlocking FCC potential with an innovative catalyst solution Best practices for inspecting
T. Tavares guyed structures

49 FCC catalyst deactivation studies to mimic 15 Digital Technology

Cut oil and gas lifecycle costs
refinery conditions for high-propylene applications with intelligent packaged power
B. Aramburu, E. Pérez, M. Miranda and M. C. Mastry
17 Digitalization
PROCESS OPTIMIZATION Maximize assets with a digital
53 Accurate prediction of phase equilibrium properties—Part 2 investment framework for oil and gas
A. Katyal

SUSTAINABILITY Cover Image: Particularly in the energy and transport

56 Diversifying the future: Incentives for worldwide adoption
of renewable fuels and chemicals—Part 2
G. Cheviron, J. M. Gacio, M. Mitschler, O. Le Coz, M. Yallambalse and D. Schwalje
61 When digital transformation hits all four sustainability buckets
P. Morse
sectors, but especially in the water/wastewater and
oil and gas sectors, plants often extend over very
large areas. Siemens’ SIMATIC PCS 7 TeleControl
combines all areas into one control station to include
common operator guidance, convenient and simple
data management, and integrated engineering.
Photo courtesy of Siemens.

ENVIRONMENT AND SAFETY

63 Use submerged combustion systems to efficiently
destroy hazardous plant waste
E. Predatsch and P. Armstrong

VALVES, PUMPS AND TURBOMACHINERY

67 Using ball valves in high-temperature applications
J. Jablonski and W. Helfer

WATER MANAGEMENT
72 Sustainability and the water management company’s role
W. Perpich
75 Improved cooling system performance begins with data
J. Dalebroux and B. Aleynik

www.HydrocarbonProcessing.com
P. O. Box 2608
Houston, Texas 77252-2608, USA
Phone: +1 (713) 529-4301
Fax: +1 (713) 520-4433
Editors@HydrocarbonProcessing.com

PUBLISHER Catherine Watkins

Industry Perspectives EDITOR-IN-CHIEF/

ASSOCIATE PUBLISHER
Lee Nichols

EDITORIAL
Executive Editor Adrienne Blume
There’s still time to vote Managing Editor
Digital Editor
Mike Rhodes
Stephanie Bartels
for the best! Technical Editor
Reliability/Equipment Editor
Sumedha Sharma
Heinz P. Bloch
Contributing Editor Alissa Leeton
As mentioned in the editorial comment of the October is- Contributing Editor ARC Advisory Group
sue of Hydrocarbon Processing, the nominees for the 2019 Top Contributing Editor Anthony Sofronas
Project awards are out. MAGAZINE PRODUCTION / +1 (713) 525-4633
Using Hydrocarbon Processing’s Construction Boxscore Da- Vice President, Production Sheryl Stone
tabase, the editors have identified nine projects that are an- Manager, Advertising Production Cheryl Willis
Manager, Editorial Production Angela Bathe Dietrich
ticipated to significantly impact the global or regional down- Assistant Manager, Editorial Production Lindsey Craun Sönmez
stream industries. Graphic Designer Krista Norman
Artist/Illustrator David Weeks
All nominees will have a considerable impact on the hy-
drocarbon processing industry, whether through capital ex- ADVERTISING SALES
penditures, satisfying domestic demand or adding to regional See Sales Offices, page 80.

demand, diversifying product offerings, or the resurgence in
refining and/or petrochemical processing capacity.
These nine projects span the world and represent more
than $65 B in total capital expenditures. This year’s refin-
ing nominees (TABLE 1) represent more than approximately
400,000 bpd of new refining capacity by 2021 and a total in-
vestment of nearly $15 B. These projects, located in Asia, Eu-
rope and the U.S., will provide additional refined products to
satisfy increasing domestic demand and/or highlight a major
trend in regional project construction.
The five petrochemical nominees (TABLE 2) have a total
cost of more than $52 B and represent more than 30 MMtpy
of additional petrochemicals production by the early 2020s.
CIRCULATION / +1 (713) 520-4498 / Circulation@GulfEnergyInfo.com
Director, Circulation Suzanne McGehee
SUBSCRIPTIONS
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This plan provides full access to all information and data Hydrocarbon Processing
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access to all posted articles (current and archived), process handbooks, the
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Because Hydrocarbon Processing is edited specifically to be of greatest value to
people working in this specialized business, subscriptions are restricted to those
engaged in the hydrocarbon processing industry, or service and supply company
personnel connected thereto.

These projects are in two different regions—Asia and the U.S.
The choice is now up to you! To vote, visit Hydrocarbon-
Processing.com and select the project you believe should re-
ceive this distinguished award. The winners will be revealed
in Hydrocarbon Processing’s December issue.
TABLE 1. Top refining project nominees
Project Location
Kochi integrated complex India
Gela Green Refinery project Italy
Hydrocarbon Processing is indexed by Applied Science & Technology Index, by
Chemical Abstracts and by Engineering Index Inc. Microfilm copies available through
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address changes to Hydrocarbon Processing, P.O. Box 2608, Houston, Texas 77252.

Davis refinery
Nghi Son Refinery and Petrochemicals
integrated complex
TABLE 2. Top petrochemical project nominees
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Project
Hengli Petrochemical integrated complex
LIWA Plastics project
Residue Upgrading Complex/Olefins
Downstream Complex (RUC/ODC)
Pennsylvania Petrochemicals Complex
Zhoushan Island integrated complex
(Phase 1/2)
Location
China
Oman President/CEO John Royall
CFO Alan Millis
South Korea Vice President Andy McDowell
Vice President, Finance and Operations Pamela Harvey
Vice President, Production Sheryl Stone
U.S. Vice President, Data Sales Harry Brookby
Publication Agreement Number 40034765 Printed in USA
China
Other Gulf Energy Information titles include: Gas ProcessingTM, Petroleum Economist ©,
World Oil ®, Pipeline & Gas Journal and Underground Construction.

4 NOVEMBER 2019 | HydrocarbonProcessing.com
Select 84 at www.HydrocarbonProcessing.com/RS
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 Editorial
Comment
Honoring the industry’s best … take 2!
Due to Tropical Storm Imelda,
Hydrocarbon Processing issued its first
force majeure in postponing the third an-
nual HP Awards. The storm, classified
as the fifth-wettest tropical cyclone on
record in the U.S., battered Houston and
outlying cities with more than 43 in. of
rainfall in less than a 24-hr period. The
storm caused severe flooding in parts
of the city, including near the venue of
the awards event. Therefore, it was in
the best interest of everyone involved to
postpone the event to a later date.
The reason I mention this event is be-
cause the award winners were intended
to be listed in the October issue; it was
even teased within the “Inside the Issue”
section on the Table of Contents page.
The HP Awards did come to fruition,
which honored the best of the hydrocar-
bon processing industry (HPI).
These awards recognize the many
technologies and people that have, and
are, making the hydrocarbon processing
industry safer, more efficient and more
profitable. Over the past several years, it
has been an honor for Hydrocarbon Pro-
cessing to compile these awards. So many
individuals, companies and teams in this
industry deserve recognition for their
achievements, and the HP Awards was
established to do just that.
The HP Awards celebrate innovative
technologies and people that have been
instrumental in improving facility op-
erations over the past year. The awards
cover 17 strategic categories in the hy-
drocarbon processing industry. Nearly
100 nominations were submitted from
more than 20 countries. Each abstract
was voted on by an independent Hydro-
carbon Processing advisory board.
The following is a complete list of
all categories that were honored at the
awards ceremony. The winners in each
category are detailed on pg. 39. The list
of award categories includes:
• Best AR/VR/AI Technology
• Best Asset Monitoring Technology
LEE NICHOLS, EDITOR-IN-CHIEF/ASSOCIATE PUBLISHER
Lee.Nichols@HydrocarbonProcessing.com
• Best Process Controls/Automation
Technology
• Best Health, Safety or
Environmental Contribution
• Best Catalyst Technology
• Digitalization—Best Digital
Twin/Operator Training
Technology
• Digitalization—Best Process/
Plant Operations Optimization
Technology
• Digitalization—Best Software
Technology
• EPC/Licensor/Consultant of
the Year
• Executive of the Year
• Best Fluid Flow Technology
• Best Gas Processing/LNG
Technology
• Best Instrument Technology
• Lifetime Achievement
• Most Promising Engineer
• Best Petrochemical Technology
• Best Refining Technology.
Hydrocarbon Processing is honored to
be among the people and companies that
make these awards possible. These tech-
nologies and people are instrumental in
providing products for everyday life, as
well as advancing and optimizing plant
operations for the good of the industry
and the world.
The people working in the HPI are
creating and optimizing technologies, as
well as engineering, testing and provid-
ing equipment and services to increase
production capacity, energy efficiency,
safety and reliability. They are doing
this while also developing systems to de-
crease emissions and carbon footprint,
and to operate cleanly and safely.
In short, the people that make up our
dynamic industry are at the forefront in
creating the products to advance mod-
ern living for billions of people around
the world. Hydrocarbon Processing is
proud to recognize these individuals and
companies for the work they do to make
life better.
INSIDE THIS ISSUE
20 Special Focus.
Plant personnel are living in
an evolving world of wireless devices
and software capabilities that allow
management decisions in real time;
all are supported by vast amounts of
process data available instantaneously.
This month’s Special Focus showcases
innovations in control devices, hardware
and software to increase plant efficiency,
reliability and safety.
36 Cybersecurity.
In a world where the threat of
cyberattacks is a real problem, luck is not
a viable strategy. This article provides
basic questions that a company should
ask regarding its cybersecurity policy.
39 HP Awards.
The winners of the third
annual HP Awards are detailed here.
The HP Awards celebrates innovative
people that have been instrumental
in improving facility operations over
the past year.
56 Sustainability.
This two-part series explores
how regulatory incentives, technology
advances and increased renewable
product demand have driven significant
investment and growth in a renewable
energy industry. Part 2, featured in
this issue, focuses on the technology
pathways to building the biorefinery
of the future.
63 Environment.
In the production of clean fuels,
plastics and other hydrocarbon-based
products, refineries and petrochemical
facilities generate unwanted (waste)
byproducts. Having no market value,
the undesired byproducts must be
recycled, minimized or eliminated. In the
case history, an HPI facility investigated
oxidation/combustion technologies
to treat caustic waste and attain
“near-zero” emissions.
Hydrocarbon Processing | NOVEMBER 2019 7
 | Construction
Hydrocarbon Processing’s Construction Boxscore Database is
tracking more than 1,430 active downstream projects around
the world, representing nearly $1.9 T in capital expenditures. This
month’s Business Trends highlights some of the major projects and
contracts that have been announced over the past two months.
These projects will be instrumental in satisfying regional demand
for finished hydrocarbon products.

Photo: As part of the renovation and modernization program at its Moscow

refinery, Gazprom Neft is upgrading the plant’s process furnaces and switching
to environmentally friendly gaseous fuel. Photo courtesy of Gazprom Neft.
LEE NICHOLS, EDITOR-IN-CHIEF/ASSOCIATE PUBLISHER
Lee.Nichols@HydrocarbonProcessing.com
AFRICA
Total plans to take a final investment
decision (FID) on the Nigeria LNG ex-
pansion project by the end of this year. If
greenlighted, the 7-MMtpy LNG train
would increase the Bonny Island LNG
terminal’s capacity to nearly 30 MMtpy.
If built, Train 7 is expected to be opera-
tional by 2023.
Carbon Holdings awarded Maire
Tecnimont an engineering, procurement
and construction (EPC) contract for a
grassroots ammonia project in Egypt.
Located in Ain Sokhna, the 1.32-MMtpy
facility will use KBR technology. The
ammonia facility is scheduled to be com-
pleted in 3Q 2022.
Nigeria is planning to start a rehabili-
tation program on all domestic refiner-
ies in January 2020. Nigerian National
Petroleum Corp. made the announce-
ment in late September. The program
calls for the rehabilitation of the follow-
ing refineries:
• Kaduna Refining and
Petrochemical Co.’s 110,000-bpd
refinery in Kaduna state
• Port Harcourt Refining Co. Ltd.’s
Port Harcourt refinery—includes
a 150,000-bpd full-conversion
refinery and a 60,000-bpd
hydroskimming refinery
• Warri Refining and
Petrochemical Co.’s 125,000-bpd
refinery in Delta state.
The rehabilitation plan will help Ni-
geria satisfy domestic fuels demand and
mitigate costly imports.
JFT—a consortium between JGC
Corp., Fluor and TechnipFMC—was
awarded an EPC contract to build Mo-
zambique Rovuma Venture SpA’s on-
shore LNG export terminal. Located in
Cabo Delgado, Mozambique, the on-
shore terminal will have a total capacity
of 15.2 MMtpy. The terminal will process
natural gas from Area 4 operations in off-
shore Mozambique.
ASIA-PACIFIC
Bora Enterprise Group and Lyondell-
Basell plan to invest $12 B over the next
decade in several petrochemical projects in
Panjin, China. The JV’s Phase 1 activities
include an investment of more than $2.5 B.
This investment includes the construction
of an 800,000-tpy polyethylene (PE) plant,
a 600,000-tpy polypropylene (PP) plant
and a 350,000-tpy styrene plant.
Pertamina, Indonesia’s national oil
company (NOC), awarded an EPC con-
tract to Hyundai Engineering for the
Balikpapan refinery modernization and
expansion project. The $3.9-B project
will expand the refinery’s capacity from
260,000 bpd to 360,000 bpd, along with
upgrading the facility to produce Euro
5-specified fuels.
The Balikpapan refinery project is part
of Indonesia’s ambitious $30-B Refinery
Development Master Plan. The program’s
goal is to mitigate refined fuel imports by
doubling the nation’s refining capacity to
approximately 2 MMbpd in 2026/2027.
This plan includes the upgrade and expan-
sion of existing assets, as well as the con-
struction of grassroots refineries.
The government of Papua New Guin-
ea (PNG) said it will honor a previously
signed gas deal with PNG project devel-
opers ExxonMobil, Oil Search Ltd. and
Total. The statement provides the consor-
tium with a go-ahead to develop a $13-B
project to expand LNG exports from the
island nation. The expansion project con-
sists of adding two liquefaction trains, with
a total installed capacity of 5.4 MMtpy.
Hanwha Total Petrochmical, a JV be-
tween Hanwha Group and Total, com-
pleted a $450-MM ethylene expansion
project in Daesan. With the completion
of the expansion, the company increased
ethylene production by 30% to 1.4 MMt-
py. The expansion project is one of three
petrochemical capacity investments being
made at the Daesan integrated complex.
The JV is investing approximately $300
Construction
MM to expand PE capacity by 50% to 1.1
MMtpy and is investing $500 MM to in-
crease PP capacity by 60% to 1.1 MMtpy.
The PE project will be commissioned
by the end of 2019, with the PP project’s
completion set 2020.
Air Liquide Engineering and Con-
struction and Samsung Engineering are
preparing a front-end engineering design
(FEED) study for Sarawak Petchem’s
methanol plant. The 5,000-tpd facility will
be in Bintulu, Sarawak State, Eastern Ma-
laysia. If greenlighted, the methanol plant
will begin operations in 2023.
Gulf MPT LNG Terminal Co., a JV
between Thailand’s Gulf Energy De-
velopment and PTT, is investing more
than $1.3 B to build a gas terminal and
port on the country’s east coast. Phase 1
includes the construction of a 5-MMtpy
LNG import terminal. The terminal’s
import capacity could increase to nearly
11 MMtpy in the project’s second phase,
if needed. Phase 1 is scheduled to begin
operations by 2025.
Private Coogee Chemicals Pty. Ltd.
is conducting a feasibility study to build a
$335-MM, 350,000-tpy methanol plant in
Darwin, Australia. Private Coogee Chemi-
cals plans to take FID in early 2021. If
greenlighted, the Darwin methanol plant
could begin operations in 2024.
The company is also working with
Wesfarmers and Mitsubishi to possibly
develop a $938-MM, 1.8-MMtpy metha-
nol plant on the Burrup Peninsular in
Western Australia. No timetable has been
announced on the project’s FID or com-
missioning.
EUROPE
BASF plans to invest nearly $550 MM
to increase ethylene oxide (EO) and EO
derivative capacity at its Verbund site in
Antwerp, Belgium. The project will in-
crease EO and EO derivative capacity
by approximately 400,000 tpy. EO de-
rivatives being expanded included non-
Hydrocarbon Processing | NOVEMBER 2019 9
 Construction
ionic surfactants, glycol ethers and other
downstream alkoxylates. These units are
scheduled to be operational in 2022.
In Tiszaújváros, Hungary, MOL Pet-
rochemicals is developing a grassroots
polyols project. The $1.3-B project is
part of the MOL Group’s 2030 strat-
egy to boost petrochemical production.
Once operational in 2021, the plant will
produce 200,000 tpy of polyols.
Gazprom Neft completed the main
section of its delayed coking project at
the Omsk refinery in Russia. The project
is part of Phase 2 of the more than $4.6-
B Omsk refinery expansion and mod-
ernization project. With the completion
of the delayed coker project, the Omsk
refinery will be able to process heavy oil
fractions into gasoline and diesel, as well
as increase conversion rates and light-
product yield. The refinery expansion
and modernization project is scheduled
to be completed in 2021.
ExxonMobil is investing nearly $1.2
B in the UK. Most of these investments
are being made at the company’s Fawley
refinery in Southhampton. The expan-
sion project will enable ExxonMobil to
produce additional volumes of ultra-low-
sulfur diesel. In Fife, Scotland, the com-
pany is investing more than $172 MM
to upgrade an ethylene plant. The proj-
ect—scheduled to be completed in 4Q
2022—will boost the facility’s reliability
and performance.
In early October, INEOS Phenol
broke ground on a grassroots 750,000-tpy
cumene plant. Located in Marl, Germany,
the facility—to be completed in 2021—
will provide cumene to customers, as
well as raw material feedstock to INEOS’s
phenol and acetone plants in Gladbeck,
Germany and Antwerp, Belgium.
In early October, Eni announced it
officially opened the Gela biorefinery
in Italy. The project converted the Gela
refinery—a traditional refinery—into a
biorefinery. The 750,000-tpy facility will
use algae, animal fat and vegetable oil to
produce biofuels. The conversion proj-
ect’s cost was more than $321 MM. An
additional $79 MM is being invested to
pretreat biomass and provide the refin-
ery with second-generation raw material.
10 NOVEMBER 2019 | HydrocarbonProcessing.com
This phase is expected to be completed
in 2Q 2020.
Evonik Industries broke ground on
its $444-MM Polyamid 12 project. The
plant, located in Marl, Germany, is sched-
uled to be completed in 2021.
LATIN AMERICA
GF International plans to initiate
pre-FEED and FEED work on the Salina
Cruz LNG project in southwest Mexico.
Sembcorp Marine will handle all pre-
FEED and FEED work on the project.
Located in Oaxaca, the 500,000-tpy
LNG terminal secured $250 MM in debt
financing to continue moving the project
forward. The terminal will provide off-
take for natural gas producers in the Ve-
racruz and Sureste basins.
MIDDLE EAST
Kuwait National Petroleum Co.
(KNPC) announced a drawback in the
country’s refinery buildout program.
Initially, Kuwait’s goal was to increase
domestic refining capacity from approxi-
mately 700,000 bpd to 2 MMbpd by
2025. However, the country has scaled
back the plan to 1.6 MMbpd by 2025.
Kuwait is investing heavily to boost
clean fuels production. The country is
focusing on two capital-intensive refining
projects—the Clean Fuels Project (CFP)
and grassroots Al-Zour refinery. These
two projects represent more than $30 B in
total capital expenditures.
Once completed, the CFP and Al-
Zour refineries will propel Kuwait to one
of the largest producers of clean fuels in
the Middle East.
In late September, Pakistan announced
five companies have been approved to
build LNG terminals in the country.
At present, Pakistan has two opera-
tional LNG terminals, each with a ca-
pacity of 4.5 MMtpy. A third terminal
is being built—with a capacity of 4.5
MMtpy—and is scheduled to be opera-
tional in 2020. The five companies that
were approved include:
• Tabeer Energy
• Energas and ExxonMobil
• Trafigura
• Engro and Shell
• Gunvor and Fatima.
These terminals will provide much-
needed natural gas for Pakistan to pro-
vide feedstock for power generation and
fertilizer production.
To help mitigate imports of PP,
Ceyhan Polipropilen Üretim is devel-
oping a 457,000-tpy propane dehydro-
genation (PDH) unit in Ceyhan, Turkey.
The facility will utilize technology li-
censed by Honeywell UOP. Once opera-
tional in 2023, the grassroots PDH unit
will reduce Turkish PP imports by 25%
and offset approximately $13 B in im-
ported petrochemicals.
U.S.
Enterprise Products Partners is
developing a second PDH project—
PDH 2—in Mont Belvieu, Texas. The
grassroots facility will process 35,000
bpd of propane to produce up to 1.65
Blb/yr of propylene. S&B Engineers
and Constructors were awarded the
EPC contract for the project. Operations
are scheduled to begin in 1H 2023.
Motiva is considering building a pet-
rochemical complex near its Port Arthur,
Texas refinery. The complex’s original de-
sign, which could cost more than $9.7 B,
would include a steam cracker, a PE plant
and an aromatics plant. However, in early
October, Motiva announced it will pur-
chase Flint Hills Resources’ Port Arthur
chemical plant. Since the newly acquired
plant contains an ethane cracker, Motiva
plans to accelerate the construction of a
grassroots PE plant, while slowing progress
on the additional ethane cracker and aro-
matics unit. Motiva plans to take FID on
the PE and aromatics projects in late 2021.
Although LyondellBasell will not
pursue a grassroots PDH unit, the com-
pany plans to add additional petrochemi-
cal capacity in the near term. At present,
LyondellBasell is building a 500,000-tpy
high-density polyethylene (HDPE) unit
in La Porte, Texas, as well as a $2.4-B pro-
pylene oxide/tertiary butyl alcohol (PO/
TBA) plant in Houston. The HDPE plant
will be completed by the end of 2019,
with the PO/TBA plant’s completion set
for 3Q/4Q 2021.
The company has also announced sev-
eral new units by the mid-2020s. These
projects include a 500,000-tpy PP plant,
a 500,000-tpy PE plant and the debot-
tlenecking of its Channelview cracker,
which will add 250 MMtpy of additional
ethylene production.
 HEINZ P. BLOCH, RELIABILITY/EQUIPMENT EDITOR
Reliability Heinz.Bloch@HydrocarbonProcessing.com

Improve condition monitoring

with shock pulse technology
Shock pulse technology is generally well known to vibration
analysts and reliability technicians. A handheld combination of
sensor and display meter would typically be used to detect dis-
continuities in bearings and would respond to the impact of two
masses. The resulting shockwaves will create a shock pulse of a
certain magnitude that commonly manifests itself at a particular
repeat frequency. The respective magnitude of relevant excur-
sions and their trends can be observed by the person entrusted
with the monitoring task.
While the underlying principles have remained the same,
progress was recently made with electronic means of detection
and display. New portable sensors and intuitive mobile apps
put simplified equipment inspection, machine health data col-
lection and improved data analysis within reach of different job
functions and workforce members.
The SKF Pulse (FIG. 1) is among the latest devices that com-
bine an easy-to-use handheld sensor with a mobile app, allow-
ing users to quickly monitor rotating equipment and machine
health. Depending on machine type and design details, the
monitor-collector is among the small devices that can predict is-
sues and improve reliability before plant operation is impaired.
For more advanced analysis, users can request an SKF Pulse
Check directly via the app. The request goes to an SKF Diag-
nostics Center, where experts remotely analyze the machine
data and, if required, respond with recommended corrective ac-
tions to improve equipment performance.
Many users describe the SKF Pulse as incorporating an in-
tuitive visual interface that guides them through the data collec-
tion process. User personnel enter asset information that auto-
matically configures alarm thresholds based on ISO standards,
although thresholds can also be customized, if desired.
The device features include:
• Velocity, acceleration and temperature measurement
of rotating equipment
• Bluetooth communication with iOS mobile devices
• Rugged industrial design—drop test of six feet,
and water- and dust-resistant (IP65)
• A rechargeable lithium battery (with an 8-hr charge
under normal usage).
SKF anticipates that many job functions in modern industry
will utilize the versatile device. The aim is to use it as a predic-
tive tool, which gives greater predictive maintenance accuracy
and allows better timing of preventive maintenance. Unlimited
assets can now be monitored with one sensor, although more
sensors can be added as part of a broader vibration analysis
program. Of course, data and asset information can be shared
throughout the facility or corporation.
FIG. 1. The SKF Pulse provides an entry point to a preventive
maintenance program and requires no specialized training or
expertise. It provides a real-time indication of machine health,
plus the reassurance of connecting with experts, if needed.
It can be reasoned that the user community wants simplicity
and ease of checking vibration. Here we have a method allowing
routine vibration checks with the ability to quickly involve ex-
pert help, if needed. Modern instruments and software combine
features that include easy setup, portability, effortless data collec-
tion and, in many cases, immediate insight into asset condition.
Technically sound technology is quite obviously moving in the
right direction, and we look forward to locating users willing to
report on the cost-effectiveness of making the fullest possible
use of this promising new tool.
In the interest of full disclosure, one other feature that condi-
tion monitoring devices do exceedingly well is that they allow us
to ascertain that staffers tasked with visiting assets in the field are,
in fact, doing so in a timely manner. Are the pillow block bearings
on a fan drive 60 ft aboveground being overlooked? The true/
false answer from the hand-held device will be unimpeachable.
HEINZ P. BLOCH resides in Montgomery, Texas. His professional
career commenced in 1962 and included long-term assignments
as Exxon Chemical’s Regional Machinery Specialist for the U.S.
He has authored or co-written more than 750 publications,
among them 21 comprehensive books on practical machinery
management, failure analysis, failure avoidance, compressors,
steam turbines, pumps, oil mist lubrication and optimized
lubrication for industry. Mr. Bloch holds BS and MS degrees (cum laude) in mechanical
engineering from the Newark College of Engineering. He is an ASME Life Fellow and
was awarded lifetime registration as a professional engineer in New Jersey.

Hydrocarbon Processing | NOVEMBER 2019 11

 M. SEN. GUPTA
Process Safety ARC Advisory Group, Dedham, Massachusetts
Process safety in a connected world
Traditionally, conversations around automation and safety
have focused largely on logic solvers and instrumentation.
However, new disruptive technologies and a rapid expansion in
networking and computing resources have broadened the scope
of automation’s reach. These transformative technologies and
approaches promise to reduce incidents and increase produc-
tion in ways industry could only imagine in the past; but while
the “pieces” are available, organizational silos and entrenched
cultures stand in the way.
Today, the large, complex, relay-based safety systems of the
past have been replaced by microprocessor-based logic solvers
that offer even greater flexibility and ease-of-maintenance over
previous systems. These systems also provide users with more
feedback relative to system status and readiness. Recent tech-
nologies will confirm compliance to the original design, alert
users to maintenance issues and simplify auditing procedures.
Safety automation, however, has always centered around
the automation involving process-connected devices. Other as-
pects of safety in the process continue to be handled manually
and administered by offline databases, especially people-centric
interests.
New technologies expand automation’s reach. Recent
advancements in computing and connectivity promise to ex-
pand the use of automation within a facility’s overall process
safety program. This goes well beyond the technology—ex-
panding regulations and public perception contribute to the
wider reliance on automation.
Analytics already play a growing role in process safety, but
not just directly related to the control systems. Predictive/pre-
scriptive analytics can enhance process safety in a variety of
ways, primarily in avoiding unanticipated failures. Being able to
predict when a large piece of equipment will fail is a big win for
operations and maintenance planning, but it also means that the
facility operates safer because operators are less likely to make
a mistake reacting to the failure, and a breach of containment
is less likely. This technology has expanded beyond individual
pieces of equipment to cover an entire processing unit and even
extend throughout the supply chain.
Applications of artificial intelligence (AI), another related
technology, also center around prediction. With AI, the learn-
ing aspect of the technology implies that it can infer things that
people have not recognized and alert users in advance. Again,
this helps avert dangerous situations that increase risk. AI is
also being applied to video feeds. The technology can recog-
nize who is where, and alerts operations to unauthorized access,
improperly dressed personnel or physical abnormalities in the
unit. It can also be used with thermal cameras to provide alerts
related to process deviations and/or personnel.
Obviously, all this technology must be connected. New wire-
less technologies are poised to provide a step change in perfor-
mance. More than just connecting data, these will enable tracking
for safety applications. Knowing where people are in the plant is
important. Knowing the location and status of mobile equipment
can help avoid collisions with structures or piping. Several ven-
dors now offer wearable analyzers that enable owner-operators
to identify who is where, but also to what they may be exposed.
Robots and drones also continue to storm the industrial
scene. Some can go into confined and/or potentially dangerous
spaces and be instrumented with sensors and cameras to provide
more information about the processing and asset environments.
How can all these technologies be brought together?
Comprehensive safety automation. Consider a compre-
hensive safety automation scenario in which a predictive algo-
rithm recognizes a potential disruption in the process unit. Due
to the nature of the exothermic process, this provides less than
an hour’s advance warning of a release of gases. The warning
comes from a group of machine-learning algorithms trained via
historical data and simulation from a high-fidelity model exer-
cised through an automated testing application. Obviously, an
automatically initiated warning would be sent to the operator,
but also to those people known to be in the danger zone. AI sys-
tems would then push alerts to available experts about the issue.
These experts might be located anywhere globally and may or
may not be on staff.
Automation would run through various scenarios. The sys-
tem would present real-time recommendations as personnel re-
act to the situation. Some recommendations could be executed
automatically without operator intervention; others would re-
quire operator choice or manual steps.
Systems would also be aware of the state of the control and
safety systems. They would understand issues with any bad sen-
sors and the implication for the current situation. Other systems
would identify in-plant resources to prepare for an emergency.
In addition to in-plant personnel, these resources could also in-
clude drones/robots that would respond in ways and in areas
where personnel safety is at higher risk.
Digital transformation promises disruption across all areas
of business, including safety. Data can flow in ways we still do
not understand, challenging traditional operating methods.
This data flow has the potential to radically improve how busi-
ness gets done safely. It will also challenge the way the people
involved think and work.
MARK SEN. GUPTA is Research Director for ARC Advisory Group. With more than
30 yr of experience in industrial automation and change management, he assists
ARC’s clients with their digital transformation initiatives, with particular focus
on how digital transformation affects people and the organization.
Hydrocarbon Processing | NOVEMBER 2019 13
 A. ANWER
Inspection Contributing Writer, Abu Dhabi, UAE
Best practices for inspecting guyed structures
Guyed structures are common in petrochemicals, oil and gas
and chemical industries. Half of the installed flare structures at
many facilities are guyed. Various routine inspection programs
are in place to examine these structures. This work describes
some very basic checks, which should be in place to maintain
their mechanical integrity.
Before proceeding to inspect guyed structures, major compo-
nents need to be listed (FIG. 1). These include:
• Guy wire
• Guy attachment
• Anchor
• Structure.
Inspection programs must be developed based on these four
components.
The most important component in a guyed structure is the
guy wire. Since all the load is transmitted through this compo-
nent, it is the primary lifeline of the structure. Other compo-
nents—the anchor, guy attachment and the supported struc-
ture—are important, but their chances of failure are remote.
Guy wire. The basic and the foremost inspection of a guy wire is
to perform a thorough visual check. This should provide infor-
mation related to the general condition of the wire, especially the
lubricated portion. Grease is an essential component to protect
the guy wire from external conditions. A visual inspection will
determine the condition of the grease. With the passage of time,
grease solvent dries out and starts to crack. These cracks eventu-
ally provide access to external conditions, especially air moisture
that can penetrate the guy wire and cause internal corrosion. An
effective penetrative lubricating system should be made essential
for guy wires to protect against the external atmosphere. That
system should be applied at a set interval (e.g., every 2 yr).
Tensioning of the guy wire is essential to its load bearing ca-
pability and overall stability of the whole guyed structure. This
should be ensured as per the recommendations provided by the
manufacturer. This exercise is normally coupled with a vertical-
ity survey, as well where the readings are taken, and appropriate
tensioning of wire is completed.
The third check on a guy wire is to perform an electromag-
netic test—magnetic flux leakage (MFL) to ensure if there is any
active internal corrosion. This is important regarding the condi-
tion of grease/lubrication over the guy wire. Typically, internal
corrosion testing should be completed every 2 yr–3 yr. Guyed
structures installed in moist, humid or marine environments
should be inspected for internal corrosion on a regular basis.
Guy attachment. This attachment is a set of components at
the structure/stack side of the guy wire. It typically includes a
lug, which is normally welded to the structure. Along with the
14 NOVEMBER 2019 | HydrocarbonProcessing.com
Guy attachment
Guy
Anchor
Guy lead
FIG. 1. Typical guyed structure.
lug, there is an anchor shackle and connectors, such as eye bolts,
thimbles or ferrules, which hold the wire in position. This set
should be inspected visually for their external condition, which
is essentially a check on their coating system. Any discovery
on their galvanizing condition or other coating system should
be addressed. A zinc epoxy coating system can be used for any
touch-ups required or a full round of blasting and painting. A
lug attachment weld should be considered for a general check-
up using the dye penetrant testing method.
Anchor. A guy wire is connected to the guy anchor, which
contains components such as turnbuckles, thimbles and wire
rope clips. Wire rope clips should be checked for any loose-
ness. Turnbuckle threads need to be inspected against envi-
ronmental protection. External corrosion is the major damage
mechanism that can affect the functionality of these com-
ponents. Selection and application of an effective protective
coating system should be ensured. A concrete ground anchor
should also be examined for any abnormality. If required, a
civil inspector may be requested to join for a combined inter-
val inspection.
Structure. Mechanical integrity of the structure being sup-
ported through a guy wire is also important. A hollow struc-
ture, which is carrying the load of the main component being
supported, should be inspected visually and with appropriate
non-destructive testing of its weldments. Structures having
verticality issues, along with gaps in guy wire tensioning, can
develop defects over a period, which may go unnoticed.
 JOE MATHEYS
Digital Technology Rockwell Automation, Milwaukee, Wisconsin

Cut oil and gas lifecycle costs

with intelligent packaged power
Oil and gas companies have realized big cost savings over
the years by having suppliers source all elements of the electri-
cal control system in a fully integrated package. However, this
methodology fell short of delivering the kind of insights and
efficiencies that companies expect and require in oil and gas
operations today.
To achieve these efficiencies and insights, a tighter integra-
tion between process control and electrical control systems is
required. Traditionally, these are two completely disparate sys-
tems with separate hardware and software for monitoring and
control needs. This limits the productivity of plant personnel.
An intelligent packaged power system provides a better al-
ternative. It can connect electrical devices to a process control
system, providing access to electrical device data for better
insights. Such a system also allows companies to leverage and
use control and electrical data in innovative ways—such as
machine learning—to predict and proactively address produc-
tion issues (FIG. 1). FIG. 1. Integrating power and process control into one unified system
can simplify project startups and reduce operational downtime.
This smarter and more integrated approach to accessing
electrical data is helping oil and gas companies address two ma-
jor financial drains: project startups and operational downtime. overall configuration efforts. Rather than running multiple
wires to each device, only a few ethernet cables are needed
Faster, less costly startups. When bringing operations across the entire system. During configuration, engineers do
like offshore platforms or onshore processing facilities online, not need to create a profile for every device. Instead, they can
startup delays can cost a company millions of dollars per day. use the intelligence within the system to create reusable pro-
Intelligent packaged power systems that reduce system wiring files and automatically configure devices.
and engineering can help companies avoid such delays and
keep projects on schedule. Drive out costly downtime. Some of the world’s biggest oil
In traditional packaged-power systems, every device signal and gas companies are deploying integrated power and process
must be hardwired to the process control system. This can re- control to reduce downtime and improve worker safety.
quire a lot of engineering hours to configure all signals, and For example, one global exploration and production com-
even more hours to test and confirm that they are correctly pany recently deployed an intelligent packaged power system
wired into the control system. to optimize worker visibility and response times at a new on-
An intelligent packaged power system communicates to shore processing facility. The system uses smart motor control
devices over a network that avoids much of this work. It only center technology, modern controllers and an e-house solu-
requires wiring motors to the motor control center. Motor and tion, all tied to analytics software. This gives the company’s
electrical device information is then available over ethernet to workers remote access to operational data, allowing them to
the control system, and devices can be configured digitally. manage and troubleshoot the system from a central location
To get a sense of potential cost savings, consider a system rather than from inside the e-house, reducing potential haz-
of 1,000 intelligent devices. Adopting an intelligent packaged ards to workers.
power strategy for implementing this system could reduce Another oil and gas company is using intelligent packaged
costs by up to 90% compared to a fully hard-wired system. power electrical control at an existing refinery to improve
This can add up to a significant amount of cost savings. monitoring of the complete electrical distribution system and
The biggest portion of these savings comes during the reduce downtime and the mean-time to repair (MTTR) of
installation phase. Simplified connections and intelligent in- electrical system trips. The system seamlessly integrates con-
frastructures significantly reduce or eliminate the need for trol and information from field electrical devices to the plant’s
I/O panels, device connection documentation and labor, and distributed control system and is built on a secure ethernet
Hydrocarbon Processing | NOVEMBER 2019 15
 Digital Technology
network infrastructure for guaranteed communications per-
formance. Workers now have immediate access to real-time
diagnostic information that helps them quickly spot and re-
solve issues.
When it comes to reducing downtime, what sets an intel-
ligent packaged power system apart from a traditional system
is how it accesses data.
A traditional packaged power system requires companies to:
• Identify in advance all the motor and device data
variables they will need to monitor production and
troubleshoot issues.
• Then, they must individually configure each of
those data points. This process can be complex
and time consuming.
• Furthermore, production visibility is hindered
by traditional hardwired or multi-network systems
because data access is limited.
For example, imagine a scenario in a processing plant where
a pump goes down because of a failed motor. A hardwired sys-
tem that uses a data interface module might alert technicians
to the issue when it occurs, but it likely will not provide many
specifics about the failure.
As a result, technicians must physically go to the motor,
spend time diagnosing the problem, retrieve the right spare
parts and return to the motor to make the repair. This entire
process could take hours, which is too long when downtime
costs are hundreds of thousands of dollars per hour.
16NOVEMBER 2019 | HydrocarbonProcessing.com
With an intelligent packaged power system that operates
on a single network and native communications to electri-
cal devices, operators can remotely identify and investigate
problems from a human-machine interface (HMI) or mobile
screen. This allows them to more quickly diagnose the prob-
lem and send a technician with the right parts to make the
required repair.
An intelligent packaged power system can also use ad-
vanced analytics to help predict when failures are going to oc-
cur. This can help companies more proactively service equip-
ment and avoid downtime issues.
Smart savings. Realizing the potential of the digital transfor-
mation in oil and gas operations requires having the right tech-
nology in place. Whether a company is deploying a new facil-
ity or upgrading or expanding an existing one, an intelligent
packaged power system can help reduce project costs, onshore
or offshore. An intelligent, modern system can help workers
harness the combined power of energy and process control
data to reduce the toll of downtime on the bottom line.
JOE MATHEYS has worked for Rockwell Automation since
2011 and began as an Applications Engineer for the
CENTERLINE 2100 product line. He later transitioned to the
product management team for IntelliCENTER & Intelligent
Packaged Power and is now responsible for low-voltage drives
software. Mr. Matheys earned a BS degree in mechanical
engineering from the University of Minnesota.
 F. SHONG, EY Oil and Gas, Ernst & Young LLP, Chicago, Illinois;
Digitalization W. CHUNG, EY Oil and Gas, Ernst & Young LLP, Los Angeles,
California; and R. THAPAR, EY Oil and Gas, Ernst & Young LLP,
New York, New York
Maximize assets with a digital investment
framework for oil and gas
Oil and gas investments are diversifying as the industry leans
toward a more digitally conducive environment. Asset analysis
was initially evaluated based on an asset’s technical parameters,
pricing and operationality. In this new digital world, however,
variables such as service quality, innovation, compliance, flexibil-
ity and scalability require quantification. Refinery data contin-
ues to be critical to evaluate investments, but is often incomplete.
Digital technology investments in refining often have benefits
that extend beyond a discrete asset. Having a coherent stream
of data can achieve a balanced investment assessment across se-
lected assets and can reap significant benefits to the bottom-line
growth for an organization. However, investment analysis often
requires an end-to-end view of the value chain and a pre-invest-
ment evaluation to provide maximum business impact (FIG. 1).
Digitally diversified focused investments. If digital invest-
ments are aligned with strategic business objectives and core
business functions, they can lead to production increases of
2%, labor cost savings of 10%, transportation cost savings of ap-
proximately 30%, inventory cost savings of 20% and integrated
value chain cost savings of 50%.1 The big question is how to
evaluate digital investments? Examples of these types of new
investments include:
1. Diversified assets in midstream operations, such as
the use of parallel computing and data analytics,
to estimate the product wear/tear years before the
actual failure, thereby reducing the downtime
2. Diversified assets in upstream, such as prototype
applications designed to augment strategic decision-
making to optimize production, including cognitive
technology to increase field productivity and minimize
exploration risks
3. Focused supply chain investments, such as end-to-
end assessment across supply and trading, contract
administration, and controllers identifying efficiency
gain and cost savings opportunities through targeted
process improvement and automation implementation
via robotic process automation (RPA).
Types of investment analysis. When performing invest-
ment analysis, two different investment models are considered:
external and internal.
External investments primarily focus on partnerships, buy-
outs or contracts with external organizations. To harness the
digital capabilities in external investments, a thoughtful frame-
work must evaluate the acquired asset’s ability to impact busi-
ness variables with a time-bounded outcome on the investment.
However, an external investment is highly situational and de-
pendent on varied business parameters, such as core objectives
and future growth.
For example, a major diversified energy company worked
with a customer experience management company to develop a
tool that can help predict how improvements in consumer expe-
rience can grow fuel sales. Using advanced analytics to provide
insights, the teams were able to identify operational metrics that
drive fuel-volume performance and incorporated these insights
into a web-based calculator. This calculator shows operators
how improvements on specific metrics can increase fuel volume.
Internal investments are operational in nature. Technical and
commercial operations have changed drastically with targeted
digital investments in high-impact areas. In upstream opera-
tions, drones and autonomous robots are resulting in more than
a 25% reduction in inspection and maintenance costs and 20%
lower employee cost in all areas.2 For these investment scenari-
os, consultants identify a process unit, gather development and
test data sets to train a deep-learning neural network to create
a financial model and prove the business case for investments.
The impact of digital on internal investments, such as peo-
ple, is a major precursor to build a digital oil and gas business
of the future. RPA and artificial intelligence (AI) for automat-
ing mundane tasks has diverted the focus of the “human work-
force” on more intuitive areas. By 2025, connected workers in
upstream operations could be up to 15% more productive with
wearables and the availability of enhanced training at virtual-
reality centers than their non-connected counterparts. Down-
stream operators are also expected to see a potential 15% im-
provement in employee productivity.2
EY teams are also working to establish the use cases for tech-
nologies such as chatbots, which cost around $0.70 compared
with a human workforce that can cost $6–$25 per interaction
(by 2022). Also, approximately 92% of customers prefer text
message discussion for resolving their problems—hence higher
customer satisfaction rates with targeted investments. For ex-
ample, an integrated company has developed an AI platform for
its industrial sector and a chatbot that provides users real-time
access to product support, technical services and product data.
Using frameworks for evaluating investments. Digital is
changing the way businesses should evaluate CAPEX invest-
ments. Consulting teams created a strategic, 10-step framework
that can assist in allocating digital investments across the value
Hydrocarbon Processing | NOVEMBER 2019 17
 Digitalization

Feedstock Best Connected

mastery Optimization operations supply
chain

Real-time Proactive and Blend

Feedstock Reduce LDC Data-driven Digitally enabled Market optimization
optimization via logistics refining process decision-making predictive transparency and
to drive optimized operations maintenance and
“real-time assay” predictability optimization excellence route to market Demand
utilization reliability sensing

Secure, simplfied, standardized and digitally enabled enterprise

What if you could anticipate/predict feedstocks in transit What if you had an intelligent refinery that could balance What if your operators could have a conversation What if you knew your competitiive cost to supply
to reset the optimum refinery run plan in real time? and optimize each interconnected production unit? with their equipment? vs. competition at a micro market level?

What if you could predict changes in feedstock quality What if the production units talked to each other? How could you ensure that contractors are as effective What if you could eliminate demand
and adjust planning and pricing? and efficient as company employees? uncertainty/unpredictability?
Opportunities

What if you could predict feedstock arrival to react What if accessing data was as easy as saying “hey Siri”? What if you could economically sensor all equipment What if you could nimbly push and pull products to
and plan more effciently and reduce LDC? to predict impending failures? highest-value customers and markets?

What if you could predict market changes by the What if your assets told you how much needed to be What if technicians had all the information they needed, What if you could predict and manage with greater
in-transits of your competitors? budgeted each year, with +/–5% accuracy? before heading out for repairs or routine maintenance? certainty total system inventory?

FIG. 1. Creating a refining “North Star” requires an end-to-end orientation and well-evaluated plan for capital expenditure (CAPEX) allocation
for going digital. Source: EY Analysis.

chain to maximize impact: • Increase ethylene uptime and production by 2%

1. Conduct a review of key business drivers with material • Reduce maintenance spend with advanced chemical
impact on revenue and profitability treatment and predictive analytics.3
2. Determine magnitude of the financial impact Over a 10-yr period, total savings were estimated at $97 MM
3. Rank areas of importance based on the financial impact to $141 MM per ethylene plant. This approach also offered an
4. Assess present state of digital capabilities immediate $7 MM savings in 2018 through a combination of
5. Determine the digital capability gaps deferred capital and reduced maintenance. The business case
6. Determine what additional digital tools are needed was driven by three key outcomes:
and the right approach • Generate estimated CAPEX savings of $7 MM in 2018
7. Determine the investment required to deploy new • Generate $97 MM–$141 MM in total benefits
digital capabilities per ethylene plant, of which $63 MM represents
8. Build a return on investment (ROI) business case reduced maintenance costs
for digital investment linked to desired key • Seamlessly support turnaround programs—
performance indicators Productivity 10.0 and Manufacturing 2020
9. Prioritize and allocate digital investment based on initiatives—and manufacturing centers of
output of ROI business case analysis, time to value, excellence and innovation centers.3
execution risk and resource availability The ultra-competitive business environment tends to cre-
10. Test run and align the strategy, as per early response ate a sustained pressure on business. An investment evaluation
from the user model that provides the most effective CAPEX allocations can
11. A strategic analysis of the requisite internal and external deliver benefits reasonably closer to the maximum value.
parameters within an organization will provide a NOTE
sustained impact on the CAPEX allocation. The views reflected in this article are the views of the authors and do not neces-
sarily reflect the views of the global EY organization or its member firms.
Digital asset evaluation—case study. Ethylene cracking LITERATURE CITED
is core to chemical processing and is a material driver of profit 1
Ernst & Young, “Optimize downstream operations,” September 2017.
margins. Consulting teams evaluated the benefits of investing 2
World Economic Forum, “Digital Transformation Initiative 2017,” 2017.
in digital technology that would extend the turnaround interval 3
Ernst & Young, “Manufacturing digital transformation ethylene interval extension
executive briefing document.”
on an ethylene cracker. Key assumptions included:
• Reduce turnaround time by 15 d—perform a minor FAY SHONG is a Partner based in Chicago and is the Global Digital Solutions Lead
turnaround with vendor’s compressors and defer for the EY Oil and Gas practice of Ernst & Young LLP.
a major turnaround WINSTON CHUNG is a Senior Manager based in Los Angeles and focusing on
• Extend ethylene compressor intervals by up to 30% digital and corporate M&A strategy for Ernst & Young LLP.
through a combination of vendor’s instrumentation, ROHAN THAPAR is a Consultant based in New York and focusing on digital
chemical services and digital capabilities turnaround for top- and bottom-line growth for Ernst & Young LLP.

18 NOVEMBER 2019 | HydrocarbonProcessing.com
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 | Special Focus
INSTRUMENTATION AND AUTOMATION
As the downstream processing industry moves toward a more digital
world, advanced process control, instrumentation and automation
solutions provide hydrocarbon processing companies with inventive ways
to manage difficult and complex operational and reporting applications.
New products, services and technologies are making refinery and
petrochemical plant operations more efficient, safer and profitable.

Plant personnel are living in an evolving world of wireless devices and

software capabilities that allow management decisions in real time; all
are supported by vast amounts of process data available instantaneously.
This month’s Special Focus showcases innovations in control devices,
hardware and software to increase plant efficiency.

Photo: Air Liquide’s pipeline operations and industrial gas production facilities are
monitored 24/7 within the company’s leading-edge operations control center located
in Houston, Texas. Photo courtesy of Air Liquide.
 Special Focus Instrumentation and Automation
Y. ABUALSOUD and E. A. BUHULAIGA,
Saudi Aramco, Dhahran, Saudi Arabia

The future of digital transformation

and smart manufacturing
In today’s challenging oil and gas op- and loss prevention; and corporate main- into insight and knowledge by identifying
erations, it is vital to have a robust oper- tenance, which actively participated in areas of improvement, contributing root
ating system that supports each facility’s the design and development of imoms causes and suggesting corrective actions.
goal of operational excellence (OE). Dig- with the system integrator. The platform helps owner-operators
ital transformation and smart manufac- The system improves product quality, move from being reactive and trying to
turing are being implemented by Saudi minimizes giveaways, reduces hydrocar- resolve issues into being proactive by pre-
Aramco as a coined umbrella term: in- bon losses, maximizes gross profit mar- venting the issues from happening. This
tegrated manufacturing operations man- gins and improves asset performance. It platform will allow authorized users to ac-
agement system (imoms). This integrat- also helps minimize environmental im- cess operational data anytime, anywhere.
ed digital plant and smart manufacturing pact, reduce hydrocarbon footprint and
cloud-based infrastructure comprises a increase safety performance. Core functional areas. The solution
set of advanced and innovative decision The right information is presented to provides tools and templates based on ISA
support systems. Imoms supports the the right user to make the right decision at 95 guidelines to enable implementation
business processes of the Jazan refinery the right time. This platform converts raw of standard business processes. The JRC
complex ( JRC), the integrated gasifica- data into information by putting it into benchmark was implemented to capture
tion combined-cycle (IGCC) facility the right context and then channeling that all the information in reusable templates.
and the marine terminal. The system is
designed to achieve OE by providing ad-
vanced tools that will help improve prof-
itability, efficiency, reliability and, most
importantly, health, safety and the envi-
ronment (HSE).
The JRC imoms project paves the way
for refineries and operating facilities to
leverage the imoms implementation. This
platform introduces several digital trans-
formation technologies for the first time
in Saudi Aramco, including asset perfor- FIG. 1. Enterprise control systems integration.
mance management, machinery diagnos-
tics and prognostics, predictive mainte-
nance, process safety, electronic work
permit, operational risk management,
field mobility and environmental man-
agement systems. Imoms is the first Saudi
Aramco mobile-enabled digital plant plat-
form that avails all operational data.

The digital refinery. The imoms proj-

ect was a collaborative effort between the
Saudi Aramco project management team;
the Jazan complex proponents; subject
matter experts (SMEs) from engineering
services, information technology, oil sup-
FIG. 2. Core functionality of imoms.
ply planning and scheduling (OSPAS),
Hydrocarbon Processing | NOVEMBER 2019 21
 Instrumentation and Automation
FIG. 3. imoms digital transformation footprint.
FIG. 4. System functionalities and benefits.
JRC imoms was developed leveraging
best practices to cover core manufactur-
ing functional areas, shown in FIG. 1: regu-
latory compliance management, inven-
tory operations management, production
operations management, reliability and
integrity management, and quality op-
erations management. This platform in-
tegrates a plant’s process control systems
with enterprise resources planning by au-
tomating the business process involved in
the digital plant five functional areas.
It consists of 20 innovative integrated
solutions (FIG. 2) that will digitally trans-
22 NOVEMBER 2019 | HydrocarbonProcessing.com
form the plant’s operation and enable OE,
integrating more than 26 applications
residing on more than 100 servers, and
serving more than 1,000 users at the JRC.
By leveraging existing corporate ap-
plications, such as data acquisition and
historian systems and laboratory infor-
mation management systems, the imoms
platform integrates with core digital op-
erational technologies, including:
• Operation monitoring, instruction,
logbook and advisory
• Blending and movement
automation systems.
These applications are then comple-
mented with advanced digital engineer-
ing technologies (FIG. 3), including:
• Production planning, scheduling
• Mass and energy balance
• Energy performance management
• Key performance management
• Online fault monitoring
• Predictive analytics
• Lifecycle reliability and integrity
• Maintenance, turnaround,
inspection
• Process safety and operations
risk management
• Environmental management system.
The platform helps in managing the
end-to-end business processes of the
JRC, from the moment the planning
group receives the order from the OSPAS
department to the moment products are
shipped from the terminal. The process
begins with receiving the order from the
OSPAS group, followed by allocating the
needed resources, planning, scheduling
the execution of the order, dispatching
the order automatically to the plant, and
communicating the plan to concerned
parties. After the plan is executed, imoms
collects the data to track the performance
of the executed orders and analyzes the
performance to ensure that the order has
been produced in the most effective and
economical way, meeting product speci-
fications without any giveaways. These
data are accessed via three standard plat-
forms (role-based dashboard, 3D digital
twin and digital operational mobility).
The platform ensures that the plant’s re-
liability continuously improves, and that

the plant is operated within optimal pro-
cess safety and environmental limits.
Cloud-based technology and service.
While all imoms technologies developed
for the Jazan project are cloud-based (on-
premise), these technologies can also be
made available for off-premise/hybrid
cloud infrastructures. The solution is
configured atop off-the-shelf commercial
technologies and establishes an integrat-
ed digital transformation, cloud-based
infrastructure. It consists of configuring
off-the-shelf commercial products with
no customization to ease the process of
support and expansion for other facilities.
The JRC imoms was designed taking
into consideration the industrial integra-
tion, security and governance guidelines
following the service-oriented architec-
ture (SOA) designing principle to pro-
vide “imoms-as-a-service.” It helps end
users to identify, manage and govern
the different users, systems, data and
business processes involved within the
imoms ecosystem.
Core functionalities provide the
imoms manufacturing intelligence and
advanced analytics infrastructure:
• Data aggregation
º Identify the data sources
• Data normalization
º Ensure that the data are reliable
and trustworthy
º Massage the data to fit the
format and schema (source vs.
destination format); this is done
using cross-reference tables and
SOA registry and repository
º Ensure consistent use of units
of measurements
º Ensure consistent naming
convention
• Data contextualization
º Implement master and
manufacturing data management
º Build plant reference models,
templates and user profiles
º Build alerting and notification
templates
º Use abstraction (aliases rather
than physical tags)
º Identify the users of the different
data points (user, system,
business process, etc.)
• Data analysis
º Build the data warehouses, data
marts and data cubes for the
complex
Instrumentation and Automation
º Enable static, real-time and
ad hoc reporting
º Alert and notify
º Enable drill-down, roll-up
and benchmarking analysis
• Data visualization
º Standard user-driven,
role-based dashboards
º Show the right information
to the right user at the right time
for the right purpose to make
informed and timely decisions
• Data propagation
º Show the performance from
plant/floor asset to the admin
area, and vice versa.
JRC imoms was designed with scal-
ability and expandability in mind, and
following:
• Cloud computing concept
• Standard, hardware, software,
integration and visualization
infrastructures
• Hierarchal plant reference model
• Major asset templates
• Role-based visualization, alerting
and notification templates
• Consistent naming convention
using aliases rather than
physical tags.
Benefits. The solution implementation
endeavors to achieve automation that
meets several key objectives (FIG. 4):
1. Streamline operations by
establishing a collaborative
environment that provides
operators, engineers, plant
management and decision-makers
with accurate information across
all departments.
2. Provide better visibility of plant
processes and business aspects,
essentially leading to optimized
and safe asset utilization, and
maximized production capacities
and profitability.
3. Improve agility by enabling timely
responses to market changes,
minimizing the loss of business and
market opportunities to improve
Jazan’s customer satisfaction.
4. Measure actual production and
performance, analyze performance
and compare to planned and
benchmark data with the ability
to analyze causes of deviations.
5. Establish the basis for a system that
is user-friendly, flexible, easy to
maintain and can grow along
with Saudi Aramco’s present and
future expansions.
6. Maximize ROI in solutions by
balancing the introduction of new
technologies while embracing and
integrating established solutions.
7. Manage business process
workflows to extend business
process automation to more
people, places and devices
identified in functional design.
Takeaway. The design and implementa-
tion approach of Jazan imoms will help
optimize imoms related to capital expen-
ditures (CAPEX) and operating expendi-
tures (OPEX) through standardization,
leveraging synergies and support between
existing and future projects. Leveraging
imoms for other refineries and operating
facilities will deploy standardized business
processes and imoms architecture across
other facilities; improve operating facili-
ties’ gross margins, depending on the cur-
rent baseline of each operating facility; re-
duce the overall IT CAPEX compared to
a standalone implementation; standardize
processes and plant IT/OT architecture
in the cloud; implement a cross-plant gov-
ernance; create one interchangeable team;
and reduce runs and maintain costs over
the software lifecycle.
YOUSIF ABUALSOUD heads the
Jazan refinery complex production
operations management system
project for Saudi Aramco. He is one
of the original members of the
integrated manufacturing operation
management system (imoms) team
that pioneered the development of integrated refinery
operation management solutions for Saudi Aramco.
His background includes process engineering, energy
optimization and project management. He has been
involved in several technology reviews, designs,
implementations and operation of various
manufacturing operations management systems.
EYAD A. BUHULAIGA is a Senior
Projects Manager heading the
Jazan Refinery Complex imoms
project team. He holds two titles
from Stanford University: Stanford
Certified Project Manager and
Stanford Certified Professional
in strategic decision and risk management. He
recently completed an MIT management executive
education program, co-authored an ISA-95 Best
Practices Book 2.0, and was a contributing editor
of ISA-95 Best Practices Book 3.0. He has published
several technical papers related to the digital
transformation and Industrial Revolution 4.0 at
international forums, such as IEEE, ARC Industry
Forum, AFPM (NPRA) ISA and MESA Intl.
Hydrocarbon Processing | NOVEMBER 2019 23
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 Special Focus Instrumentation and Automation
C. LOGUE, Emerson Automation Solutions,
Minneapolis, Minnesota

Building industrial networks to serve IIoT

and digitalization
Two of the terms growing in popular-
ity over the past few years are “digital na-
tive” and “digital immigrant.” Natives are
those individuals young enough to have
known computers and the internet since
childhood. For them, such technologies
have always existed. Immigrants, either
through age or circumstance, had no ex-
posure until later in life. Hopefully, for
them, such technologies are a welcome
addition to work and life, but they can re-
member times when most activities were
more manual, local and isolated.
For people working in processing in-
dustries, there has been a different expe-
riential division related to computer tech-
nology, and this one is more complicated.
Most engineers and technicians work-
ing in refineries have experience with
distributed control systems (DCSs)—
the automation systems running their
plants and process units. Those around FIG. 1. IT and OT networks can be connected on many levels, often making the differences
retirement age can probably remember between them difficult to distinguish.
back to the early 1980s when these sys-
tems were still new, but it was clear that
computer-based technology was the best technology (OT)—with its distinct Where does that leave us now? Both
way to run these facilities. practices and requirements—to distin- worlds have been populated with their re-
Simultaneously, in the early 1980s, guish it from IT. spective digital natives, but it is a different
the concept of information technol- OT and IT continued on parallel and understanding of what “digital” means,
ogy (IT) was filtering into our minds as separate courses until two major changes with different languages and cultures.
computer systems were moving more began to happen. First, DCS builders The trends that started decades ago are
into offices with the introduction of the found that IT platforms had advanced continuing, so the separation has been
personal computer (PC). Over time, this enough in power, reliability and versatil- breaking down as IT has moved increas-
involved PCs replacing mainframes and ity to support many DCS needs. They ingly into the OT world and has replaced
minicomputers, with desktop units turn- realized it was no longer necessary to the old proprietary platforms. OT has no
ing up in totally new places. create and manufacture so much propri- practical choice but to accept the change
The world of the plant and the world etary hardware and software, especially and learn the new language. The cultural
of the office grew in different direc- for human machine interface (HMI) differences are not as easy to resolve, but
tions with specialized and proprietary platforms. Second, refinery management they can be smoothed over as IT people
hardware and software running the started gathering manufacturing data learn what OT is about, particularly the
plants, while increasingly standardized from individual plants and process units. special needs of manufacturing. Digitali-
hardware and software ran offices and IT departments were then building con- zation programs require extensive blend-
corporate networks. The former was nections to the OT systems to extract ing of IT and OT, and it is often difficult
eventually characterized as operations data, and OT was no longer isolated. to determine the dividing line.
Hydrocarbon Processing | NOVEMBER 2019 25
 Instrumentation and Automation

Wired and wireless Ethernet net- the time, with wireless Ethernet (e.g.,
works are part and parcel of plant infra- WiFi) being a critical tool.
structure and are becoming increasingly
pervasive. Nonetheless, OT is still alive A typical plant task, then and now.
and well at the lower levels of plant net- Many years ago, technicians who were
works (FIG. 1). Individual field devices sent to replace general-purpose valve
(such as instrumentation and valve actu- actuators in operating refinery units had
ators) still communicate using purpose- several tasks. They would have to hunt to
designed protocols rather than Ethernet. find the specific valve, verify its tag num-
Most field devices are wired, but grow- ber, and engage with the control room
ing numbers are communicating via operators while doing the mechanical
an industrial wireless protocol, such as work and electrical connections. This
WirelessHART. Digitalization projects back-and-forth would be done via walk-
must bridge this persistent hardware and ie-talkie as the test actions were carried
software connectivity gap, but the mech- out. The technician would ask the op-
anisms for doing so are getting better all erators to ensure that the data from the
new actuator appeared correctly on the
screens, and then to send commands to
the valve via the control system to verify
correct function from that direction.
Under ideal conditions, this practice
typically worked well. Provided the op-
GLOBAL erators were not busy with something
else, like an upset or product grade
change, they could give the well-trained
CERTIFI­ technician enough attention to work
through the checklist of function veri-
fications. Conversely, many things can
CATION go wrong with such interactions, or they
can simply drag out and consume too
much time. Progress slows if the control
Electric actuators for all types room is trying to juggle multiple distrac-
tions, or if the technician encounters a
of industrial valves
FIG. 2. Ruggedized computer hardware can be problem and must ask for help with a
Reliable and long-term service. used in plant environments, with some units configuration setting or unclear wiring
AUMA offers a comprehensive certified for hazardous locations. termination.
portfolio.
Q Customised solutions thanks
to the modular scheme
Q Corrosion protection with
offshore certification
Q Temperatures down to –60 °C
Q Integration into all
conventional distributed
control systems
Q Worldwide certifications and
vendor approvals
Q Service worldwide

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the oil and gas industry
www.auma.com

FIG. 3. Finding critical information on the spot can be a huge time saver during commissioning,
troubleshooting or other activities.

26NOVEMBER 2019
01.10.2019 08:17:30

Let us consider the same task, this
time approached using the more sophis-
ticated digital technology that is available
now. Our technician has a ruggedized tab-
let (FIG. 2) communicating over the plant
WiFi network. The work order appears
on the screen, including the relevant valve
actuator tag number, along with detailed
product information. Reading a barcode
on the actuator verifies the correct unit,
and the technician can send a message
back to the control room warning opera-
tors that the device is switching to manual
mode, although the valve will stay in its
present position. All the necessary in-
structions and parameters for installing
and configuring the actuator are acces-
sible on the tablet.
Communication from the tablet can
be established with the actuator via the
network whether the actuator is wired
or using WirelessHART. All configura-
tion points can be transferred through the
network rather than being entered manu-
ally by the technician. All the verification
tests, from the field end or control room
end, can be run from the tablet since it can
Instrumentation and Automation
take on either role. This avoids involving
the control room, although the operators
can see what is happening, if necessary,
and they can even verify the technician’s
location from the control room, thanks to
location awareness technologies.
When the installation and testing are
completed, the technician closes out the
task on the tablet to automatically com-
plete the work order. Then, the techni-
cian restores the actuator view back to the
control room, and lets the operators know
it is back online and in automatic mode.
The actuator replacement is completed,
and the operators were barely aware of the
situation since they had little to do with
the procedure, other than to monitor the
technician’s activity at a high level.
Walking the rounds. The technician
may also have responsibilities to perform
plant rounds of one or more units. In the
past, this would mean carrying a clipboard
and checking a pressure gauge reading
and/or oil level, and then noting the infor-
mation on a sheet that would be turned in
to the control room or maintenance office.
Those functions are now likely per-
formed by instruments, but many plant
managers still like to have human beings
walking around the facility, using their
eyes, ears and even noses to notice things
that might escape the instrumentation.
Manual rounds may require being out
in bad weather or potentially hazardous
areas of the plant, so they are not always
a popular assignment, but digitalization
projects can help improve low-tech tasks.
The traditional clipboard is replaced
by the ruggedized tablet, complete with
instructions related to anything special
to watch for on the shift (FIG. 3). A note
section may display items such as “op-
erators complained that valve 210B was
sticking, so make sure that the actuator
mounting is tight. PT-48 seems sluggish,
so check the impulse lines.”
The technician can communicate
back to the control room from anywhere
via the tablet and can take photos or a
video of a piece of equipment for the op-
erators or anybody in the company to see
via the corporate network. This is simple
because, given the correct authoriza-
Hydrocarbon Processing | NOVEMBER 2019 27
 Instrumentation and Automation
TABLE 1. Present-day routers are more capable than they were 5 yr–10 yr ago.
Specifications WAP (present)
Protocols supported WiFi, WirelessHART
Device capacity 100 WirelessHART devices
Power supply 24 VDC input voltage
Operating temperature –40°C–55°C (–40°F–131°F)
Hardware Bulky and heavy all-in-one
access point
Other No fiber capability Global Class Fiber capability Global Class 1/
1/Division 2 Certification
FIG. 4. Routers can handle more devices
while tolerating extreme plant environments.
Modular construction makes them easier to
configure and deploy.
 PRESSURE VESSELS
tion, the information is accessible over
HEAT EXCHANGERS the company intranet, and possibly over
the internet.
 PROCESS If the technician needs technical in-
formation on a piece of equipment, it is a
TECHNOLOGY simple matter to look for it on the plant’s
database or on the original manufac-
 BALL VALVES turer’s documentation on the web. If it is
necessary to ask for help from a trouble-
shooter back at the manufacturer, it is a
simple task to send photos or a video of
the problem for evaluation. The situation
may not call for the manufacturer to send
a serviceperson, saving time and cost.
www.borsig.de Safety is always an important consid-
eration when people are moving around a
BORSIG GmbH
Phone: + 49 (0)30 4301-01
unit, particularly when rounds necessitate
Fax: + 49 (0)30 4301-2236 going into particularly hazardous areas.
E-mail: info@borsig.de Plant networks have provisions for emer-
Egellsstrasse 21 gency “worker down” calls, but they can
13507 Berlin
Germany
also add location awareness functions,
triangulating a radio source to a very ac-
curate position in three dimensions.
28NOVEMBER 2019
Next-generation WAP
WiFi, WirelessHART, ISA100
More than 200 WirelessHART devices
or more than 200 WirelessHART
and 100 ISA100 devices
10.5–30 VDC input voltage
110 VDC/220 VAC line power
–50°C–75°C (–58°F–167°F)
Lightweight, modular design
for greater deployment flexibility
Division 2 Certification
Improved coverage makes it practical.
The scenarios mentioned are nothing
new, but not all refineries are using them
to the extent suggested. Various vendors
have been talking about mobile workers,
personnel location and such capabilities
for several years. At present, the differ-
ence is improved network coverage and
bandwidth. Think about someone own-
ing a smartphone 10 yr ago. This early
smartphone was web-enabled, but trying
to reach a website or download a docu-
ment in an airport or on the street was a
catch-as-catch-can situation. Watching
the ever-downloading spinning wheel
was a typical experience, and many users
simply gave up as often as not. Why? Us-
ers wanted more performance than they
could get. Network coverage in most ar-
eas was too thin and bandwidth too low
to meet expectations.
Many in-plant WiFi networks had,
and may still have, the same problem.
Theoretically, there was coverage, but
moving any amount of data was an iffy
proposition. Many companies imple-
menting networks also underestimated
the usage they would have to accom-
modate and did not include enough in-
frastructure for full coverage or enough
bandwidth. In the last few years, both
public and plant network hardware have
advanced enormously in coverage and
bandwidth handling capability. Let us
concentrate on in-plant networks.
At present, an industrial-grade WiFi
router can support more protocols and
more devices, and can operate in more
challenging conditions than a router
from just a few years ago (TABLE 1), with
more modular designs that are easier
to deploy (FIG. 4). Such routers sup-
port high-bandwidth WiFi networks,

and can work in conjunction with Wire-
lessHART field devices, using WiFi as
the backhaul network.
A wireless router can also serve as a
gateway for WirelessHART and ISA100
Wireless devices, if both are deployed.
Wireless instruments and actuators still
communicate using their dedicated pro-
tocols, but communication with host
systems, such as a DCS or an asset man-
agement system, can be either wired or
via WiFi—in both cases, typically using
an Ethernet protocol.
This blending of WiFi and Wire-
lessHART enables the realization of
Industrial Internet of Things (IIoT)
concepts in which IT and OT are inte-
grated as never before. These networks
encompass wireless field devices, smart
sensors, asset management solutions and
analytics that are able to deliver digital
transformation.
Making it happen to the fullest ex-
tent requires many WiFi wireless access
points (WAPs) using high-bandwidth
technology. At the scale of a typical re-
finery, this could mean anywhere from
100 WiFi WAPs–400 WiFi WAPs to
achieve complete and seamless coverage.
When implemented, access is available
anywhere, allowing the capabilities of
mobile workers and rapid wireless instru-
mentation deployment to be realized.
Routers simplify deployment plan-
ning, thanks to their modular design. If it
is necessary to add a WirelessHART or an
ISA100 gateway to a given unit, this can be
done easily. Smart antennas for wireless
instrumentation can improve range, while
restricting coverage to inside the fence
line. Most routers are Class 1/Division 2
rated, and antennas are Class 1/Division 1
for extension into hazardous areas.
Some users are suspicious of wireless
networks believing they add a larger at-
tack surface for cyber criminals. Fortu-
nately, networks and their current-design
hardware use very strong defensive mech-
anisms. For example, WirelessHART is
protected by 128-bit AES encryption at
the network/transport layer and a two-
factor network joining mechanism. De-
sign of WiFi networks and interfaces with
other systems will normally be left to the
IT group, so it can use the latest security
tools and practices to avoid vulnerabili-
ties at data hand-off points. Companies
that routinely update routers and other
network equipment avoid the problems
Instrumentation and Automation
resulting from keeping multi-generation- startup, which can lead to millions
al hardware in place, which forces the use of dollars in revenue, thanks to
of older security techniques. additional uptime
• Higher plant availability through
User advances. How are companies a reduction in unexpected
putting these technologies to work? shutdowns.
Companies that have implemented im- These are all elements of digitali-
provement programs with digitization zation, and there are many more pos-
point to a variety of areas where they sibilities, as clever and creative people
have seen major advances: discover new ideas. When wireless
• Improved WiFi and WirelessHART infrastructure performs to the extent
infrastructure with higher data that users do not have to think about it,
transfer rates and reliability whether at the device or corporate net-
• Improved personnel safety with work level, great progress can be made.
location and mustering capabilities When vendors and users can point to a
• More detailed energy consumption global installed base with wireless net-
data, resulting in conservation and works, smart sensors and asset manage-
cost savings through expanded ment solutions, this is the realization of a
monitoring and data analysis digitalization vision.
• Improved manufacturing asset
reliability and availability CHRISTOPHER LOGUE is the
Global Product Manager for
• Increased productivity resulting wireless technologies at Emerson’s
from quick responses to Automation Solutions business.
abnormal conditions using In this role, he serves as an IIoT
mobile worker tools enabler for the implementation
of new wireless technologies in
• Faster execution of loop checks process plants worldwide. He holds a BSME degree
during commissioning and from Villanova University.
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 Special Focus Instrumentation and Automation
A. KERN, APC Performance LLC,
Red Lodge, Montana
Process engineering, optimization
and advanced process control
A recent Hydrocarbon Processing “Industry Perspectives”
survey found that process engineering and optimization is the
number-one topic that readers want to read about most.1 Pro-
cess engineering and optimization rated higher than the next-
highest topic (maintenance and reliability) by a factor of 2:1,
and higher than every other topic by a factor of at least 4:1. Pro-
cess control and instrumentation made the top ten list, albeit
below process engineering and optimization by a factor of 7:1.
These results suggest that managers and engineers want
optimization more than ever, but also that optimization makes
the most sense to them in the context of process engineering,
rather than process control. This raises the question: Exactly
how do optimization, process engineering and advanced pro-
cess control (APC) work together in an industrial process op-
eration environment?
Optimization by the layers. FIG. 1 is a common high-level
view of process optimization. However, what does optimiza-
tion look like from a more detailed, low-level view, especially
for sites that consist of multiple interconnected units, such as oil
refineries or petrochemical plants?
The top tier is site-wide production planning and optimi-
zation (PPO). PPO sets production plans and optimization
goals for each unit based on feedstocks, prices, commitments,
blendstocks, equipment in service, etc., in addition to (at least
rudimentary) models of individual unit performance capa-
bilities and the inter-relationships between units. From this
activity, each unit receives its production “marching orders,”
usually on a daily basis. This tier is the best-known aspect of
optimization, and indeed is the only tier that can generate a
complete site-wide optimization solution, comprising up-
dated production targets, optimization goals and constraint
limits, across all units. Subsequent (lower) tiers ideally should
implement or enforce the PPO optimization solution, not gen-
erate new or different solutions.
The second tier in optimization takes place at the unit
operation level, where each unit operating team implements
their piece of the site-wide optimization solution. This tier
is perhaps best represented by process engineers (also some-
times called production or operation engineers), who are of-
ten the most active players when it comes to following up on
production plans and optimization goals in actual operation
throughout the day, week and month. They tend to ensure
that targets, both short-term and long-term, are on track, and
Generates Site-wide optimization
Business layer
optimization Production planning and
solution optimization (PPO) planning
Plant intelligence
feedback
Unit optimization
Process engineering and operation Operation layer
Open-loop boots on the ground
Implements
optimization
solution
Control layer
Advanced process control
Closed-loop, sans optimizers automation
FIG. 1. A typical process optimization schematic, with additions to
highlight important aspects of APC 2.0, especially the distinction
between optimization solution generation vs. implementation, and
the role of APC multivariable control in a closed-loop implementation
support role, rather than acting as a separate, independent
optimization activity.
often pursue possibilities for exceeding targets, such as extra
volume, higher yield or greater efficiency. When actual pro-
duction either exceeds or falls short of PPO plans, it is often
the process engineer who troubleshoots operation, identifies
options and feeds this plant intelligence back to the business
planning side for continuous improvement of the planning
cycle. While the first tier is optimization planning, this tier is
optimization boots on the ground.
A third tier of optimization activity is APC. The role of
APC in operations and optimization is best understood as be-
ing ancillary to the role of process engineering—i.e., to imple-
ment the PPO optimization solution, rather than to generate
new or different optimization solutions. Additionally, the im-
portant distinction between the role of APC and the role of
the process engineer is that APC is closed-loop and on the job
continuously, whereas process engineers (and other operating
personnel) take breaks and have competing priorities. The
closed-loop nature of APC brings many obvious opportuni-
ties to improve upon the task of optimization implementation,
over what can be expected from the open-loop efforts of en-
gineers and operators. APC brings the same well-understood
Hydrocarbon Processing | NOVEMBER 2019 31
 Instrumentation and Automation
benefits as closing single-loop controllers, except APC con-
trollers in effect close multiple loops together, using multivari- solution normally does not change in real time. Typically, the
able control algorithms. This tier is optimization automation.
Experience has shown that communication
requirements between the optimization
solution and the APC controller are not
nearly as extensive or time-sensitive as
it was once thought they might become.
Optimization in the control layer? In this low-level look,
the role of the conventional embedded APC optimizer at the
control layer comes into question (noting that conventional
APC comprises a multivariable controller and an embedded op-
timizer). What is the role of the embedded APC optimizer at the
control layer, relative to the PPO solution at the business layer?
The embedded APC optimizer may have been necessary in
the 1980s, when few other computer optimization programs
existed in either the business or control layers, but today the
embedded APC optimizer can be seen as extremely limited
relative to modern business layer PPO solutions, which encom-
pass more extensive (site-wide) information and employ mod-
ern planning and optimization tools that have kept better pace
with technology. Can the PPO solution in the business layer
be adequately leveraged by the APC controller in the control
layer, thereby potentially eliminating the APC embedded opti-
mizer—which (after model maintenance) has been one of the
largest sources of APC’s continued high maintenance and high
total cost of ownership?
Experience has shown that communication requirements
between the optimization solution and the APC controller are
not nearly as extensive or time-sensitive as it was once thought
they might become. APC control must run at high frequency,
since process values change in real time, but optimization does
Solves move direction for
all handles simultaneously, Directional move-solver 5-sec period
based on gain direction, (or faster) implementation
constraint limits and
optimization targets
Implements pre-selected
move rates (also known as Pre-engineered
process speed limits) based move rates
on experience and safe
operating practice
Uses rate-predictive control,
a novel patented control Rate-predictive
algorithm, to taper moves control
predictively
FIG. 2. A proprietary APC 2.0 solution implements multivariable
control and optimization without reliance on detailed models or an
embedded optimizer.
32NOVEMBER 2019 | HydrocarbonProcessing.com
not need to run at high frequency, because the optimization
PPO plan is updated daily and affects only a handful of param-
eters that need to be pushed to the control layer, which are
normally passed down through the operating chain
of command rather than via network connectivity.
This allows for vetting and awareness of planned
changes before they are made, and allows opera-
tions to time the changes when necessary, based
on conditions on the ground. This picture suggests
that leveraging the PPO solution by APC is not
only possible, but for many purposes has already
become established as industry best practice.
Another rationale for the embedded APC opti-
mizer is its role in arbitrating the use of manipulated
variables (MVs) when more than one is available to
address a particular constraint control or optimiza-
tion objective. However, the majority of APC applications in
industry resorted long ago to using APC optimizer prices as
course tuning parameters, rather than real prices. This has the
effect of simply prioritizing the use of MVs, rather than assign-
ing them based on (often fragile) economics.
In industrial process operation, MV choice is primarily
an operation question and not a purely economic question.
This experience suggests that in many APC applications, a
straightforward prioritization scheme may be a more reliable
and effective approach to MV arbitration than an economic
optimizer.
New optimization and APC paradigm. The reader survey
results reflect sentiment for a more effective optimization para-
digm, especially in view of several inefficient legacy aspects of
the conventional “APC 1.0” paradigm. The APC 1.0 paradigm
remains on a trajectory of high cost and maintenance, and
end users are no longer confident that this trajectory can (or
should) be overcome without fundamental changes.
One potential change in a new “APC 2.0” paradigm, from
an optimization standpoint, is elimination of the embedded
APC optimizer in favor of better leveraging of the PPO so-
lution. This has the potential to bypass problematic aspects
of the embedded APC optimizer, while leveraging increased
value from the PPO activity (FIG. 2).
Another potential change is an organizational change,
wherein APC fills a straightforward closed-loop optimization
support role, rather than acting as its own op-
timization activity, separate and independent of PPO, which
has led to several inefficiencies.
LITERATURE CITED
1
Nichols, L., “Industry Perspectives: The topics our readers want most,”
Hydrocarbon Processing, July 2019.
ALLAN KERN is the owner of APC Performance LLC. He has
more than 30 yr of advanced process control (APC) experience
and has authored numerous papers on effective, low-
maintenance APC solutions. He is the inventor of patented
Rate-Predictive Control (RPC), industry’s only inherently
adaptive control algorithm; and of XMC, industry’s only
model-less method of multivariable control. Mr. Kern holds
professional engineering licenses in control systems and
chemical engineering, is a senior member of the International Society of
Automation (ISA) and is a 1981 graduate of the University of Wyoming.
 Special Focus Instrumentation and Automation
H. BOGER, Independent Consultant,
Birmingham, Alabama
The future of wireless control
In 1864, James C. Maxwell predicted the existence of radio-
waves by means of a mathematical model. The so-called Max-
well equations are the most famous and successful formulas.
In 1884, John H. Poynting realized that the Poynting vector
would play an important role in quantifying electromagnetic
energy. In 1888, bolstered by Maxwell’s theory, Heinrich Hertz
first succeeded in showing experimental evidence of radio-
waves using his spark-gap radio transmitter. The prediction
and evidence of radiowaves were the beginning of wireless
power transfer (WPT).1,2
During the same period, when Marchese G. Marconi and
Reginald Fessenden pioneered communication via radiowaves,
Nicola Tesla suggested the idea of wireless power transfer and
carried out the first WPT experiments in 1889.
To focus on the transmitted power and to increase the trans-
fer efficiency, a higher frequency than that used by Tesla is re-
quired. In the 1930s, significant progress in generating high-
power microwaves in the 1 GHz–10 GHz range was achieved by
the invention of the magnetron and klystron. After World War
2, high-power and high-efficiency microwave tubes were ad-
vanced by the development of radar technology. The power de-
livered to a receiver can be concentrated with microwaves. WPT
using microwaves is called microwave power transfer (MPT).
On the basis of the development of microwave tubes during
World War 2, W. C. Brown introduced the first MPT research
and development in the 1960s. First, Brown developed a rec-
tifying antenna, which he named a “rectenna” for receiving mi-
crowaves and rectifying microwaves. With the rectenna, Brown
successfully applied MPT to a wired helicopter in 1964 and to a
free-flying helicopter in 1968.
During the 1960s, numerous MPT laboratory and field
experiments were carried out around the world. A Canadian
group successfully conducted a fuel-free airplane flight experi-
ment using MPT in 1987. In Japan, several field MPT experi-
ments were conducted, such as fuel-free airplane experiments
with MPT phased arrays. Present work is centered on the charg-
ing of electric vehicles.
This article discusses a novel process for the wireless transfer
of power around an industrial site.
Existing wireless process devices. The introduction of
battery-powered field devices in September 2008 has enabled
manufacturers in the process control industry to add instru-
ments to applications where the cost of wired field devices
could not be justified. As a result, the use of wireless technology
has increased dramatically.
10
12
20 30 40 45 50 60
14
Source Receiver Field
device
87
85
Control
80 center
FIG. 1. Illustration of an exemplary process control apparatus.
Due to the conservative nature of the process industry, wire-
less analog and discreet field devices were initially installed to
better monitor process operation. However, as plant personnel
have gained experience with wireless technology, a growing in-
terest has been seen in using wireless measurement and wireless
actuators in closed-loop control. The cost advantages, along
with the proven reliability of wireless communication, are key
factors behind this change in practice.
Wireless field devices are offered by several suppliers, includ-
ing Fisher Controls, GE Measurement and Control, Honeywell,
Pepperl+Fuchs, Rosemount, Siemens, TopWorks and Yokogawa.
Each power module within the wireless unit contains two
C-size lithium/thionyl chloride batteries. Each battery contains
approximately 2.5 g of lithium, for a total of 5 g in each pack. Un-
der normal conditions, the materials are self-contained and are
not reactive as long as the batteries and pack integrity are main-
tained. Care should be taken to prevent thermal, electrical and
mechanical damage. Contacts should be protected to prevent
premature discharge.
Furthermore, power modules should be stored in a clean and
dry area. For maximum power module life, storage temperature
should not exceed 30°C. Caution should be used when han-
dling the power module, as it may be damaged if dropped from a
height of 20 ft or more. Also, battery hazards remain when cells
are discharged.
As with any battery, local environmental rules and regulations
should be consulted for proper management of spent batteries. If
no specific requirements exist, recycling through a qualified re-
cycler is encouraged. Consult the materials safety data sheet for
specific information.
Hydrocarbon Processing | NOVEMBER 2019 33
 Instrumentation and Automation

The WPT concept. An original concept for WPT has been Some field devices may include a transducer. Here, a trans-
patented in the U.S., and an international patent application has ducer means either a device that generates an output signal
been filed with the PCT. based on a physical input or that generates a physical output
Control systems are used to monitor and control inventories based on an input signal. Typically, a transducer transforms
of industrial processes. Typically, the control system performs an input into an output having a different form. A transducer
these functions using field devices distributed at key locations may include, for example, a pressure sensor, thermistor, ther-
in the industrial process and coupled to the control circuitry in mocouple, strain gauge, flowmeter, pH meter, positioner, ac-
the control center by a process control loop. The term “field de- tuator, solenoid, stepper motor, relay and indicator light.
vice” refers to any device that performs a function in a distrib- Typically, each field device also includes communication
uted control or process monitoring system, including all devices circuitry that is used for communicating with a process con-
used in the measurement, control and monitoring of industrial trol center, or other circuitry, over a process control loop. In
processes. As used here, “industrial process” refers to an oil re- some installations, the process control loop is also used to
finery, a chemical production facility or an electrical power gen- deliver a regulated current and/or voltage to power the field
eration station, for example. device. The process control loop also carries data in either
analog or digital format.
Traditionally, analog field devices have been connected to
300
the control center by single, two-wire process control current
312
340 loops for each device. Typically, a voltage differential is main-
20 30 350
342 45 352 tained between the two wires of the process control loop, gen-
HF energy HF 355 erally within a range of 12–45 volts for analog mode and 9–50
generator filter volts for digital mode.
353
Some analog field devices transmit a signal to the control
DC center by modulating the current running through the cur-
357f filter
rent loop to a current proportional to the sensed process vari-
387 able. Other analog field devices can perform an action via the
380 Control DC control center by controlling the magnitude of the current
center filter 360 through the loop. Additionally, or alternatively, the process
385 control loop can carry digital signals used for communication
FIG. 2. Source and receiver for a process control apparatus.
with field devices.
Digital communication allows a much larger degree of com-
munication than analog communication. Field devices that
557b 512 communicate digitally can respond to, and communicate selec-
514 tively with, the control center and/or other field devices. Fur-
560b
550b 516 thermore, such devices can provide additional signaling, such
545b
557a 545a 550c 560c as diagnostics and/or alarms.
In some installations, wireless technologies have been used
557c to communicate with field devices. Wireless operation simpli-
540a 545c fies field device wiring and setup. At present, wireless installa-
560a 550a
585b tions are used in which the field device is manufactured to in-
585a 585c clude an internal battery, potentially charged by a solar cell, or
580 585g another technique to obtain power without a wired connection.
Problems exist in using an internal battery, as the energy
Control demands of wireless devices may vary greatly depending on
center
585f numerous factors, such as the device reporting rate, device ele-
585d ments, etc., so that the battery may become exhausted unpre-
585h
557f dictably. When the battery is exhausted, the replacement of the
585i 560f battery usually requires a technician who is specially trained
550f
545f for that task. The battery may be physically difficult to access
545d 540b 545i 545g 557g for replacement due to elevation, due to being located within a
557d 557i
nest of pipes or equipment, or due to being placed in a hazard-
585e ous location, to name a few examples.
545h 540c
560d 550d 545e 560i 550i 550g 560g The battery is also known to transmit power to a field de-
560e 560h vice using non-radiative fields. For example, magnetic induc-
550e 550h tion may be used to transfer energy from a primary coil to a
557e 557h secondary coil without a direct electrical connection.3 Induc-
tive chargers, such as those found commonly in electric tooth-
FIG. 3. An exemplary process control apparatus that includes brushes, operate on this same principle.
field devices dispersed about the industrial process to wirelessly However, for these systems to operate efficiently, the pri-
communicate power to the receivers.
mary coil (source) and secondary coil (device) must be located
34 NOVEMBER 2019 | HydrocarbonProcessing.com
 Instrumentation and Automation

in close proximity and carefully positioned with respect to one

another. Therefore, the magnetic coupling between the source
and device coils must be large for proper operation. Further-
more, one primary coil transfers energy to one secondary coil.
Accordingly, there is a need for improved apparatus, as well
as related methods for control of industrial processes.

Novel process for wireless power transfer. These and other

needs and disadvantages may be overcome by the apparatus and
related method of operation discussed here. Additional improve-
ments and advantages may be identified upon further study.
The process control apparatus for the control of an industrial
process described here may include a single source of electrical
power supply dispersed across an industrial process. The source
converts the electrical power into a power signal. A number of
receivers may be dispersed across the industrial process, with
each receiver adapted to receive the power signal wirelessly, con-
vert the power signal into electrical power, and communicate
the electrical power into a field device. The power signal may in-
clude an oscillating magnetic field, M, or electromagnetic waves
that are generally in the ultra-high-frequency (UHF) range.
FIG. 1 illustrates an exemplary process control apparatus, in-
cluding a power supply, rectifier, source, receiver and field de-
vice. FIG. 2 illustrates the source and receiver. As shown in FIG. 2,
the rectifier inputs a voltage signal, which is sinusoidal, into a
source. The source further includes a capacitor and inductor in
series to resonate in response to the voltage signal and produce
an oscillating magnetic field.
FIG. 3 illustrates an exemplary process control apparatus that
includes field devices dispersed around the industrial process to
communicate power wirelessly to receivers. Receivers convert
power signals into electrical power and then transmit the elec-
trical power into the field devices.

Advantages of wireless power transfer. Wireless power

transfer eliminates the need for batteries and their replace- CHALLENGE
YOUR HORIZON
ment. The replacement of batteries may require a skilled tech-
nician to climb partway up a 100-ft-tall distillation tower on
the midnight shift. Personnel safety is an issue here. Due to the
desire to prolong battery life, update timing is sacrificed. Im-
proved process control will offset the cost of WPT.
Do you want to bring cylinder lubrication and
Recommendation. The author believes that wireless power compressor reliability into a harmonious
relationship?
transfer will be adopted in the process control industry. In the
The XperLUBE system supplies your
meantime, benefits and cost savings within the grasp of oppor-
compressor with exactly the right amount of
tunity are being lost. lubricant. At all times. Under any conditions.
LITERATURE CITED
1
Shinohara, N., Wireless Power Transfer Via Radiowaves, Wiley, Hoboken, New xperlube.hoerbiger.com
Jersey, 2014.
2
Blevins, T., D. Chen, M. Nixon and W. Wojsznis, Wireless Control Foundation:
Continuous and Discrete Control for the Process Industry, International Society of
Automation, October 2014.
3
Boger, H. W., “Wireless power transfer for process control,” US Patent No.
9,923,418, March 20, 2018

HENRY BOGER is a former VP of Masoneilan and is now an

independent consultant. He is credited with 23 U.S. patents
and has authored many published articles.

Hydrocarbon Processing | NOVEMBER 2019 35

XperLUBE_85x255.indd 1 04.03.2019 09:45:28

 Cybersecurity
J. BRAJKOVICH, ABB, Cleveland, Ohio
Pay attention: LockerGoga and Trisis/Triton
demand an improved cybersecurity strategy
The need for a solid cybersecurity
strategy has been discussed and debated
for nearly half a century. However, the ba-
sic worm-type attacks first documented
in 1972 are still with us today. Why? The
reason is because even the most basic
measures to protect control systems from
these types of attacks are still not system-
atically employed.
It is hard to believe that there are still
thousands of systems in operation with-
out any basic security controls in place.
If you own a car, a house or a boat—just
about any “big-ticket” item that would
be expensive to replace—you protect
that asset with insurance. Even though
you cannot see it or feel it, you know, in-
stinctively, that it is worth the money. You
sleep better at night knowing you have it,
and that it would be a high-priority item
to reacquire if you lost it, especially if it
contributes to your livelihood. However,
when it comes to control system cyberse-
curity, for some reason, this type of think-
ing is often not applied. Cyber experts are
still struggling to convince senior man-
agement that they need to spend money
to protect their control system assets.
However, starting in 2017, major se-
curity events set off alarm bells in board
rooms across the industrial world. Two
viruses—WannaCry and NotPetya—
wreaked havoc on companies that were
running older Microsoft Windows op-
erating systems but failed an entry-level
cybersecurity test: keep your systems
patched and up to date. More recently,
newer ransomware such as LockerGoga
and malware like Trisis/Triton have tak-
en down entire company networks.
All these viruses were destructive.
WannaCry and LockerGoga were standard
ransomware, but NotPetya was a wiper
bug that masqueraded as ransomware. Its
purpose: cause maximum damage to the
36 NOVEMBER 2019 | HydrocarbonProcessing.com
systems it infected. It forced thousands of
large, complex operations in many indus-
tries to halt production by scrambling data
and offered no way out to its victims, such
as paying for decryption keys. Similarly,
Trisis is malware that targets industrial con-
trol systems, specifically the safety systems
that allow industrial facilities to shut down
safely in emergency situations. Reports
show that the group behind Trisis/Triton
continued to attack distributed control sys-
tems (DCSs) throughout 2018 and 2019.
Companies that were impacted dis-
closed the financial impact of these at-
tacks. These include:
• One of the world’s largest producers
of lightweight metal suffered
losses worth $52 MM in 1Q 2019
• One of the world’s largest container
shipping companies, with substantial
oil and gas assets, wiped as much as
$300 MM off its books in 3Q 2017
• A French building materials
manufacturer lost approximately
€250 MM in sales
• The worldwide pharmaceutical
production of a major drug producer
was disrupted, and the total financial
impact is still unknown
• A major international package
delivery company announced
losses of $300 MM.
This money could have refreshed lega-
cy systems, acquired new assets, invested in
research and development, paid employee
bonuses, delivered stockholder dividends,
etc. Some of it should have been spent
hardening these organizations’ systems
against such events. So why was it not?
Why companies do not invest in cy-
ber security. Part of the answer is sim-
ple. It is hard to convince companies to
spend money on something that has no
measurable return on investment. Basi-
cally, it is hard to put a dollar value on an
event that may not happen.
Everyone knows that cybersecurity is
important and that it falls into the gen-
eral category of risk management. How-
ever, as an event such as the massive oil
spill in Alaska’s Prince William Sound in
1989 proves, the cost of doing nothing is
far greater than the cost of being proactive
(super tankers are now made with double
hulls to prevent a repeat of that ecologi-
cal disaster). It is not that control system
owners do not deploy cyber and security
solutions; they do. They are aware of the
problem and take actions to avoid risks.
However, many in the industrial world
are still too focused on the big attack or
hack—the nation-state that blacks out
an entire region or shuts down the water
supply to a city—when the bigger risk is
common malware that impacts a control
system because it is running older, unpro-
tected and unpatched operating systems.
This risk exists even if the system is
“air-gapped” from the business’ network.
People going about their daily routines
often introduce data and software using
removable media, such as USB drives, to
make changes to their systems, introduc-
ing the potential for viruses along the way.
As these air-gapped systems become more
interconnected to enable integration with
business applications, they become in-
creasingly exposed to the internet. There-
fore, it is far more likely that common mal-
ware is the threat that will cause the most
damage in the long run—just as we have
seen with the string of cyberattacks over
the last several years.
A fundamental disconnect exists in
securing operational technology (OT)
vs. information technology (IT). As OT
becomes more exposed to the internet,
it faces the same cybersecurity threats as
any other networked system. This is be-
 Cybersecurity

cause operators have adopted the same
hardware, software, networking protocols
and operating systems that run and con-
nect everyday business technologies, such
as servers, personal computers (PCs) and
networking gear.
Simultaneously, many machines and
legacy systems are so old and propri-
etary, no self-respecting cyber-criminal
would ever write malware to attack
them. Why? The answer is there are not
enough of these systems to make it prof-
itable or notorious.
This leaves control system operators
in a tough position. If they try to deploy
the same security measures as IT, then
(1) they may not work or (2) IT security
measures, when effective, may shut down
a running production process. This could
be more harmful for the business than
the cyber-attack.
The problem is that IT cybersecurity
solutions tend to focus on locking down
data when there is a threat. That makes
sense if it is a credit card database, but
it does not work out so well if a firewall
blocks programmable logic controllers
(PLCs) from opening and closing valves
in an oil refinery or pulp mill.
Luck is not a strategy. Then, there is
just human nature. Many operators sim-
ply rely on wishful thinking that goes
something like this: “We have not had an
incident; therefore, we must be doing the
right things.” Well, not really. If you as-
sume not having been attacked or hacked
means you are doing enough, think again.
You could just be lucky. Being lucky is
great, but you should not rely on luck as
a strategy. Talk to a professional gambler
and they will tell you the same thing—
eventually your luck runs out.
How do you know the difference be-
tween luck and “doing the right things?”
Ask the following questions. If you an-
swer “no” or “don’t know,” then perhaps
you should consider your organization
“lucky” and start taking a hard look at
your cybersecurity posture and policies:
1. Do you regularly train your
employees on cybersecurity
best practices?
2. Do you have a comprehensive
list of cyber assets?
3. Have you performed an
operational risk assessment?
4. Have you performed a
cybersecurity assessment?
5. Have you implemented proper
network segmentation?
6. Have you implemented
endpoint malware prevention,
and do you update the
signatures daily?
7. Do you patch your systems
on a regular basis (minimum
quarterly, ideally monthly)?
8. Are you monitoring your system
logs and network traffic?
9. Do you have a backup of all
your assets, such as switches,
routers, firewalls, PLCs, remote
terminal units (RTUs), intelligent
electronic devices (IEDs) and
every other digital control asset
with a configuration file?
10. If your system were compromised
today, do you have a recovery
and response plan ready?
If you answered “no” to one or more

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Hydrocarbon Processing | NOVEMBER 2019 37

 Cybersecurity

of these questions, you are not alone.
Most control system owners do not em-
ploy this level of cybersecurity readiness.
However, at a base level, if you do not
have proper network segmentation, up-
dated system software, endpoint protec-
tion and hardened systems, then you are
probably lucky that your system has not
been compromised.
Getting up to cyber speed. When
thinking about how to get started, do not
just look for some new technology that
claims to mitigate all your risks—it does
not exist. Doing the basics well before
investing in advanced cyber technologies
is the key. To minimize your risks and get
the most protection in the least amount
of time, you will first need to plan and de-
velop a cybersecurity program that:
1. Identifies what assets must
be protected
2. Determines how to protect
those assets
3. Enables intrusion detection
and monitoring
4. Defines incident response
processes and procedures
5. Verifies mechanisms to restore
and recover assets.
All the cybersecurity best practices
frameworks can be distilled into these ba-
sic steps: identify, protect, detect, respond
and recover. For example, putting in a
firewall to separate your control system
from the corporate/business network is
a great idea. However, if you do not have
an inventory of critical assets and applica-
tions, you may still be vulnerable to risks
from employees and contractors who use
laptops and removable media. Develop
strong security policies and practices, and
map out a 3 yr–5 yr journey that leads to
security maturity.
Some effective technology tactics
to consider are instilling hardened pe-
rimeters, adopting a defense-in-depth
approach, whitelisting, investing in net-
work intrusion prevention, air-gapping
control systems and scheduling security
awareness training for all employees. In
addition, make sure to include specific
contractual language about cybersecurity
in your OT/control system requests for
proposals. To execute your plan, leverage
your IT and OT teams, but also look for
OT suppliers that can offer comprehen-
sive cybersecurity services.
Takeaway. The list of things you should
do to protect your operational technol-
ogy is long and beyond the scope of this
article, but if you continue to do nothing,
pretending that your systems are safe from
attack, it is only a matter of time before
you will no loner be pretending. Eventual-
ly, your luck will run out, and maybe it will
be your systems that go down, and your
company that ends up in the headlines.
JOHN BRAJKOVICH is the
Operations Manager of the
U.S. Advanced Services group at
ABB. He has more than 10 yr of
experience in OT. Mr. Brajkovich
oversees a team of engineers that
deliver a wide range of services,
including process optimization, system performance
optimization and cybersecurity. Outside of supporting
solutions, Mr. Brajkovich is also involved in consultative
efforts in corporate security control frameworks and
emergency procedures for OT cybersecurity breaches.
His background in industrial control systems is an
asset for cybersecurity working alongside IT.

LIVE WEBCAST
Tuesday, November 26, 2019 | 10 a.m. CST | 4 p.m. UTC

Asset Performance Management: Creating an effective

Glyn Rhodes strategy that delivers
VP of Software Product Management
Lloyd’s Register Whether RBI or RCM, the methodology that you follow is only one part of developing
an effective asset performance strategy. More often than not, it is the commercial
imperatives that can dictate and drive how organizations implement their strategy. At
a time when operators are looking to achieve more with the same, or less, maintaining
a level of robustness and flexibility in your asset performance management strategy is
essential. Digital platforms play a critical part but having to strike a balance between
technology and methodology to achieve your commercial goals is no longer a decision
one needs to make.

Register for Free:

MODERATOR: HydrocarbonProcessing.com/Webcasts
Mike Rhodes
Managing Editor
Hydrocarbon Processing

38 NOVEMBER 2019 | HydrocarbonProcessing.com
 2019 AWARDS

WINNERS
Hydrocarbon Processing, the downstream processing sector’s leading technical
publication, has announced the winners for its third annual awards. The HP Awards
celebrate innovative technologies and people that have been instrumental in improving
facility operations over the past year. The awards cover 17 strategic categories
in the hydrocarbon processing industry. Nearly 100 nominations were submitted
from more than 20 countries. Each abstract was voted on by an independent
Hydrocarbon Processing advisory board. The following is a complete list of the
winners in each category. The winners were announced during a black-tie gala at
The Houstonian Hotel in Houston, Texas on November 6.

HYDR OCAR BONP R OCESSIN G. COM / AWA R DS

 BEST AR/VR/AI TECHNOLOGY
FINALISTS: AI Operator, Chemtech AI; NuSpace, Imaginate Software Labs Pvt. Ltd.

WINNER: COMPACS System, Dynamics Scientific Production Center USA

The COMPACS system provides an objective
real-time monitoring of each machine of an
entire process unit. Artificial intelligence generates
real-time prescriptions and predictive analytics
that identify future malfunctions and defects.
This analysis can dramatically reduce accidents
and fires, increase uptime of process units
and provide reasonable maintenance costs.

BEST ASSET MONITORING TECHNOLOGY

FINALISTS: Stingray Online Tank Inspection System, Diakont;
Salus, Smith and Burgess Process Safety Consultants

WINNER: Mtell®, Aspentech

Aspen Mtell® delivers the earliest, most accurate warning of
equipment failures and prescribes detailed actions to mitigate
or solve problems. Using machine learning, Aspen Mtell can
recognize precise patterns in operating data that indicate
degradation and impending failure—well before it happens.

BEST CATALYST TECHNOLOGY

FINALISTS: Celestia™, ExxonMobil/Albemarle; Ionikylation, Well Resources Inc.

WINNER: Valor™, BASF

Valor™ is a next-generation fluid catalytic cracking (FCC) catalyst technology designed
to enhance the performance of FCC catalysts processing heavy residuum oil feedstock.
Refineries using Valor™ technology in their FCC units achieved catalyst activity
retention with lower hydrogen and coke yields. This new catalyst achieves efficient
passivation of vanadium with increased tolerance against sulfur, effectively enabling
refiners to increase resid processing without sacrificing conversion or product yields.

40 NOVEMBER 2019 | HydrocarbonProcessing.com
 DIGITALIZATION—BEST DIGITAL TWIN/
OPERATOR TRAINING TECHNOLOGY
FINALISTS: Honeywell Forge for Industrial, Honeywell Process Solutions; Operational Risk Management software, SPHERA

WINNER: ROMeo Process Optimization, AVEVA

Rigorous Online Modeling with Equation-based
Optimization (ROMeo) is a digital twin for operations
and planning activities that uses real-time process and
economic data to determine set points that guarantee
maximum operating profit, while satisfying all regulatory
requirements. Plant processes are digitally represented
with well-defined, first principle models, which provide
the basis for simulation, data reconciliation and
optimization in real time.

DIGITALIZATION—BEST PROCESS/
PLANT OPERATIONS OPTIMIZATION TECHNOLOGY
FINALISTS: DCP Strategy 2.0, DCP Midstream; gPROMS® Digital Applications Platform, Process Systems Enterprise;
Integrated Manufacturing Operations Management System, Saudi Aramco

WINNER: Unified Operations Center, AVEVA

The Unified Operations Center empowers the whole team with a centralized
view to help make informed decisions. This improves process safety,
operational efficiency and profitability. The center is based on a “systems-
of-systems” approach, which includes plug-in and integrated apps, analytics,
closed-circuit television, GIS maps, ERP systems, engineering piping and
instrumentation diagrams, etc. The Unified Operations Center integrates
these aspects, departments and sites under one platform.

DIGITALIZATION—BEST SOFTWARE TECHNOLOGY

FINALISTS: Digital Terminal, Atomiton; Polarion®, Siemens

WINNER: Secure Media Exchange, Honeywell Process Solutions

This technology provides a new type of cybersecurity defense layer for industrial
companies, protecting critical systems against threats introduced by universal serial
bus (USB) devices. The software not only watches for and controls malware on USBs,
but also helps detect malicious USBs that attempt to take advantage of protocol
to perform unauthorized actions.

Hydrocarbon Processing | NOVEMBER 2019 41

 EPC, LICENSOR, CONSULTANT OF THE YEAR
FINALISTS: S&B Engineers and Constructors, Smith and Burgess Process Safety Consultants

WINNER: McDermott
Within the past year, Lummus Technology joined
McDermott. McDermott’s Lummus Technology business
offers the most broad, diversified technology portfolio
in the marketplace, with more than 120 licensed
technologies and 3,100 patents and patent applications.
In the past year, Lummus has been awarded more than
80 contracts and reached numerous milestones, including the licensing of the largest PDH unit in the world and the largest CDAlky®
unit ever. Being part of the new McDermott allows Lummus Technology to offer complete EPC and modular solutions in addition to
the company’s technology portfolio, and allows McDermott to leverage additional regional resources to expand its global footprint.

BEST FLUID FLOW TECHNOLOGY

FINALISTS: Barracuda Virtual Reactor®, CPFD Software; FT4X Thermal Mass Flowmeter, Fox Thermal

WINNER: Cavitation Detection System, Yokogawa Electric Corp.

Pumps used in process and
manufacturing plants are often
vulnerable to failure from cavitation.
In the past, it has been difficult to
detect the early signs of cavitation
before substantial damage occurs.
However, Yokogawa’s new cavitation
detection system uses advanced
analytics to interpret minute pressure
changes stemming from cavitation
events, revealing very early cavitation
conditions before vibration or noise
events are noticed. More importantly,
the information can be applied to troubleshoot root causes. This technology enables refiners to save significant amounts of
money on maintenance and downtime costs.

BEST GAS PROCESSING/LNG TECHNOLOGY

FINALISTS: Enhanced C2 recovery process by utilizing demethanizer bottom reflux, Saudi Aramco;
CYNARA PN-1, Schlumberger; SIDRIVE IQ, Siemens

WINNER: Deep Dewpointing Process, Fluor

Fluor’s cryo-gas technology application is designed for rich, unconventional gas applications
(e.g., shale gas) with ethane liquid contents of 6 gpm–12 gpm and feed pressure ranging from
500 psig–900 psig. The process can achieve 95% propane recovery in full ethane rejection
mode and can recover 60% ethane in ethane recovery mode. This innovative technology is
critical for midstream organizations that need flexibility, performance and capital efficiency
in processing rich natural gas.

42NOVEMBER 2019 | HydrocarbonProcessing.com

 BEST HEALTH, SAFETY AND ENVIRONMENTAL CONTRIBUTION
FINALISTS: SMR integration and increased CO2 production—Stage 3, Air Liquide; Building Technology HSSE app, Siemens

WINNER: Process Safety Suite, Honeywell Process Solutions

Most hazard and operability studies and layer of protection analysis documents sit on the shelf
until the next revalidation. Honeywell’s Process Safety Suite (PSS) software employs the user’s
own risk analyses to create a digital twin for safety. PSS continuously validates the user’s actual
performance against the assumptions in the risk analysis, providing insights to all levels of the
organization, from the control room to the boardroom.

BEST INSTRUMENT TECHNOLOGY

FINALISTS: SmartLine® Application and Validation Tool, Honeywell Process Solutions;
OndaVia Analysis System, OndaVia, Inc.; Nexis™ SCD-2030, Shimadzu Corp.

WINNER: Rosemount™ 928 Wireless Gas Monitor, Emerson

This wireless gas monitor continuously monitors for the presence of toxic hydrogen sulfide gas in
challenging, difficult-to-reach locations, thereby enhancing worker safety through early gas leak
detection while eliminating the need for expensive wiring.

BEST PETROCHEMICAL TECHNOLOGY

FINALISTS: Chlorinated Polyvinylchloride production technology, Reliance Industries Ltd.;
Ethylebenzene production technology, Sinopec

WINNER: CDAlky® and Olefins Conversion Technology, McDermott

The company recently expanded two of its technology platforms—CDAlky® and
Olefins Conversion Technology (OCT)—to commercialize efficient alkylation of C5s
in a novel reactor system or two-stage catalytic conversion of C5s to higher-value
propylene employing catalytic distillation and metathesis via OCT. The CDAlky®
sulfuric acid alkylation reactor design eliminates mechanical agitation with a unique
patented reactor internals design that uses the fluid motive force for efficient mixing
at lower temperatures, resulting in less acid consumption and superior alkylate
properties. Catalytic distillation plus OCT is a two-stage system that utilizes catalytic
distillation to tailor the feed mixture to the metathesis reactor to convert C5 olefins
to high-value propylene.

Hydrocarbon Processing | NOVEMBER 2019 43

 BEST PROCESS CONTROLS/AUTOMATION TECHNOLOGY
FINALISTS: General Dynamic Optimization Technology, Aspentech; Experion® Local Control Network, Honeywell Process Solutions;
OpenTAS® Terminal Management System, Implico Group; Process IQ, Schlumberger

WINNER: Catalyst Removal Amphirol (CAROL), Advisian Digital

Advisian Digital, part of the Worley Group, has developed an innovative technology
for robotic catalyst removal from refineries and LNG vessels using a remote-
operated, screw-propelled vehicle. CAROL helps reduce human risk and turnaround
durations. The technology has successfully completed several catalyst removal
projects in varying environments, reducing the need to put personnel in harm’s way.

BEST REFINING TECHNOLOGY

FINALISTS: Salus, Smith and Burgess Process Safety Consultants; Ionikylation, Well Resources Inc.

WINNER: IsoAlky™, Honeywell UOP

Honeywell UOP, in partnership with Chevron, has introduced a new alkylation technology that employs ionic liquids as a
catalyst to produce high-octane motor fuels. IsoAlky™ liquid alkylation technology uses a non-aqueous liquid salt, or ionic liquid,
at temperatures below 100°C to convert a typical stream from an FCC into a high-octane blending component that lowers
the environmental impact of motor gasoline. The ionic liquids process can be used in new refineries, as well as in existing
facilities undergoing capital expansion.

MOST PROMISING ENGINEER

FINALISTS: Yusuf Ahmed Al-Nafaiei, Bahrain National Gas Co.;
Abdulrahman Al-Shammari, Kuwait Integrated Petroleum Industries Co.; Chris Jansen, Advisian Digital;
Chris Runneberg, S&B Engineers and Constructors

WINNER: Kathleen Wills, Halliburton

Ms. Wills provides engineering support for Athlon Solutions, a Halliburton Service field sales and
service team focusing on corrosion control in refineries, with a major emphasis on crude unit
overhead condensing corrosion control. Over the past several years, she has quickly become
the go-to person for tough corrosion problems, has been asked to join several refinery corrosion
teams as an ad-hoc member, has helped develop monitoring programs and has helped advance
the company’s ionic equilibrium modeling technology. She is active in several associations,
including the National Association of Corrosion Engineers, where she chairs a subcommittee
on crude unit corrosion, and the American Fuel and Petrochemical Manufacturers.

44 NOVEMBER 2019 | HydrocarbonProcessing.com
 EXECUTIVE OF THE YEAR
FINALISTS: Jon Camp, Tube Tech International; Albert Rooyakkers, Bedrock Automation

WINNER: Kathleen Eisenbrenner, NextDecade Corp.

Kathleen Eisbrenner was an entrepreneur, visionary and major innovator in the natural gas
industry with more than 30 yr of experience and accomplishments in various leadership roles. In
2010, she founded NextDecade LLC, an LNG development company focused on export projects,
including Rio Grande LNG. She remained Founder, CEO and Chairman until February 2018, and
was still Chairman at the time of her passing in May of 2019. Ms. Eisbrenner was previously the
Executive Vice President at Royal Dutch Shell for Shell’s Global LNG strategy, was the Founder
and CEO of Excelerate Energy and the Chief Commercial Officer at El Paso Global LNG. She held a
BS degree in civil engineering from the University of Notre Dame and participated in the Harvard
Business School Strategic Marketing Management Program.

LIFETIME ACHIEVEMENT
FINALISTS: Harold Eggert, Halliburton; Michael Stilley, S&B Engineers and Constructors

WINNERS: James Sorokes, Siemens; Pinti Wang, Sulzer GTC Technology

Mr. Sorokes will soon celebrate 43 yr with Dresser-Rand (now Siemens GP Oil and Gas).
His outstanding contributions to compressor aerodynamics, radial compressor design and
testing are widely recognized throughout the industry. His long-standing professional
association with the company, publication in industry journals and periodicals and
participation as an instructor in several short courses have established him as a world-class
expert in the area of aerodynamics and fluid-induced vibrations of centrifugal compressors.
Mr. Sorokes has been an active member of the ASME and the ASME IGTI Turbomachinery
Committee for several decades, and is a regular lecturer and tutorial/short course instructor
at the Texas A&M Turbomachinery Symposium and other university and technical conferences
and private business venues. He has authored or co-authored 54 technical papers and holds
10 patents for designs associated with aerodynamic component design and manufacturing.
In 2008, he was named an ASME Fellow and launched a program to promote cross-functional
engineering training, hosting more than 120 sessions with attendees spanning five continents.
In 2015, he was inducted into Dresser-Rand’s Engineering Fellowship Program.

Mr. Wang is the President and CEO of GTC Technology. After completing his BS degree in
chemical engineering, Mr. Wang served as a Second Lieutenant in the Republic of China Air
Force. After completing his military service, he relocated to the U.S. and earned an MS degree
in chemical engineering from the University of Kansas. He began his career at Mass Transfer.
Over the next 17 yr, he was appointed to a variety of high-level technical and commercial
roles worldwide. In 2002, Mr. Wang and several colleagues purchased Glitsch Technology Corp.
from Foster Wheeler and formed GTC Technology, with Mr. Wang as Chairman and CEO. The
company has celebrated dozens of successful licenses throughout the world, while gaining
recognition in the aromatics and refining fields. In 2019, as a result of the company’s growth
and success, GTC Technology became a part of Sulzer. Mr. Wang continues to play a vital role
as GTC Technology’s President, overseeing a smooth transition into Sulzer and ensuring the
profitability of the company.

Hydrocarbon Processing | NOVEMBER 2019 45

 Catalyst
T. TAVARES, W. R. Grace & Co.,
Baltimore, Maryland
Unlocking FCC potential with an innovative
catalyst solution
In 2010, a JV a embarked on the deployment of a MHY
zeolite technology b developed at the Massachusetts Institute
of Technology. This novel zeolite technology improves tradi-
tional zeolite catalysts through the introduction of highly in-
terconnected channels of medium pore size, which enhance
diffusion of feed molecules inside zeolite crystals, leading to
higher-value product yields, improved process efficiency and
increased refinery profitability. The JV co-developed and
commercialized this groundbreaking new fluid catalytic crack-
ing (FCC) catalystc in 2012.
Introducing ordered mesoporosity. The MHY-zeolite
catalyst technology is a surfactant-templated, post-synthesis
zeolite, meso-structuring process that introduces ordered,
well-controlled and hydrothermally stable mesoporosity into
zeolite crystals (FIG. 1). The MHY-zeolite manufacturing pro-
cess is engineered to allow a high degree of control in the size
and the amount of ordered mesopores created inside the zeo-
lite crystal, resulting in homogeneously distributed and inter-
connected pores.
The MHY-zeolite catalyst technology enhances feed mol-
ecules’ access to and from active catalytic sites in the zeolite.
As a result, the MHY-zeolite catalyst’s zeolites crack larger FCC
feed molecules more selectively than conventional active ma-
trix materials. This allows refiners to make more primary crack-
ing products, including LPG olefins and less coke per unit of
conversion, both of which are highly valued by many refiners.
In FIG. 2, the image on the left shows a scanning electron mi-
croscope (SEM) photomicrograph of a conventional Y-zeolite.
Each crystal face contains millions of 7.5-angstrom diameter
FIG. 1. Controlled and ordered mesopores formation.
46 NOVEMBER 2019 | HydrocarbonProcessing.com
micropores, which are too small to see even at 100,000 times
magnification. The image on the right shows a photomicro-
graph of the MHY-zeolite at similar magnification. While the
micropores still cannot be seen at this magnification, the ex-
tensive network of MHY-zeolite’s mesopores is clearly visible.
SEM, HR-TEM, electron tomography and rotational elec-
tron diffraction all show co-existence of mesoporosity and
crystallinity/microporosity within the same zeolite crystal.1 It
is this proximity of micro and mesoporosity within the same
zeolite crystal that provides the MHY-zeolite catalyst technol-
ogy its enhanced catalytic performance characteristics (FIG. 3).
The MHY-zeolite catalyst advantage. With conventional
Y-zeolites, molecules with kinetic diameters up to approxi-
mately 1 nm (10 Å) can directly enter the Y-zeolite structure.
This corresponds to hydrocarbons that boil up to 510°C
(950°F). Larger hydrocarbons boiling above this temperature
are traditionally cracked in the FCCU by mesoporous alumi-
nas. These materials have somewhat less selective acid sites,
and the goal is to cleave off hydrogen-rich side chains, which
can subsequently enter the zeolite cage.
With the vast network of ordered mesopores (3 nm–5
nm; 30 Å–50 Å) in the MHY-zeolite catalyst, larger feed mol-
ecules—which boil at temperatures in the range of 510°C–
593°C (950°F–1,100°F)—are now able to directly access
the strong acid sites in the zeolite (FIG. 4). The MHY-zeolite
catalyst can crack these larger feed molecules more selectively
than conventional active matrix materials. This translates
commercially into coke-selective bottoms cracking. In addi-
tion, the MHY-zeolite catalyst technology rapidly channels
the valuable cracked products out of the zeolite before they
succumb to potentially undesirable reactions, such as over-
cracking, hydrogen transfer or condensation reactions, to
form coke within the catalyst pores.
Among the primary and secondary “cracked products,”
LPG olefins are very reactive, particularly at the high tem-
peratures present within the FCCU riser and reactor. If these
valuable, reactive molecules spend too much time inside the
catalyst, they can become saturated through hydrogen transfer
reactions into less valuable LPG paraffins. The MHY-zeolite
catalyst’s ordered mesopores allow rapid transport of valuable
LPG olefins out of the zeolite. Preservation of primary prod-
ucts, in conjunction with reduced hydrogen transfer, also leads
to a boost in research octane number (RON).
 Catalyst

This new catalyst represents the first and only use of ordered
mesoporosity in FCC zeolites or catalysts and can provide a
step change in value for many FCC operations. The result:
enhanced diffusion of hydrocarbons both into and out of the
catalyst particle. This adds options to process heavier feeds, re-
duce feedstock costs, circulate more catalyst and preserve valu-
able products, increasing operating flexibility for the refiner.
Performance signatures of the MHY-zeolite catalyst include:
• Increased LPG olefinicity
• Increase gasoline octane
• Decreased delta coke
• Improved bottoms upgrading
• Increased operational flexibility to the refiner.
Refiners around the world have used these signature ben-
efits to increase FCCU profitability in several different objec-
tive/constraint scenarios. These benefits improve operational
flexibility, allowing refineries to pursue heavier feedstocks via
delta coke reduction, reduce FCC dry gas without loss in LPG,
increase volume swell in delta coke limited operations and alle-
viate existing unit constraints, such as main air blower rate, wet
gas compressor rate and regenerator temperature.
• Main air blower rate—Increased feed preheat
temperature or decreased riser outlet temperature,
producing less coke and alleviating the air blower
constraint. These actions decrease catalyst circulation
and bottoms conversion, but the new catalyst’s improved
coke selectivity counteracts them. The feedrate can be
increased until a new constraint is met.
• Wet gas compressor rate—Enhanced diffusion reduces
over-cracking of valuable hydrocarbon products to dry
gas. This allows the feedrate—or operating severity—
to be increased until a new constraint is met.
• Regenerator temperature—Improved coke selectivity
increases the catalyst circulation rate, lowering the
regenerator temperature. This allows the feedrate—
or feed residue content—to be increased until a

Commercial success. The MHY-zeolite catalysts have been

used successfully in numerous commercial operations. No in-
crease in catalyst losses or stack opacity have been noted at any
of these locations, confirming the excellent physical proper- FIG. 2. Photomicrographs of conventional zeolite (left) and the
ties of the catalyst supplied. Several sets of commercial results MHY-zeolite technology c (right). At similar magnifications, micropores
(including stack opacity comments) have been published. in conventional zeolite are not viewable, while the 40-angstrom
Case Study 1. A previously published article2 detailed the network of mesopores within the MHY-zeolite technology are viewable.
ongoing operations at a former Motiva refinery (now Shell)
along the U.S. Gulf Coast. This FCCU processes a mix of
vacuum gasoil, heavy coker gasoils and resid. The feedrate of
10,000 bpd–15,000 bpd is typically pushed to a maximum air
blower/supplemental oxygen limit. The catalyst circulation
rate could be increased by approximately 10% over base levels
before meeting the maximum allowable circulation rate. The
catalyst addition was 50% fresh catalyst and 50% purchased
equilibrium catalyst (Ecat), mainly to assist with metals man-
agement. API and continuous catalytic reforming (CCR)
generally remained in similar ranges as before the trial. The
MHY-zeolite catalyst demonstrated notable improvements in
coke selectivity, dry gas selectivity, LPG olefinicity, bottoms
reduction and C3+ total liquid volume (FIG. 5). The result was
an uplift in the range of $0.40/bblFF –$1.20/bblFF depending FIG. 3. Mesopores are integral to the MHY-zeolite technology crystal.
on the market economics.
Case Study 2. A commercial trial—in a “high added-iron
(Fe)” (e.g., +0.4 wt% added Fe) operation—had the primary
objective of reducing the regenerator temperature for a given
amount of vacuum tower bottoms in the feed. Over the course
of the trial, the delta coke and regenerator temperatures both
steadily decreased, as desired (FIG. 6). The MHY-zeolite cata-
lyst provided the refinery with increased operating flexibility to
process lower-cost feeds, while not exceeding unit constraints.

Overcoming constraints. The MHY-zeolite catalyst provides

improved bottoms upgrading, increased olefinicity and octane,
decreased delta coke and decreased dry gas production. Refin-
ers have used these trademark benefits to increase FCC feed FIG. 4. Advantages of utilizing the new MHY-zeolite catalyst in
FCC operations.
throughput by alleviating existing unit constraints, such as:
Hydrocarbon Processing | NOVEMBER 2019 47
 Catalyst

new constraint is met. As demand for petrochemicals increases, the addition of the
This improved operating flexibility allows for increased cata- MHY-zeolite technology will allow additional solutions and
lyst circulation via lower delta coke, or the introduction of heavi- greater flexibility in converting crude oil to petrochemical feed-
er opportunistic feeds, if increased circulation is not possible. stocks and other chemical applications.
NOTES
What’s next? This technology has broad applicability to a
Refers to the JV consisting of Rive Technology Inc. and W.R. Grace Co.
different types of zeolites. Demand for transportation fuels is b
Refers to Molecular Highway® zeolite technology developed by Dr. Javier Garcia-
projected to peak in the next decade, as competing influences Martinez
c
Refers to Rive® FCC catalyst powered by Molecular Highway™ Y-zeolite (also
of population growth and higher living standards are offset branded as MHY™)
by fuel efficiency trends. Many refiners are considering shift- LITERATURE CITED
ing FCC objectives to produce light olefins for petrochemical 1
Garcia-Martinez, J., et. al, “Evidence of intracrystalline mesostructured porosity
feedstocks to best utilize existing FCC assets. It is estimated in zeolites by advanced gas sorption, electron tomography and rotation electron
that the demand for petrochemical feedstocks will increase by diffraction,” ChemCatChem, 2014
2
Rakasekaran, K, R. Adarme, C. Cooper C and N. Faulkenberry, “Motiva unlocks
more than 7 MMbpd over the next 20 yr, surpassing oil de- value in FCCU through an innovative catalyst solution from Rive and Grace,”
mand from the transport sector. AFPM Meeting, 2017

112 1,370
Incumbent
111 1,350 MHY-zeolite catalyst

Regenerator bed temperature, °F

110
1,330
C3+ total liquid volume, %

109
1,310
108
1,290
107
1,270
106
105 Incumbent 1,250
MHY-zeolite catalyst
104 1,230
75 85 95 105 115 965 970 975 980 985 990
Total feedrate, thousand bpd Riser outlet temperature, °F
3.5 2.50
Incumbent Incumbent
3.3 MHY-zeolite catalyst MHY-zeolite catalyst
2.00

3.1
Total dry gas, %

Slurry ash, wt%

1.50
2.9
1.00
2.3

0.50
2.3

2.3 0.00
965 970 975 980 985 990 12/22 2/20 4/20 6/19 8/18 10/17 12/16
Outlet temperature, °F Date

FIG. 5. Case study 1: Operational data on the new MHY-zeolite catalyst.

34 14 1,370 0.90
Regenerator dense bed temperature, °F

Incumbent Trial began Coke selectivity began to manifest Incumbent

33 12 1,360 0.85
MHY-zeolite catalyst MHY-zeolite catalyst
Catalyst circulation rate, tpm

1,350
Percentage VTB in feed

32 10 0.80
Delta coke, wt%

1,340
31 8
1,330 0.75
30 6
1,320 0.70
29 4 1,310
Percent VTB in feed 0.65
28 2 Regenerator dense T 1,300
27 0 1,200 0.60
5/9 5/29 6/18 7/8 7/28 8/17 5/9 5/19 5/29 6/8 6/18 6/28 7/8 7/18 7/29 8/7 5/9 5/29 6/18 7/8 5/28 8/17
With similar VTB content and significantly higher feed metals,
regenerator T decreased by about 15°F

FIG. 6. Case study 2: Over the course of the trial, the delta coke and regenerator temperatures both steadily decreased while using the
new MHY-zeolite catalyst.

48 NOVEMBER 2019 | HydrocarbonProcessing.com
 Catalysts
B. ARAMBURU and E. PÉREZ, CEPSA,
Madrid, Spain, M. MIRANDA and M. C. MASTRY,
BASF, Sevilla, Spain

FCC catalyst deactivation studies to mimic

refinery conditions for high-propylene applications
The fluid catalytic cracking unit (FCCU) is a conversion For this reason, the La Rábida refinery decided, based on
unit located at the heart of many refineries. Its main pur- laboratory testing and an FCCU trial, to use a maximum pro-
pose is to crack crude oil-derived feedstocks into valuable pylene catalyst technology—a technology that is aimed at
liquid products, primarily LPGs (propylene and butylenes), processing challenging and changing feeds, while maximizing
and gasoline and light-cycle oil (LCO) precursors. The pro- propylene production through both high-conversion and high-
cess uses a fluidizable catalyst, comprising an alumina-silica propylene selectivity.
framework and tailored for each refinery to meet its specific To support this historical change, CEPSA’s research center,
needs. Often, the changing of a catalyst includes catalyst test- located in Madrid, Spain, was tasked with catalyst evaluation.1
ing evaluations, employed by about 50% of the FCCUs in the The CEPSA organization follows a robust testing evaluation
world. The testing process is cumbersome, in which multiple process for the implementation of catalyst changes. This in-
methods are available to refineries. volves receiving potential catalyst samples and testing these
The first step to a laboratory catalyst evaluation is the de- samples in a circulating pilot plant. The research center has
activation step. In this step, laboratory scientists aim to mimic undertaken multiple projects to increase technical expertise in
what happens in a refinery over the course of several weeks the space of FCC catalyst deactivation and testing to prepare
or months within just hours in the laboratory. It becomes for future catalyst evaluation exercises.
more complicated when a test aims to replicate the effect of
contaminant metals that come into the FCCU via crude oil Catalyst deactivation study. This FCC catalyst study fo-
processing and deposit onto FCC catalyst particles. Multiple cused on evaluating the effect of multiple deactivation variables
deactivation methods are available, with the most common in catalyst evaluation. These included:
methods being:
• Only steam TABLE 1. Deactivation conditions for multiple samples
• Cyclic propylene steaming (CPS), which involves metals
impregnation using a solvent and subsequent redox cycle Sample Base catalyst deactivation ZSM-5 deactivation
• Cyclic metals deposition unit (CMDU), which employs Ecat N/A N/A
a cracking method.
Dcat B CPS with 1/3 Ecat metals 15 hr, steam only
After deactivation, refiners have the choice to test on a bench-
scale unit or on a larger unit (e.g., a circulating pilot plant). This Dcat C 5 hr, steam only 5 hr, steam only
article is a study in which a circulating pilot plant was employed, Dcat D 5 hr, steam only 15 hr, steam only
and multiple deactivation methods were examined. Dcat E 5 hr, steam only 30 hr, steam only
Dcat F 5 hr, steam only 75 hr, steam only
Catalyst evaluation at CEPSA La Rábida refinery. CEPSA
provides transportation fuels and petrochemical feedstocks to Dcat G 5 hr, steam only 100 hr, steam only
domestic and international markets. It operates three refineries
in Spain, with two refineries operating FCCUs (La Rábida in TABLE 2. Deactivated catalyst properties compared against
Huelva and Gibraltar San Roque in Cádiz). The FCCU at the Ecat sample
La Rábida refinery was originally designed to produce a wide
Sample TSA, m2/g ZSA, m2/g Ni, ppm V, ppm
range of FCC products. One of the more important products
for the La Rábida refinery is propylene (C3=), which allows Ecat 204 147 800 2,500
the refinery to be highly competitive in a challenging market. Dcat B 178 125 253 851
Future expectations for the petrochemicals market and histori- Dcat C 165 121 0 0
cal FCC data (equilibrium catalyst trends and refinery requests
Dcat D 165 118 0 0
statistics) both strongly suggest that the demand for propylene
has been strong and will continue to be strong in the near term. Dcat G 163 113 0 0

Hydrocarbon Processing | NOVEMBER 2019 49

 Catalysts

1. Steaming only vs. metals impregnation
2. Time dependence of ZSM-5 steam deactivation.
Previous CEPSA studies conducted with high ZSM-5 con-
tent (e.g., 5%–10% or more) have deactivated pre-mixed cata-
lyst and ZSM-5, as well as catalyst separately from the ZSM-5.
This part of the study represented an optimization for CEPSA’s
testing protocol. CEPSA is in a unique position to conduct this
study because of the high ZSM-5 content, but also the trans-
parency between supplier and operating company with respect
to ZSM-5 loading. The loading is agreed upon by CEPSA and
the supplier through unit optimization exercises.
In CEPSA’s case, when a base catalyst and ZSM-5, in high
quantities, are deactivated together, the ZSM-5 activity can be
10
9 Ecat
CPS deactivation
8 Dcat C
7
Coke selectivity, %
too high. For this reason, in CEPSA’s high ZSM-5 loading cas-
es, the deactivation of ZSM-5 requires either a higher steam
temperature or longer steaming times. Because CEPSA’s
very high ZSM-5 case is so different than most refineries, the
CEPSA research and development (R&D) center prefers to
receive base catalyst and ZSM-5 additive separately (i.e., not
in the same particle).
To ensure the most accurate comparison of the laboratory
evaluation with refinery conditions, the benchmark chosen
was an equilibrium catalyst (Ecat) from the La Rábida refinery.
The following deactivation conditions were chosen for this:
1. A comparison of pure steam deactivation and metals
impregnation via CPS. In the latter case, because
the CPS method is known to exaggerate metals
activity,2 leading to higher hydrogen and coke
than Ecat, the level of metals chosen in this study
Dcat B was one-third that of the Ecat.
Dcat D
2. A ZSM-5 deactivation duration study was also
Dcat G conducted. For the separate ZSM-5 additive

6
deactivation ladder, a time ladder was chosen
5 between 5 hr–100 hr. The final evaluation of
4
3 Ecat and steam deactivation
TABLE 3. Feed properties used in cracking study
2
1 Property Unit Value
0 Refractive index, 67°C 1.48
10 10.5 11 11.5 12 12.5 13
Cat-to-oil, wt/wt Density, 15°C g/cc 0.896

FIG. 1. Coke selectivity vs. catalyst-to-oil ratio comparing CPS Aniline point °C 98.6
and steam deactivation methods. MCRT % 0.1
Asphaltene content % 0.05
39
Total N ppm 885
37
S % 0.39
35
Na ppm <1
33
LPG, wt%

Cu ppm < 0.1

31
Ecat Fe ppm 0.1
29 Dcat C
Dcat D Ni ppm 0.2
27 Dcat G
V ppm < 0.1
25
74 75 76 77 78 79 80 81 Ca ppm < 0.1
Conversion, wt%
Mg ppm < 0.1
FIG. 2. LPG selectivity of Ecat vs. three Dcat samples. Boiling point, ASTM 1160
5% °C 378.4
20
10% °C 394.2
18 30% °C 421.3
16 50% °C 441.9
Propylene, wt%

14 70% °C 472.2

Ecat 90% °C 525.9

12
Dcat C
Dcat D UOP K 12.19
10 Dcat G
Molecular weight g/mol 446.4
8
74 75 76 77 78 79 80 81 Aromatics % 14.97
Conversion, wt%
Naphthenics % 21.18
FIG. 3. Propylene selectivity of Ecat vs. three Dcat samples. Paraffins % 63.85

50 NOVEMBER 2019 | HydrocarbonProcessing.com

this deactivation study is to weigh both the
deactivation/testing outcome and the practicality
of running a long test.
The conditions implemented in this study are shown in
TABLE 1. In all cases, the ZSM-5 additive content in the catalyst
was set at 17%. The base catalyst was the same for each deac-
tivation, being deactivated either by CPS or only steam. The
deactivation catalyst (Dcat) is the deactivated fresh catalyst +
deactivated ZSM-5 additive.
Due to the objectives of this study, results from Dcat B are
used to study the CPS effect, and results from Dcats C, D, and
G were used to study the steaming time effect. The deactivat-
ed catalyst properties were compared against the Ecat sample
(TABLE 2).
Results and discussion. The Ecat and Dcat samples
were evaluated in a circulating riser pilot plant located at the
CEPSA R&D center in Madrid, Spain. Each sample was tested
at 3-4 catalyst-to-oil ratios. In each cracking evaluation, the
riser temperature was maintained constant at 530°C/986°F.
To ensure the most representative yield slate for the crack-
ing evaluation, feed from the La Rábida refinery was used
in the cracking evaluation. The feed properties are shown in
TABLE 3. Because the 15-hr deactivation for ZSM-5 was found
to best match Ecat performance, only the results for 5 hr, 15 hr
and 100 hr are summarized in TABLE 3 for conciseness.
Coke selectivity was examined first to compare the two
deactivation methods: CPS with metals and steaming only.
In FIG. 1, the Ecat and all steam Dcats (C–G) gave similar
coke selectivities (3%–5%). Conversely, the coke selectivi-
ties given after CPS deactivation (Dcat B) were double that
of Ecat (e.g., 8.5–9.5%). This mismatch indicates that, even
at one-third the metals seen on the Ecat, the metals effect
from this CPS deactivation was not representative of the re-
finery operations. For instance, the CPS deactivated metals
distribution is not the same. It was seen that CPS deactiva-
tion gives a homogenous distribution of contaminant nickel
(Ni)—whereas, in a refinery and on Ecat samples, it is well
known that Ni is not homogeneously distributed, but rather
concentrated on the outer portion of the catalyst particles.2
Furthermore, the redox cycles in CPS are often not enough to
condition the metals sufficiently.
Because of these two effects, namely maldistribution and
insufficient metal deactivation through conditioning, the ef-
fect of metals is often exaggerated even when loaded at lower
than Ecat levels. When coke selectivity does not match the
refinery operation, this affects all other yield slates in a test-
ing exercise. For example, higher coke selectivity often means
higher hydrogen selectivity. If both coke and hydrogen are dis-
proportionately represented, so will the liquid product yield
slate. Therefore, steam deactivation protocols were deemed
more representative of refinery operations. The rest of the
study will focus on the results of this process.
Focusing on the steam deactivation protocols, the next
evaluation compared the yield selectivities of Dcats C, D and
G. Since total LPG and propylene are the La Rábida refinery’s
focus for liquid products, these were examined first. The total
LPG yield of Ecat and Dcat D (with ZSM-5 deactivated for 15
hr) best matched one another (FIG. 2). Shorter ZSM-5 deac-
tivation gave LPG yields far exceeding the Ecat. Conversely,
Catalysts
the 100-hr deactivation time (Dcat G) gave much lower LPG.
The same results were seen when looking at propylene yield
(FIG. 3), with Ecat results matching best with Dcat D.
The same conclusion can be drawn when examining gaso-
line yield (FIG. 4). These results are expected, since the effect
being studied is a ZSM-5 deactivation effect, which will give
gasoline and LPG split differences, while largely leaving other
yields unaffected.
The heavier product yields are as expected, with no effect
seen between the deactivation protocols on LCO and HCO
yields—as shown in FIG. 5 and FIG. 6, respectively.
Finally, when looking at octane [(RON + MON)/2] in
FIG. 7, Dcat C was found to match that of Ecat, while the value
50
45
Gasoline, wt%
40
35
Ecat
Dcat C
30 Dcat D
Dcat G
25
74 75 76 77 78 79 80 81
Conversion, wt%
FIG. 4. Gasoline selectivity of Ecat vs. three Dcat samples.
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Hydrocarbon Processing | NOVEMBER 2019 51
 Catalysts

of Dcat D (15-hr ZSM-5 deactivation time) was also found to ploy a cracking deactivation method (e.g., CMDU), in which
closely match, although it was lower by half a number. metals are appropriately distributed and conditioned, or to
move to a steam-only deactivation campaign, as was done in
Takeaways. This comprehensive study of deactivation vari- this exercise.
ables provides valuable insights into best practices for catalyst The second conclusion from this study was that the opti-
evaluation. The CPS deactivation study demonstrated that, mal steaming time for a ZSM-5 additive was 15 hr. After exam-
even for a refinery running approximately 3,400 ppm Ni and ining yields from a range of ZSM-5 additive steaming times,
V, steam deactivation is the protocol that best matches refin- this case best matched all major product yields and closely
ery Ecat. Using CPS deactivation would exaggerate the coke matched gasoline octane. As expected, heavy products, such
selectivity. If an evaluation is conducted at iso-coke, an exag- as LCO and HCO, were unchanged by this deactivation lad-
gerated coke selectivity response can lead to non-representa- der, and still matched the yields of Ecat.
tive conclusions. One solution to this could be to lower the Finally, an important learning was uncovered when looking
metals even further (e.g., 15%–20% that of Ecat), or to em- at Dcat properties vs. Ecat properties. It was determined that
the physical parameters were not indicative of performance.
13 This study showed that the Dcat sample that most closely
matched Ecat physical parameters was the least representative
12 sample in terms of product performance. This learning em-
phasizes the importance of focusing on performance testing
11 vs. trying to match a set of physical parameters in the deactiva-
LCO, wt%

tion procedure design phase.

10 Ecat A robust laboratory facility, and a close partnership with
Dcat C the catalyst provider, led to this comprehensive study in which
9 Dcat D
Dcat G learnings can be applied to future studies. Studies like this are
8 the enabler to continued value generation from the CEPSA
74 75 76 77 78 79 80 81 R&D center for its partner refineries.
Conversion, wt%
LITERATURE CITED
FIG. 5. LCO selectivity of Ecat vs. three Dcat samples. 1
Llanes, J. M., et al., “New catalyst increases FCC olefin yields,” Hydrocarbon
Processing, April 2014.
2
Xiao, F. S. and X. Meng, Zeolites in Sustainable Chemistry, Springer Berlin
Heidelberg, Berlin, Germany, 2016.
Get the inside 16

intelligence for the 14

gas processing industry

HCO, wt %

12

Ecat
10 Dcat C
Dcat D
Technology and Business
Dcat G
Information for the Global
Gas Processing Industry
8
74 75 76 77 78 79 80 81
GasProcessingNews.com
| MAY/JUNE 2019
Conversion, wt%

FIG. 6. HCO selectivity of Ecat vs. three Dcat samples.

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Visit GasProcessingNews.com FIG. 7. Octane of Ecat vs. three Dcat samples.

52 NOVEMBER 2019 | HydrocarbonProcessing.com
 Process
Optimization
A. KATYAL, Independent Researcher/Inventor,
New Delhi, India

Accurate prediction of phase equilibrium

properties—Part 2
Phase equilibrium properties, such as bubble point, hydro-
carbon dewpoint, water dewpoint, phase envelope, two-phase
compositions, compressibility factor, hydrate equilibrium
properties, etc., for hydrocarbon mixtures have been calculated
accurately using the Peng-Robinson cubic equation of state by
implementing constant and temperature-dependent binary in-
teraction parameters in the Van der Waals mixing rule.
These phase equilibrium properties find usage in the design
and operation of all kinds of hydrocarbon equipment, such as
hydrocarbon pipelines, hydrocarbon pumps, pressure vessels,
hydrocarbon storages and distillation columns. Phase equilibri-
um properties are also required in upstream oil and gas activities
like well simulation and oil and natural gas production. Atmo-
spheres of various heavenly bodies are made of hydrocarbons,
such as methane (CH4), ethane (C2H6), propane (C3H8), etc.,
and inorganic gases like nitrogen (N), carbon dioxide (CO2)
and hydrogen sulfide (H2S). Simulation of these atmospheres
also requires knowledge of phase equilibrium properties.
A new vapor liquid equilibrium (VLE) softwarea has been
developed using basic calculation tools like MS Excel and Visual
Basic for Applications (VBA, macro programming) to accu-
rately calculate various phase equilibrium properties. The Peng-
Robinson cubic equation of state and Van der Waals mixing rule,
using a combination of temperature-dependent and constant bi-
nary interaction parameters, are used for these calculations.
Part 1 (October 2019) discussed how the proprietary phase
equilibrium softwarea is designed to give accurate phase equi-
librium properties for any mixture of nonpolar or mildly polar
hydrocarbons and inorganic gases up to a maximum number of
112 components in the hydrocarbon mixture.
Hydrate-forming components included in the phase equilib-
rium software are CH4, C2H6, C3H8, n-butane, i-butane, ethyl-
ene, propylene, cyclopropane, acetylene, N, H2S, CO2, carbon
monoxide (CO), argon and oxygen. Additionally, the effects of
hydrate inhibitors, such as salts (LiCl, NaCl, KCl, CsCl, CaCl2
and MgCl2); salt mixtures; organic liquids (methanol, ethyl-
ene glycol, ethanol, 1-propanol, 2-propanol, t-butyl alcohol
and glycerol); sugars (deoxyribose, ribose, fructose, sucrose,
glucose and maltose); urea; and formamide can be included in
the calculation of gas hydrate equilibrium properties, using the
phase equilibrium software.
Gas hydrate properties. Gas hydrate equilibrium properties
calculated using the phase equilibrium software include:
• Equilibrium temperature
• Hydrocarbon liquid and vapor phase compositions
• Aqueous phase composition in cases where aqueous
phase exists
• Hydrate phase composition
• Fraction of hydrocarbons in liquid phase
• Type of hydrates formed (S I or S II)
• Hydration number of hydrates formed
• Density of hydrates formed.
800
Bubble point
700 Dewpoint
Hydrate point
600
500
Pressure, bar

Gas hydrate equilibrium properties for mixtures of nonpolar 400

or mildly polar hydrocarbons and inorganic gases existing with
water and including at least one hydrate former can be calcu- 300
lated using the phase equilibrium software. It uses temperature-
200
dependent binary interaction parameters, as per the Enhanced
Predictive Peng Robinson 78 (E-PPR78) equation, to calculate 100
component fugacity. These parameters are used in an accurate
0
and reliable statistical thermodynamic model for clathrates 0 50 100 150 200 250 300 350
developed by Van der Waals and Platteeuw in 1959 to predict Temperature, K
gas hydrate equilibrium curves and properties for any mixture
of non-polar or mildly polar hydrocarbons and inorganic gases FIG. 1. Phase envelope curve with hydrate equilibrium curve for a typical
natural gas composition, using proprietary phase equilibrium software.
existing with water and including at least one hydrate former.6
Hydrocarbon Processing | NOVEMBER 2019  53
 Process Optimization
Gas hydrate equilibrium properties are calculated at inter-
vals of 0.4 bar, beginning with 0.4 bar and ending at 800 bar
(FIG. 4 and TABLE 5). Apart from calculating hydrate equilib-
rium temperature values and gas hydrate properties through-
out the gas hydrate equilibrium curve, the phase equilibrium
software also calculates hydrate equilibrium temperature val-
ues and gas hydrate properties at any desired pressure value
below 800 bar.
The calculation of the fraction of hydrocarbon mixture
converted to gas hydrates, the composition of gas hydrates
formed, and other properties of formed gas hydrates at tem-
peratures below the gas hydrate equilibrium temperature at
the system pressure are desirable in the prediction of pipeline
blockage due to hydrate formation. These calculations are also
required in the use of the gas hydrate concept in the separation
of hydrocarbon mixtures. The phase equilibrium software can
calculate the fraction of gas hydrocarbon mixture present in
gas, liquid or two-phase form converted to gas hydrate at a
temperature value lower than the gas hydrate equilibrium
temperature at the system pressure. This applies to any mix-
ture of non-polar or mildly polar hydrocarbons or inorganic
gases containing at least one hydrate former. It also calculates
the final hydrate, liquid and vapor composition; the average
hydration number; the average hydrate density; and the total
fraction of initial mixture of water and hydrocarbons/inorgan-
ic gases converted to gas hydrates. Additionally, it calculates
the gas hydrate equilibrium curve and gas hydrate equilibrium
properties at the system pressure (< 800 bar).
If gas hydrates are formed from a hydrocarbon mixture
at a temperature slightly lower than the equilibrium hydrate
formation temperature at the system pressure, then a small
amount of hydrates will form and some hydrocarbon mixture
will convert to hydrates. The composition of hydrate formers
in the hydrate phase will be different from the composition of
hydrocarbon mixture in the gas or liquid phase, resulting in a
change in composition of the hydrocarbon mixture in the gas
or liquid phase after a small amount of hydrates form. This
results in the separation of the hydrocarbon mixture.
Therefore, the phase equilibrium software can be used for
hydrate-based gas separation (HBGS) calculations. This new
composition will require a lower hydrate equilibrium tempera-
TABLE 5. Phase envelope curve with hydrate equilibrium curve
for a typical natural gas composition, using proprietary phase
equilibrium software
Components Z mixtures, including a maximum of 112 components, can be
Methane (CH4) 0.7
Ethane (C2H6) 0.1
Propane (C3H8) 0.05
Iso-butane (C4H10) 0.02
n-butane (C4H10) 0.01
n-pentane (C5H12) 0.02
Nitrogen (N2) 0.03
Carbon dioxide (CO2) 0.02
Hydrogen sulfide (H2S) 0.05
Total 1 sitions, hydrate equilibrium curve and properties, and water
54 NOVEMBER 2019  | HydrocarbonProcessing.com
ture to form hydrates and will result in the formation of hy-
drates of different properties, such as type, density, hydration
number, composition, etc. The phase equilibrium software
continuously calculates hydrate properties at decreasing tem-
perature values, until the desired temperature is reached.
Additional calculations. Binary VLE curves, such as the
concentration diagram (x-y plot), temperature concentration
diagram (T-x-y plot) and enthalpy concentration diagram
(H-x-y plot) used in the McCabe Thiele and Ponchon Savarit
methods to design binary distillation columns, can be calcu-
lated using the phase equilibrium software. Binary VLE curves
for any binary mixture of non-polar or mildly polar hydrocar-
bons and inorganic gases at a column operating pressure value
of less than the lower critical pressure among the critical pres-
sures of the two pure components of the binary mixture can be
calculated using the phase equilibrium software.
Rigorous and more accurate, basic, stage-by-stage design
calculations for binary and multicomponent distillation col-
umns can be performed using the phase equilibrium software
to calculate minimum reflux ratio, number of equilibrium
stages in the rectification and stripping sections, equilibrium
temperature of various stages, and liquid and vapor composi-
tions at various stages. The phase equilibrium software calcu-
lates the minimum reflux ratio and attainable distillate compo-
sition using the Underwood correlation, as well as the overall
column efficiency, actual number of stages, column diameter
and column height for the distillation column being designed
to separate binary and multicomponent mixtures. Distillation
column design calculations for the separation of multicom-
ponent mixtures of any number of non-polar or mildly polar
hydrocarbons and inorganic gases (up to a maximum limit of
112 components at an operating pressure lower than the low-
est critical pressure among the critical pressures of the pure
components included in the binary or multicomponent mix-
ture for suitably chosen light-key and heavy-key components)
can be performed using the phase equilibrium software.
Various thermodynamic properties (enthalpy change from
standard conditions, entropy change from standard condi-
tions, Gibbs free energy change from standard conditions,
specific heat at constant pressure, specific heat at constant
volume, specific heat ratio, sonic speed, isobaric thermal ex-
pansivity and the Joule-Thomson coefficient) throughout the
phase envelope curve at intervals of 0.4 bar for pure non-polar
or mildly polar hydrocarbons and inorganic gases and their
calculated using the phase equilibrium software.
Heavier components in oil and natural gas samples are
sometimes characterized as pseudo components. Critical
properties of these pseudo components are not documented
like normal components, but are instead calculated theoreti-
cally based on experimentally determined properties of these
fractions (e.g., density, boiling point). These critical proper-
ties, such as critical pressure, temperature and volume, and
acentric factor, enable the pseudo components to be consid-
ered as normal components in phase equilibrium calculations.
The proprietary software can include up to 40 pseudo com-
ponents and can calculate phase envelope, two-phase compo-
 Process Optimization
Put the Solution
dewpoint curve for hydrocarbon mixtures, including these
pseudo components.
Ammonia (NH3) is being widely used as a refrigerant be-
Before the Problem
cause of its excellent thermos-physical properties and ozone-
friendly characteristic. VLE properties of mixtures contain-
ing NH3 are desirable in numerous design calculations. The When you’re measuring pressure,
Peng-Robinson cubic equation of state being used in various inaccuracies or instrument failures will
calculation modules of the phase equilibrium software gives
accurate results of VLE properties only for mixtures of non- compromise production and safety.
polar or mildly polar compounds, whereas NH3 is highly po-
lar in nature. Therefore, the Peng-Robinson equation in its
You can avoid these problems by
usual form cannot be used to find VLE properties of mixtures designing-in our expert solutions.
containing NH3.
However, temperature-dependent binary interaction pa-
rameters can be calculated for pairs containing NH3 with few
non-polar compounds or water, and used in the Peng-Rob- Gauges with
inson equation to calculate VLE properties of mixtures con- the PLUS! ™
taining NH3. As temperature-dependent binary interaction performance
parameters can be calculated for pairs containing NH3 with option dampen
CH4, nitrogen (N2), argon (Ar), hydrogen (H2) and water
pulse & vibration
(H2O), VLE properties can be calculated for binary or multi-
component mixtures of CH4, N2, Ar, H2, NH3 and H2O. The for easier reading
various calculation modules of the phase equilibrium software and longer life.
that can be used for binary or multi-component mixtures of
NH3 with CH4, N2, Ar, H2 and H2O include:
• Bubble point temperature calculator
• Dewpoint temperature calculator
• Bubble point pressure calculator
• Dewpoint pressure calculator
• Two-phase composition calculator The 2198 MicroTube™
• Phase envelope calculator siphon dissipates
• Thermodynamic properties calculator. heat to avoid damage.
As the phase equilibrium software is made using basic cal-
culation tools, such as MS Excel and VBA (macro program-
ming), and is executed on a laptop computer of standard
configuration, it can be slow in its execution. However, the
emphasis of the phase equilibrium software is not on giving
instant results, but rather on providing extremely extensive Diaphragm seals isolate
and accurate results. and protect your valuable
Graphical results of the phase equilibrium software are also assets from corrosive
provided in Part 1 of this article, which appeared in the Octo-
media.
ber issue.

NOTES
a
EQ-COMP vapor liquid equilibrium (VLE) software

LITERATURE CITED
6
Sloan, Jr., E. D. and C. Koh, Clathrate Hydrates of Natural Gases, 3rd Ed., CRC
Press, September, 2007.

AMIT KATYAL is an independent inventor and researcher based in New Delhi, We’d like to help you.
India. He has designed and developed the EQ-COMP VLE software, which is
the result of more than 15 yr of continuous research in the field of vapor-liquid
Please contact us at (203) 385-0635 or
equilibrium of hydrocarbon/oil and natural gas mixtures and involves extensive visit our website at www.ashcroft.com
software development work to automate the calculations. Mr. Katyal earned a
BS degree in chemical engineering from the Indian Institute of Technology in
Delhi. He has 25 yr of experience in the hydrocarbon sector in diverse segments
such as research, operations and technical services. In addition to EQ-COMP,
Mr. Katyal has developed other software for the hydrocarbon sector, including
HYD-PREDIC, LIQ-PROP, BUBBLE-SIM and MIX-CP. He has also invented four
technologies for water treatment and the hydrocarbon sector. The author can
be contacted at amit@eq-comp.com.

Hydrocarbon Processing | NOVEMBER 2019 55

18_July_Hydro_Proc_015-5806 Rev #2.indd 3 7/17/18 8:22 AM
 Sustainability
G. CHEVIRON, J. M. GACIO and M. MITSCHLER,
Axens, Paris, France; O. LE COZ and M.
YALLAMBALSE, Axens, Houston, Texas;
and D. SCHWALJE, Axens, Princeton, New Jersey
Diversifying the future: Incentives for worldwide
adoption of renewable fuels and chemicals—Part 2
Bio-based, renewable fuels and chemicals can reduce the
environmental footprint of maintaining global transportation
and product demands, while also offering supplementation of
traditional fossil fuels in a global environment with increas-
ing energy demand. The renewable energy sector is large and
growing rapidly. Part 1 of this article, published in the Octo-
ber issue of Hydrocarbon Processing, focused on how regula-
tory incentives, technology advances and increased renew-
able product demand have driven significant investment and
growth in the renewable energy industry. Part 2 focuses on the
technology pathways to building the biorefinery of the future.
Technology pathways and the biorefinery concept.
A diverse toolbox of technologies exists to produce biofuels
and chemicals, with the primary routes summarized in FIG. 5.
Some of the latest and least carbon-intensive technologies are
detailed in the following sections.
Renewable diesel and jet fuel (hydrotreated vegetable
oil). Proven technologies exist to produce renewable distil-
lates from lipidsa. These lipids originate from vegetable sourc-
FIG. 5. Potential renewable pathways.
56 NOVEMBER 2019 | HydrocarbonProcessing.com
es (e.g., food crop oils), animal sources (primarily fats from
the meat processing industry), cooking sources (used cook-
ing oils) or tall oil byproduct from paper production. Lipids
consist of unsaturated and oxygen-rich molecules, namely
fatty acids and glycerides. Traditionally, those molecules were
utilized to produce biodiesel via transesterification and the
production of fatty acid methyl esters (FAME), which is lim-
ited in its demand due to poor cold flow properties, oxygen
content and cetane compared to traditional fossil diesel.
The latest evolution of lipid utilization employs solid
catalysts in fixed-bed reactors in the presence of hydrogen to
produce true drop-in ultra-low-sulfur diesel (ULSD) and jet
fuels without technical blending limitations, excellent cold
flow properties and high cetane. Product qualities are much
superior to traditional FAME; they are oxygen-free and per-
fectly stable. The technology offers the flexibility to adjust
jet and diesel yields, as well as product cold flow properties,
on the fly.
As virgin oils contain impurities (such as phospholipids
and metals) that are detrimental to catalyst performance, a
dedicated pretreatment system is critical to the economical
operation of the hydroprocessing units.
Typical product properties and weight percent yields are
summarized in FIG. 6.
Tall oil. This is another potential feedstock and is gener-
ated as a byproduct of the pulp industry by using the Kraft
process, in which wood chips are digested and filtered primar-
ily for paper production. The filtrate, called “black liquor,” is
fed to an evaporator and skim tank for soap making. The soap
is then acidulated to make crude tall oil, which can then be
further fractionated into its main components: tall oil heads,
tall oil fatty acids (TOFAs), distilled tall oil fatty acids, tall oil
rosin acids and tall oil pitch.
Tall oil is a renewable feedstock source, similar to vegetable
oils and fats, as the TOFA and rosin acid fractions can be pro-
cessed in renewable diesel units to produce diesel and jet fuel.
Second-generation biofuels. An interesting processing
route for biomass consists of gasification and conversion of the
syngas—H2 and carbon monoxide (CO)—into liquids, using
FT technology.b Each of the technology blocks in the process
 Sustainability

chain have historically been well proven, and were recently op- Cellulosic ethanol. Traditionally, bioethanol has been pro-
timized to run in an integrated biomass treating process. duced by sugars derived from agricultural food sources, includ-
The FT route is commonly accepted as one of the most ing corn and cane sugar, and converted to ethanol via fermen-
promising mid-term solutions to produce alternative fuels, tation. Second-generation ethanol is produced from non-food
lubricating oils and chemicals. It is also one of the two certi- lignocellulosic biomass, such as wood and agricultural wastes,
fied routes to produce fungible biojet fuel.b The technology including rice or wheat straw, corn stover, and bagasse. The
produces ultra-clean products (absent sulfur, metals or other two main processing routes are gasification and catalytic con-
contaminants) that can then be utilized either as high-quality version or enzymatic hydrolysis and fermentation using bio-
drop-in fuels or highly paraffinic intermediates to produce catalystsc. Both technologies are commercialized, and the latter
lubes or renewable chemicals. process is described below.
The main steps of the full biomass-to-liquids chain via gas- Lignocellulosic biomass is mainly composed of carbohy-
ification and the FT processb(FIG. 7) include: drate polymers (cellulose and hemicellulose) and aromatic
• Torrefaction. The torrefaction process is a low- polymers (lignin). These carbohydrate polymers are formed of
temperature treatment. The objective is to homogenize different sugar monomers:
the quality of the feedstock, ease the grinding • Cellulose: Primarily C6 sugar monomers
(while limiting the overall energy consumption), • Hemicellulose: Primarily C5 sugar monomers.
and increase the energy density of the biomass. The enzymatic hydrolysis and fermentation process is a
• Gasification. After being finely grinded, the biomass
enters the pressurized, entrained flow gasification Property Unit feed Summer diesel Winter diesel Jet fuel
chamber to create a renewable syngas. Entrained Freezing PT/CFPP, °C 30 0 –20 < –40
flow gasification offers high performances, including Density, Kg/m3 915 779 773 757
flexibility to deal with the large variety in biomass Cetane index 50 > 80 > 75 –
types and quality, high carbon conversion and 100
production of a tar-free, high-purity syngas.
• Syngas conditioning and purification. This step
adjusts the syngas composition and removes acid 80
components and contaminants to ensure a composition
and a purity suitable for the FT conversion. 60
• FT synthesis. The reaction can take place in a three-
Percent

phase slurry bubble column reactor, where syngas

40
is brought into contact with the solid FT catalyst
to produce long-chain liquid hydrocarbons. These
hydrocarbons are then recovered in liquid/slurry and 20
gas/liquid separators and sent to an upgrading section.
• FT product upgrading. The raw FT liquid products 0
are first stabilized and hydrotreated to remove olefins Summer diesel Winter diesel Jet fuel
and oxygenates. Hydrotreated FT effluents can then Diesel/jet yield Light end
be further hydrocracked and isomerized into superior- Naphtha yield Oxygen removal product
quality drop-in fuels (jet fuel and diesel) and paraffinic FIG. 6. Typical properties and wt% yields for renewable diesel
naphtha—or valued as specialty solvents, waxes or hydroprocessing units.
chemical steam cracker feedstock.
• Final products. Final product purity is extremely
high and absent of sulfur, metals or aromatics.
º Diesel: Variable cold flow properties varying
from arctic to summer diesel, coupled with
extremely high cetane numbers and low motor
particulate emissions
º Jet fuel: Fully fungible into JET-A1 up to 50%
volume, meeting ASTM D7566 specifications
º Naphtha can be upgraded to high-octane gasoline
or is an excellent charge to steam crackers for
biochemical production
º Hydrotreated FT waxes are highly paraffinic and
of the highest quality; they are an ideal feedstock
for biochemical production.
The FT route may become the heart of the biorefinery, as it
offers feedstock flexibility and product slates. Recent technol-
ogy integration improvements and the maturity of regulatory
incentives have improved otherwise challenging economics. FIG. 7. Biomass thermal conversion process flow.

Hydrocarbon Processing | NOVEMBER 2019 57

 Sustainability
multi-step process that includes cellulose and hemicellulose
hydrolysis followed by C5 and C6 sugar monomer fermenta-
tion, with different strategies adopted to arrange these opera-
tions in an industrial process scheme. A simplified, four-step
process is presented in FIG. 8. The process steps include:
• Pretreatment—The primary pretreatment objective
is to deconstruct the lignocellulosic biomass and
prepare three major components: cellulose,
hemicellulose and lignin. Pretreatment combines
physical and/or chemical treatments to increase
cellulose and hemicellulose accessibility and to favor
their conversion in the downstream sections. Some
of the polysaccharides are depolymerized to release
their embedded monomeric sugars. A critical feature
of this technology is control over the formation of
byproducts, which inhibits the downstream processes.
• Biocatalyst production—Typically, two biocatalysts
are used to convert free sugars and polysaccharides.
Cellulose hydrolysis is performed using enzymes that
FIG. 8. Typical flow diagram for ethanol production via enzymatic
hydrolysis.
Compression
Quench and drying
column
Innovative Ethylene Ethylene product
Reaction
heat recovery purification
section system section
Recycle Produced water
water
treatment
Ethanol feed Recycle
FIG. 9. Typical flow diagram for ethanol dehydration.
58 NOVEMBER 2019 | HydrocarbonProcessing.com
depolymerize the carbohydrate polymers into simple
sugars. The resulting free sugars are then fermented
into ethanol, utilizing yeasts. Onsite enzyme
production and yeast propagation have economic
advantages to the purchase of these biocatalysts
on the open market, as it efficiently and reliably
propagates biocatalysts, using lignocellulosic substrate,
and eliminates transportation costs and third-party
margins from the producer’s balance sheet.
• Hydrolysis and fermentation—The hydrolysis and
fermentation can be performed separately or in a
single vessel. Likewise, the C5 and C6 sugars can be
fermented independently or together. In either case,
there are several ways of arranging these operations,
with the final configuration driven by several
considerations, including optimizing operating
conditions for the microorganisms (enzymes and
yeast), balancing operating costs and capital
expenditures, and the overall integration of the
different sections of the unit. One of the most
promising strategies that has been identified for
reaching an optimal balance of high ethanol yield,
capital and operational expenditures and plant
footprint is the simultaneous saccharification and
co-fermentation approach. It leverages attractive
synergies between the biocatalyst activities by
performing the enzymatic hydrolysis and the
fermentation of both C5 and C6 sugars in the same
pot (e.g., “one-pot” process).
• Products recovery—Distillation and dehydration
processes allow the recovery of second-generation
cellulosic ethanol suitable for biofuel applications
or for further processing in chemical applications.
Lignin is recovered and routed either to energy
production or chemical derivative production, and
the most well-integrated ethanol technologies produce
zero waste. The ethanol product can either be utilized
directly in the gasoline pool or further converted to
chemicals such as ethylene and butadiene.
Renewable ethylene. Ethylene is one of the most important
building blocks of the chemicals industry, and it can be pro-
duced either via traditional fossil pathways or from renewable
feedstocks. One of the most promising routes is via catalytic
dehydration of bioethanolc, produced from any of the afore-
mentioned routes.
Bioethylened produced from first-generation ethanol or
second-generation cellulosic ethanol is chemically identical
to its fossil-based counterpart, and the commercialization of
Light ends dehydration technologies represents a significant step toward
the viability of renewable plastics such as polyethylene and
derivative chemicals, including glycols (monoethylene glycol,
C3+ diethylene glycol and triethylene glycol), ethoxylates, etha-
nolamines and polyols.
The catalytic dehydration of ethanol occurs in the vapor
phase over a fixed-bed reaction system (FIG. 9). The major
sections of the process include:
• Reaction section—Ethanol dehydration is carried
out at moderate pressure, utilizing catalysts with very
 Sustainability

high selectivity toward ethylene. Advances in catalyst Renewable aromatics and gasoline. Lignocellulosic bio-
selectivity have been a key factor for the success of the mass can also be converted to high-value products via pyroly-
technology, since it allows using a simpler and less- sis, the high-temperature processing of materials in the absence
capital-intensive downstream purification section, while of oxygen. Traditional pyrolysis units were able to produce
achieving polymer-grade ethylene quality. light hydrocarbon intermediates with high oxygen concentra-
In addition, energy efficiency is critical in making tions that prevented them from being true, drop-in fuels and
the process cost effective. The catalytic reactions chemicals. The latest generation of the technology utilizes a
are endothermic, and the ability to manage and control catalytic fast-pyrolysis processe like the fluid catalytic cracker
the endotherms drives the overall operating costs. in the traditional refinery (FIG. 10).
The most innovative process schemes utilize a heat With the right selection of operating conditions and a spe-
diluent to buffer the temperature drop in the reactors, cifically designed catalyst, the next-generation process delivers
minimizing the number of reactors required
to accomplish the reaction.
• Purification section—The reaction effluent is sent Excess heat to
power recovery H2 Naphtha for
to a purification section to remove byproducts and BTX or gasoline
blendstocke
produce finished ethylene product. Typical impurities
Product recovery,
to be removed are ethane, CO, CO2, methane, hydrogen Catalyst Fluid bed mild hydrotreating,
regenerator reactord
and C3+ hydrocarbons. The amounts of each of these and separation
Distillate
species will vary widely, depending on the dehydration blendstocke
technology applied, and, as a result, the complexity Biomass in Biomass feed
prep processes Wastewater
of the purification section will also vary. While
conventional technologies require equipment, such as Recycle CO-containing
CO2 caustic towers or ethane/ethylene splitters with compressor product gas
Excess heat to
high operating and capital demands, the most advanced CO combustion power recovery
for power
technologies benefit from catalysts with extremely generation
high selectivity toward ethylene, allowing for simple
fractionation. FIG. 10. Typical flow diagram for the catalytic fast pyrolysis unit.

LIVE WEBCAST
Wednesday, November 13, 2019 | 10 a.m. CST / 4 p.m. UTC

Craig Harclerode
Industry Principle, Oil and Gas Industry
Best Practices of Digital Transformation Initiatives in
Oil and Gas: Discussion with the Leaders Achieving
Business Value at DCP Midstream and MOLGroup
Digital transformation is a leading topic in most industries but especially in the hydrocarbon
processing industries. Digital transformation can be confusing for organizations, and in many
cases, the expected benefits unrealized. However, when successful, transformative business value
is achieved. What determines success or failure?
Tibor Komróczki
Head of Process Information and Join OSIsoft and industry leaders from DCP Midstream and MOLGroup to talk through the best
Automation practices for successful digital transformation programs, based on real-world programs by both
MOLGroup MOL ($1B in 4 years) and DCP Midstream ($50M in 2 years) that made significant impact on these
organizations around the dimensions of business value, culture, work processes, and technology
including IIOT and “analytics”.

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Damon Vinciguerra
PI System Applications Lead
DCP Midstream Hydrocarbon Processing | NOVEMBER 2019 59
 Sustainability
higher product yields, while significantly reducing their oxy-
gen content. The pyrolysis products are separated into (1) a
gasoline-boiling fraction, rich in aromatic molecules—namely
benzene, toluene and xylenes (BTX)—making it valuable ei-
ther as a chemical feedstock or as a high-octane gasoline blend
component, and (2) a middle distillate fraction upgradable to
renewable diesel via traditional processing.
The BTX mixture can be upgraded by existing, mature tech-
nologies to renewable paraxylene, which can complete the chain
from biomass to plastic polyethylene terephthalate bottles.
The biorefinery. Standalone technologies exist in various
stages of commercialization and/or operation that can be
(and are) utilized to convert available renewable feed sources
into a variety of fuels, chemical products, and chemical and
plastic building blocks. Each of the standalone plants are serv-
ing a specific market demand, and many are in the early stages
of operation. As each of these standalone processing units im-
proves operations and as the incentives (outlined throughout
this article) mature, efficiencies can be realized via the inte-
gration of processing blocks into true biorefineries—facilities
that feed biomass, lipids and other renewable sources to pro-
duce a diverse slate of fuels, chemicals and chemical building
block products.
The concept of the biorefinery is near, and technology
development efforts in advanced bioproducts are sufficiently
developed to turn what was once a futurist idea into a real-
ity. One of the many possible refinery flow schemes integrates
biotechnologies with traditional processing to produce a slate
of chemicals, as shown in FIG. 11.
Takeaways. The combination of regulatory frameworks,
step-change developments in technology maturity, the de-
velopment of feedstock supply networks and moderate crude
pricing has resulted in biofuel investment and production
growth, resulting in a renewable energy landscape that is dras-
tically different than it was a few short years ago. If these fac-
Biodiesel and biojet
Gasification
and FT Bio-naphtha
Steam cracker
Enzymatic
fermentation
Alcohol
Dehydration
Lignocellulosic
biomass
Lignin
Oligomerization Metathesis
Selective
dimerization
Isomerization
Isobutanol
Dehydration
Etherification
Dehydration and
oligomerization
Ethylation
Catalytic fast
transalkylation
pyrolysis
isomerization
FIG. 11. One possible biorefinery flow diagram. Source: Adapted from
IFP Energies nouvelles (IFPEN).
60 NOVEMBER 2019 | HydrocarbonProcessing.com
tors continue to have consistent positive trends, the energy
sector is poised to reach a tipping point, where both petro-
leum and renewable fuels are economically balanced to meet
society’s energy needs.
End of series. Part 1 of this article appeared in October.
NOTES
a
Axens Vegan® technology is a flexible solution for producing renewable diesel
and jet through the hydrotreatment of a wide range of lipids.
b
Axens collaboration on the BioTfuelTM project integrates biomass pretreatment,
gasification, syngas conditioning, FT and upgrading under one process train to
produce premium quality drop-in transportation fuels from biomass.
c
Axens Futurol™ technology is a comprehensive process to produce second-
generation cellulosic ethanol from biomass via enzymatic fermentation with
onsite bio-catalyst production.
d
Axens Atol® technology produces polymer-grade ethylene from ethanol, includ-
ing bioethanol produced from renewable sources.
e
Axens collaboration on the BioTCat™ project integrates biomass pretreatment,
gasification, syngas conditioning, FT and upgrading under one process train to
produce premium-quality drop-in transportation fuels from biomass.
GUILLAUME CHEVIRON is a Technologist in the Axens Clean Fuels, Bio, Olefins
and Gas Technology Group (Process Licensing Business Unit), with a focus on
biotechnologies. He started his career in 2010 at IFPEN research center (Lyon),
participating in the early phases of the BioTfueL™ project, an R&D partnership
developing 2G biofuels from forest and agricultural residues through
gasification and Fischer-Tropsch routes. Since then, he has contributed to the
commercialization of the technology. He holds a process engineering degree
from the Ècole Nationale Supérieure de Chimie de Paris (ParisTech) and the
Ècole Nationale Supérieure du Pétrole et des Moteurs (IFP School).
JORGE MARTINEZ GACIO is a Technologist in the field of biofuels and
biochemicals within the Clean Fuels, Bio, Olefins and Gas business line at Axens.
He started his professional career at Technip, where he served as a process
engineer for detailed engineering projects for the pharmaceutical industry. He
joined Axens in 2006, where he first served as a senior process engineer and
project manager in worldwide projects for the refining and petrochemicals
industry. Mr. Gacio holds an MSc degree in advanced technology in
petrochemicals, polymers and plastics from the IFP School, France, and a
chemical engineering degree from the University of Santiago de Compostela,
Spain. He also holds a chemistry degree from the University of Vigo, Spain.
MADELEINE MITSCHLER is a Technologist in the Axens Clean Fuels, Bio,
Olefins and Gas Technology Group (Process Licensing Business Unit), with
a focus on biotechnologies. She holds an engineering degree in material
science from Polytech Grenoble, and an MS degree in nanomaterial
engineering from the Université Joseph Fourier in Grenoble, France.
OLIVIER LE COZ is the Process Licensing Director for Axens North America.
Ethanol fuel After 6 yr with ESSO in France (ExxonMobil), he joined Axens in 2001 as
a technical advisor and continued as technical services manager. He joined
Axens North America in Houston in 2011 to take the lead of the local technical
Ethylene services group. Since 2015, he has been working in business development
and sales for technology licensing, covering the full portfolio of Axens
solutions. He holds an MS degree in materials science from the university
Propylene
Ècole Centrale Paris.
Butene-1
MUKUND YALLAMBALSE is Business Development Manager for Axens North
Isobutene America. He has 20 yr of downstream industry experience in process licensing
and engineering, procurement and construction. His experience covers the
ETBE complete project development cycle. At Axens, he covers the full portfolio
of Axens solutions. He holds an MS degree in chemical engineering from
Butadiene Lamar University and an MBA from the University of Texas at Austin.
Benzene
Toluene DAVID SCHWALJE is a Business Development Manager at Axens North America,
responsible for technology and project development in the North American
Orthoxylene
Paraxylene market. Mr. Schwalje specializes in renewable fuels and bottom-of-the-barrel
upgrading, including residue and distillate hydroprocessing and hydrocracking.
He has 15 yr of experience holding various roles in the Axens engineering and
technology groups. He holds a BS degree in chemical engineering from the
University of Delaware.

When digital transformation hits
all four sustainability buckets
Sustainability is emerging as a critical
business topic, as many companies focus
resources toward lowering emissions,
waste and energy use in their production
processes. This important concept can
apply broadly to company operations, es-
pecially when considering the expansive
view of the triple bottom line that mea-
sures the impact of company operations
on profits, people and the planet.
Sustainability efforts affect four key ar-
eas within a processing plant: efficiency,
business, talent and safety. While energy
sustainability may be a clearly defined
goal for some organizations, there are oth-
er areas that also benefit from energy-tar-
geted sustainability efforts and vice versa.
Digital tools have been helping with
sustainability goals for a great deal of
time, since many digitalization efforts
have always targeted efficiency improve-
ments. It is not new that digital tools have
this value-add for organizations. Howev-
er, while energy consumption reduction
used to be measured solely in dollars, the
industry is slowly moving toward more
specific metrics about processes and the
amount of energy saved. In addition,
companies are increasingly focused on
reducing waste and discharge from pro-
duction units, tasks that are more easily
executed with visualization and efficien-
cy capabilities of digital solutions.
Most advancements in digital trans-
formation tend to result in tangible ben-
efits across a variety of areas. Processes
that lead to reduced energy consumption
can lead to more business profit. Pro-
cesses (like knowledge automation) that
promote better employee onboarding or
more technical guidance will not only at-
tract and keep talent, but will also help
curb unintended manual mistakes on the
factory floor. All four buckets are linked
Sustainability
P. MORSE, Aspen Technology,
Houston, Texas
through digital transformation, and all
four have an undeniable need for in-
creased focus on sustainability.
Process efficiency. For years, technol-
ogy has had the ability to simulate and
predict carbon dioxide (CO2) emissions
for different process options. However,
as erring on the “greener” side of busi-
ness has become the norm, organizations
increasingly look for more visibility on
important targets and ask for CO2 met-
rics on their operating and reporting
dashboards. Company executive boards
actively ask for this type of process and
measurement—they seek measurements
that are not necessarily dollar-related.
CO2 emissions related to energy of the
process is the most obvious metric, but
other efficiency metrics often include
factors like on-spec or quality of produc-
tion. Cutting emissions is important, but
if a poor-quality batch is produced, that
batch can be considered waste because
it is not a valued product and is a waste
of both energy and raw material. Any
technology that can improve the qual-
ity of the products or batches ultimately
improves what companies can sell to cus-
tomers, which, in turn, creates less waste
and a more efficient process.
A great example of this is in scheduling
tools, which help companies increase effi-
ciency in production planning to eliminate
waste further down the road. Scheduling
tools can help companies decide when to
make which product, based on customer
demand, and in which order to make
them—resulting in less energy usage and
less waste in the production phase.
Digital simulation tools can also drill
down into specific emissions that are
tracked, correlating certain emissions
with various steps in a reaction. For ex-
ample, digital transformation solutions
will help organizations notate specific
correlations and will help uncover specif-
ic data about each of the processes. This is
not something that can possibly be done
on a manual level, as so many industrial
processes are too complex to track and
adjust. Meanwhile, advanced digital tools
help workers see the value in adjustments
and guide them in how to make them.
Business economics. In truth, profits
can often be tied directly to sustainability.
Think of the “bad batch” example: pro-
cesses that prevent producing a bad batch
help save money for an organization on the
back-end with less waste of raw material.
In volatile industrial markets, making
business profitability sustainable is cru-
cial. Another key technology advance-
ment that helps keep businesses more
sustainable, from a financial perspective,
is reliability software that predicts equip-
ment breakdowns, sometimes months in
advance of an unplanned or unforeseen
event. This advance warning enables
companies to avoid breakdown events
and potentially major profit losses in
production downtime—some that could
add up to a million dollars in lost profits
per day and can lead to increased emis-
sions and discharge.
Predictive maintenance is not just a
digital transformation tool, helping plants
with operational efficiencies. It has a di-
rect impact on an organization’s bottom
line by keeping machines running to the
limits of their performance while avoid-
ing maintenance and capital costs from
unexpected failure. Reliability software in
the maintenance process is a value creator
in that sense. It knows the limits of equip-
ment, so it enables organizations to get
the most out of them from a production
Hydrocarbon Processing | NOVEMBER 2019 61
 Sustainability

standpoint, knowing they are not going to
cause damage or breakdown.
Safety and talent. Along the vein of pre-
dictive maintenance, ensuring advanced
warning of equipment or asset malfunc-
tion or breakdown also helps limit the like-
lihood of unsafe plant events that can put
workers’ lives in danger. This is a central
reason why it is important to have a clear
view into the health of a plant and its as-
sets in real time. Why operate with an “un-
known” factor that could potentially cause
harm to people, when technology advance-
ments can potentially remove that factor
from the equation? The visibility and data
that modern technology provides gives
companies a fighting chance to adjust their
operations in ways that will curb danger.
Ensuring the safety of factory workers,
along with the surrounding community,
is paramount, and technology that leads
to more plant process reliability is a key
factor in making this a reality. This also
blends into the topic of talent sustain-
ability. Making factory jobs safer, and bet-
ter protecting workers through increased
plant reliability, make industrial careers
more attractive to young talent.
In addition, there is no denying that
we are facing a serious talent gap in the
industrial world. Over the next decade,
there will be 2.4 MM unfilled jobs in the
manufacturing sector.1 Apart from tech-
nology making plant work safer, it is also
helping improve workflows, especially
through operator training simulations,
allowing fresh hires to get a feel for their
responsibilities, plant operations, and the
different and challenging circumstances
that may arise in those operations, in a
totally simulated setting. It allows them
to grow and learn and make mistakes in
a closed environment that does not have
real-world impact. Using technology to
better train talent is a huge value-add to a
company, but it also helps make the work
and onboarding processes easier and
more attractive to fresh talent.
In addition, software that helps guide
talent to make better decisions and be
more efficient in their work completely
changes the nature of these industrial roles,
bringing them into the modern age and
removing a layer of complexity that has
always existed in the factory, from a histori-
cal perspective. The importance of linking
sustainability concepts to worker satisfac-
tion cannot be underestimated. For exam-
ple, at a recent industry event, Lyondell-
Basell’s CEO, Bob Patel, highlighted this
importance in his workforce noting, “Ten
years ago, employees asked ‘how do I get
ahead?’ Today a new employee asks ‘how
do I make a difference.’” Digital technolo-
gies are an important element in helping
employees achieve their full potential.
LITERATURE CITED
1
Deloitte Insights, “2018 skills gap in manufacturing
study—Future of manufacturing: The jobs are here,
but where are the people?” online: https://opera-
tionalsolutions.nam.org/mi-skills-gap-study-18/
PAIGE MARIE MORSE is the
Industry Marketing Director for
Chemicals at Aspen Technology.
She has significant experience with
leading operating companies,
including Shell, Dow, Sunoco and
Clariant, particularly in R&D,
marketing, commercial and strategy roles. Dr. Morse
earned a BA degree in chemistry from Kenyon College
and a PhD in chemistry from the University of Illinois.

Delegate
places are available,
register for yours here
www.petroleum-
economist.com/
LNGtoPower
3 DECEMBER 2019, HOUSTON

LNG to Power – opportunities and challenges in an electrifying world

Growing pressures to electrify the global energy economy are heightening interest in LNG-to-power projects – creating new
opportunities for LNG producers, project developers, equipment suppliers, engineering contractors and lenders.

The ongoing transition to a low/zero-carbon global energy economy will require widespread electrification of energy supply over
coming decades. Against this backdrop, LNG will play a growing role as an electricity generation fuel, displacing carbon-intensive
coal and partnering intermittent renewables such as wind and solar power.

Petroleum Economist’s LNG-to-Power Forum – to be held in Houston on 3 December – will examine the opportunities presented by
these trends and the challenges involved in opening up new LNG markets, expanding existing markets, and successfully structuring
bankable LNG-to-Power projects. For further details contact Owen Raw-Ress Owen.Raw-Rees@Petroleum-Economist.com

KNOWLEDGE PARTNER IOC PARTNER BANKING & FINANCE LEGAL PARTNER SOFTWARE SOLUTIONS ENGINEERING AND POWER
PARTNER PARTNER PARTNER

62 NOVEMBER 2019 | HydrocarbonProcessing.com
 Environment
and Safety
E. PREDATSCH, Selas-Linde North America,
Blue Bell, Pennsylvania; and P. ARMSTRONG,
Selas-Linde North America, Houston, Texas

Use submerged combustion systems

to efficiently destroy hazardous plant waste
In the production of clean fuels, plastics and other hydro-
carbon-based products, refineries and petrochemical facilities
generate unwanted (waste) byproducts. Having no market
value, the undesired byproducts must be recycled, minimized
or eliminated. Depending on the feedstocks, end products and
reactant materials, the unwanted materials can be gases, liquids
or multiphase materials.
In some cases, the byproducts are hazardous or toxic com-
pounds and require more complex disposal strategies. As haz-
ardous, toxic pollutants, these wastes must be managed ac-
cording to strict environmental guidelines. Many factors are
involved in selecting the best and most cost-effective solutions
to handle processing wastes. These include:
• Waste definitions determine management solutions
• Management of gases, liquids or multiphase streams
influences remediation options
• End-of-pipe technologies include different oxidation
technologies FIG. 1. HPI companies have used incineration systems to manage vapor
and aqueous wastes.
• New combustion solutions efficiently destroy waste
and yield “near-zero” emissions.
Incineration technologies have been used by the hydrocar- stocks removes salts and halogen-containing and acidic com-
bon processing industry (HPI) to manage hazardous gaseous pounds, such as carbon dioxide (CO2), hydrogen sulfide (H2S)
and liquid wastes. Growing concern from the public and regu- and others. These compounds poison processing catalysts, cor-
latory agencies to protect the environment has increased scru- rode equipment and impede desired reactions.
tiny regarding incineration operations. More than ever, efforts Depending on the industry, feedstocks, processing opera-
to minimize releases from incinerators, especially dioxins and tions and end products, waste streams will contain different
other toxic materials, are top concerns. compounds at varying concentrations and volumes. In ethylene
More efficient end-of-pipe technologies, such as submerged production, caustic is used to remove mercaptans, sulfides and
combustion systemsa, are emerging solutions to manage haz- acid gases (H2S and CO2) from the ethylene. These compounds
ardous plant waste. Operating companies want to limit offsite react with oxygen and form unwanted polymer (red) oil. Caus-
disposal of aqueous wastes and better manage all effluents and tic scrubbing is a necessary step to remove contaminants. How-
emissions. In the presented case history, an HPI facility investi- ever, the residual spent caustic is considered a hazardous waste
gated several oxidation/combustion technologies to treat caus- and must be treated and properly disposed.
tic waste and attain “near-zero” emissions. Refining operations use caustic treatment to remove acidic
compounds, such as H2S, mercaptans and naphthenic acids,
Waste definitions determine management solutions. which cause corrosion in processing equipment. Likewise, the
The processing of petroleum and natural gas into transporta- spent caustic is hazardous waste that cannot be effectively treated
tion fuels and consumer goods is not 100%. Residual wastes are in the facility’s wastewater treatment unit. Refinery spent caustic
generated during pretreatment, reaction and final processing of requires a management solution capable of handling acidic com-
intermediate and end products. Pretreatment of process feed- pounds with high chemical oxygen demand (COD) and pH.
Hydrocarbon Processing | NOVEMBER 2019 63
 Environment and Safety
Hazardous wastes must be treated properly. For the
HPI, inorganic and organic compounds are present in process
wastes. TABLE 1 summarizes common liquid wastes that cannot
be effectively handled by traditional methods. Due to biologi-
cal oxygen demand (BOD) and COD, organic liquid wastes
require specific disposal strategies. Several problematic com-
pounds (TABLE 1) found in liquid waste streams require incin-
eration as the end-of-pipe treatment. These include:
• Sulfonates
• Chloride-containing compounds
FIG. 2. The downfiring configuration assists in gravity removal of
molten salts and slag from reactor walls and improves unit reliability.
FIG. 3. Turbulent mixing of waste feed and O2 promotes 99.999% DE
of VOCs, HAPs and chlorinated compounds.
64 NOVEMBER 2019 | HydrocarbonProcessing.com
• Halogenated organics
• Alkali salts.
For proper disposal, these compounds require a high-tem-
perature destruction solution. Unfortunately, incineration of
some compounds can create molten salts or byproduct acids.
Both hinder the incineration process and require additional
control solutions.
Different solutions to manage wastes. As summarized in
TABLE 2, there are several ways to manage difficult vapor and
aqueous streams. Characterization of the contaminants greatly
influences the remediation method that is the best fit for the
waste stream and operating facility. Chemical treatments are not
always the better solution for TABLE 1 compounds. Thermal so-
lutions can provide better destruction efficiency (DE), manage
halogenated organic compounds and prevent dioxin formation
during the oxidation process (FIG. 1).
As with any hazardous waste control solution, capital and
operating costs and unit reliability are part of the decision-
making process. Such disposal/treatment technologies are su-
pervised by environmental permit requirements for the facil-
ity. Emissions from the remediation solution are regulated to
prevent releases of toxic compounds. Especially for aqueous
wastes, minimizing offsite disposal needs and charges is a criti-
cal factor. Costs for offsite management of hazardous wastes is
an expensive route. Consequently, HPI facilities seek solutions
to effectively manage toxic wastes onsite.
Incinerating waste streams of salt brines, aqueous liquids
with organic contaminates, inorganic salts, metals, polychlori-
nated biphenyls (PCBs) and dis-isocyanates pose many design
and operating challenges. Residual wastes from HPI operations
can include halogenated hydrocarbons (TABLE 1). These com-
pounds must be destroyed. During the incineration process,
most alkaline metals form molten salts (TABLE 3) that are corro-
sive and reactive with many common equipment construction
TABLE 1. Common compounds present in HPI plant wastes
Organic compounds Halogenated compounds
Acids Chlorides
Alcohols Fluorides
Amines Bromides
Organo-metallic Iodides
Maleic anhydrides Mixed halogens
Mercaptans
Nitrogen-bound Inorganic (aqueous) stream
Sulfonated Alkali salts
Suspended solids
PCBs
Di-isocyanates Dioxins and furans
TABLE 2. Different destruction/management technologies
for organic and inorganic wastes
Thermal Incineration
Wet air oxidation
Chemical Direct chemical oxidation
Deep neutralization
 Environment and Safety

materials. These waste streams and reaction byproducts cause into the burner (FIG. 3). Turbulent mixing enables complete
problems when oxidized by traditional incinerators. oxidation of waste-feed gas mixture into water vapor and CO2.
In the submerged combustion system, multiple fluid atom-
Why consider incineration as an end-of-pipe solution? izers aid in mixing wastes with combustion air. The high-swirl
Tough environmental rules strictly regulate emissions from vortex burner can use any self-sustaining waste with varying ca-
HPI facilities. Immense fears exist regarding possible toxic re- pabilities as fuel. With thorough mixing of wastes and supply
leases from incinerators. HPI companies must apply innovative gas, the submerged combustion system has a DE of 99.999%,
abatement solutions that effectively reduce hazardous materials well above the 98% level required by environmental permits.
into harmless products, such as water vapor and CO2. High temperatures and reaction times are needed to destroy ha-
Oxidation methods are chemical reactors. They apply reac-
tion kinetics and mixing characteristics to convert liquid and
gaseous wastes into desired end products. The reaction factors
governing oxidation processes are time, temperature and turbu-
lence. Successful thermal oxidation methods use intimate mixing
(turbulence) of wastes with enough oxygen (O2) and, if needed,
support fuel. Oxidation of halogenated hydrocarbons requires a
minimum temperature of 1,100°C. Likewise, control of reaction
time is governed by the flame length. Time influences the DE to
oxidize the waste compounds into harmless residuals.

Combustion solution destroys waste with “near-zero”

emissions. A submerged combustion systema uses a propri-
etary down-firing design (FIG. 2). As incineration is a kinetic re-
action, the intimate (turbulent) mixing of wastes and O2 in the
vortex burner has tremendous effects on the DE of the process.
In the submerged combustion system, waste compounds are FIG. 4. A submerged combustion systema was selected to reliably
finely atomized in the nozzle with combustion air and injected manage a high-volume spent caustic waste stream.

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Hydrocarbon Processing | NOVEMBER 2019 65

 Environment and Safety

Also, properly managing halogenated inorganic compounds

TABLE 3. Characteristics for common salts present
in spent caustic present in the spent caustic was a major design condition.
TABLE 3 summarizes the problem salts present in the facility’s
Salt Melting point, °C Boiling point, °C spent caustic.
Sodium bromide (NaBr) 747 1,447 Plant engineers selected an advanced, vertical, submerged
Sodium carbonate (Na2CO3) 850 Dissociates combustion systema. Due to the volume of spent caustic,
system reliability was a key design consideration, as summa-
Sodium chloride (NaCl) 801 1,465
rized in TABLE 4. Also, this system had to manage byproduct
Sodium fluoride (NaF) 996 1,787 salt formation. With the vertical reactor, molten salts would
Sodium sulfate (Na2SO4) 884 — gravity flow down the refractory walls to the quench chamber
(FIG. 2). The plant engineers selected the submerged combus-
tion technology to ensure that particulates were removed effi-
TABLE 4. Design considerations for oxidation/incinerator
systems quench system
ciently and remaining acid gases were scrubbed before release.

Type Advantages Disadvantages Combustion technologies handle hazardous waste.

Lower CAPEX/lower pressure No protection of downstream The production of transportation fuels and petrochemicals
Spray quench

drop
More efficient if particulate
removal is not required
Inherent protection of
Submerged quench
components with loss of
quench fluids
Nozzles prone to clogging
when fluids contain suspended
or dissolved solids
Higher maintenance
and labor costs
Higher pressure drop if
generates byproducts that must be recycled, minimized or
eliminated. The selection of the waste treatment depends on
many factors. The types of hazardous materials to be remediat-
ed narrow the possible options. Likewise, total cost of owner-
ship further limits possible abatement methods. In the case of
halogenated compounds, dioxins, furans and others (TABLE 1),
oxidation/incineration is the preferred remediation method.
In addition, waste treatment solutions must meet federal and

downstream components particulates removal is needed

Removes particulates from High CAPEX
gas stream
Eliminates risk of steam
explosions
Nonclogging nozzles
Higher unit reliability
Low maintenance
and labor costs
logenated compounds, such as PCBs and vinyl chloride mono-
mer, and to prevent dioxide formation.
In the downfiring design, the reaction chamber is vertical.
When liquid inorganic wastes are present, the feed is injected
below the flame zone. The gravity drain of the slag continuously
removes byproduct molten salts from the refractory walls into
the quench chamber.
As illustrated in FIG. 2, the hot reaction gases pass through a
water-washed downcomer tube and are chilled in the quench
tank. This tank acts as the primary scrubber and recovers a
high percentage of byproduct acids and particulates. Also, the
quench tank functions as a safety device. If the quench water
supply is lost, then the quench tank serves as a heat sink un-
til the problem is corrected. Rapid cooling of reaction gases
prevents the reformation of dioxins and furans. In the quench
tank, the level of agitation dissolves most of the byproduct
salts, ensuring that the waste gases undergo initial cleaning.
Any residual salts remaining in the gas stream are scrubbed
before release.
Case history: Spent caustic incineration project, Saudi
Arabia. A Middle East HPI facility was investigating a more
efficient way to treat and incinerate spent caustic. The new in-
cineration system needed to manage 7.4 tph of spent caustic
using a dual-fuel supply of wet gasoline and natural gas. Plume
suppression was a key factor in designing the new unit (FIG. 4).
state environmental permit requirements. More efficient oxi-
dation/incineration solutions are an emerging trend.
Advanced submerged combustion systems can effectively
destroy halogenated compounds. Such systems oxidize organ-
ics and halogenated compounds, including volatile organic
compounds (VOCs) and hazardous air pollutants (HAPs), at
99.999% DE. Technology selection for waste remediation in-
cludes the full lifecycle costs. Besides DE, total costs (capital,
operating and maintenance) are critical selection factors. From
TABLE 4, operating costs and unit reliability can provide offsets
to the higher installation solutions for the submerged combus-
tion system. Higher DE (99.999+%) oxidation technologies,
such as the advanced, submerged combustion system, can
handle hazardous materials, yield “near-zero” emission levels
and release harmless end products of water vapor and CO2.
NOTES
a
Selas-Linde North America’s Sub-X® oxidizers use a downfiring reaction chamber
with a submerged quench system.
ERIC PREDATSCH is Selas-Linde’s Product Manager for
oxidation technologies. His experience includes fired equipment
design, equipment startups, process simulations and
supervision of Selas-Linde’s oxidation laboratory testing
program. He previously worked at Dow Chemical in research
and development. Mr. Predatsch holds a BS degree in chemical
engineering from Villanova University.
PETER ARMSTRONG is the Vice President of business
development for Selas-Linde, a wholly owned operating unit of
Linde Engineering North America. He is responsible for driving
strategic sales and market development in Selas Linde’s core
technologies of LNG vaporization, thermal oxidation, ethylene
furnaces, steam reformers and specialty heaters. Prior to Selas-
Linde, Mr. Armstrong was Global Vice President of business
development and marketing for HB Rentals, and served as Director of business
development for KTI, a wholly owned subsidiary of TechnipFMC. Mr. Armstrong is
on the board of the Rice E&C Global Forum and serves on the International Refining
and Petrochemical Conference Advisory Board. He holds BS and BA degrees from
Rockhurst University and an MBA from Washington University in St. Louis.

66 NOVEMBER 2019 | HydrocarbonProcessing.com
 Valves, Pumps and
Turbomachinery
J. JABLONSKI and W. HELFER, Emerson,
Marshalltown, Iowa

Using ball valves in high-temperature applications

Ball valves (FIG. 1) are often an economical solution for con- 1,000˚F (538˚C). ASME TDP-1 requires drain valves to have
trolling flows in refinery high-temperature applications, but a minimum flow area equivalent to 85% of the adjacent pipe,
their application can be complex, particularly in high-temper- essentially favoring full-port ball valves for these applications.
ature uses.
For the purposes of this article, “high-temperature” is consid- Drivetrain performance. In high-temperature applications,
ered as anything higher than 400°F (204°C). Although API RP poorly designed valves can fail quickly in multiple ways. A com-
615 defines high-temperature service for metal-seated valves as mon mode of failure is the binding of drivetrain components.
temperatures greater than 750°F (400°C), 400°F (204°C) is a Depending on the severity of binding, one can expect acceler-
natural transition temperature where most elastomers and poly- ated wear on metal parts or a complete stall out of ball rotation.
mers break down. Also, some softer metals, such as aluminum Actuator torque can exceed the capability of the drivetrain, re-
alloys, begin to weaken as temperatures increase. Most refinery sulting in sheared keys, a twisted shaft and/or a deformed ball.
applications are less than 1,500°F (816°C). A coating failure of the ball to seat (FIG. 2) may also occur.
Reviewing industrial valve reference documents will not as- Drivetrain friction goes up with increases in temperature. Dur-
sist end users in understanding all of the critical aspects associ- ing normal operation, torque may increase up to two times com-
ated with high-temperature valve constructions because the pared to what is experienced at ambient temperature, thereby
information found in these sources is usually generic, such as making actuator sizing critical. Factors influencing this increase
recommending that plastic components be replaced with metal in torque include the shifting of parts due to thermal expansion,
or graphite. General service valves cannot be repurposed for thermal growth of complex geometries and the dissipation of
high-temperature service, as these applications require a solution assembly lubricants, such as molybdenum disulfide. Metal bear-
where all parts of the valve/actuator assembly are addressed. ings and graphite packing rings have higher friction than polymer
This article examines the design and testing of ball valves equivalents, and the softening of load-bearing parts results in
for use in high-temperature refinery applications. End users higher friction and the potential for galling or wear.
can work with suppliers to apply this information when speci-
fying ball valves. Trim troubles. Trim components within the valve assembly
must not only be compatible with the fluid; they must also be
Applications. Petroleum refining requires many high-tem-
perature processes to separate crude oil into marketable oils
and distillates. High-temperature valves are nothing new to
the industry, although applications continue to migrate toward
higher temperatures. Ball valves have not always been the valve
of choice. However, trunnion and floating ball valves are be-
ing used more frequently due to flow efficiencies and compact
form factors. Some of the most common applications and max-
imum temperatures include:
• Hydrocracker feed: 650°F (343°C)
• Gas plant debutanizer bottom product: 650°F (343°C)
• Hydrotreater: 750°F (399°C)
• Catalyst in hydrocracking: 950°F (510°C)
• Coker crude oil bottoms, furnace feed, coke slurry, drum
switching, blowdown and overhead vapor: 970°F (521°C)
• CCR and FCCU catalyst handling, flue gas
and fractionator bottoms: up to 1,400°F (760°C).
A steam power plant in a refinery may also require dozens of
FIG. 1. Floating ball valve installed in a high-temperature application.
condensate drain valves and vents with temperatures exceeding
Hydrocarbon Processing | NOVEMBER 2019 67
 Valves, Pumps and Turbomachinery

capable of withstanding high stresses. Valve stems absorb the damaging the coating. If the design cannot satisfy these require-
brunt of the torque required to actuate the valve, so they should ments, then excessive seat leakage will occur.
be made from a corrosion-resistant material that maintains high Metal bearings, particularly stainless steels, are usually coat-
yield strength and torsional stiffness at elevated temperatures, ed to reduce friction and minimize wear. To aid in reducing the
such as Inconel 718, 17-4 stainless steel or Nitronic 50. rate of wear, the contact stress between the stem and bearings
Since the ball and seats are in the flow stream, the only op- should be reduced. Some materials, such as duplex and precip-
tion is a metal-to-metal seal. Obtaining tight shutoff with metal itation-hardened stainless steels, can become brittle at elevated
seats provides a greater challenge than with soft seals. To main- temperatures. In extreme applications, ceramic trim and linings
tain a leak-free joint between the ball and seats, the following may be used due to their excellent erosion/corrosion resistance
parameters must be controlled: fit of parts, surface finishes and high-temperature strength.
and a contact stress that provides the desired shutoff while not
Internal coatings. Hardening the outer surfaces of various
TABLE 1. Expansion coefficients trim components can extend usable life. Some of the more com-
mon hardening methods are:
Average expansion Average expansion • Chrome carbide and tungsten carbide, applied by
Material (in./in./°F) 70°F to 500°F (in./in./°F) 70°F to 1,000°F
high-velocity oxygen fuel thermal spray, can be used up
A105 7.3 × 10-6 8.1 × 10-6 to 1,500°F (816°C). Tungsten carbide is the preferred
F22 7 × 10 -6
8 × 10-6 coating below 900°F (482°C), due to its superior
F316 9.7 × 10-6 10.3 × 10-6 abrasion and erosion resistance at lower temperatures.
Hardness value should be a minimum of 65 Hardness
F6a 6 × 10 -6
6.6 × 10-6
Rockwell C (HRC).
Inconel 625 7.3 × 10-6 7.8 × 10-6 • Spray coatings can be fused via a secondary oven or
manual torch operation to ensure a proper metallurgical
bond with the substrate, thus eliminating coating spalling.
These coatings are especially hard, at about 65 HRC,
and maintain their hardness across a wide range of
temperatures.
• Alloy 6 weld overlays can be used up to 1,800°F (982°C),
but are normally limited to 1,000°F (538°C) due to
softening. This material has many desirable aspects,
such as good resistance to corrosion, galling, oxidation
(regardless of temperature) and thermal shock. The typical
hardness for Alloy 6 ranges from 36 HRC–40 HRC.
• Hard chrome plating is recommended for temperatures
up to 800°F (427°C). It can be used at higher
temperatures, but its hardness diminishes as temperatures
exceed 800°F (427°C). Results from laboratory tests
indicate that chrome plating will lose half its hardness as
temperatures approach 1,200°F (649°C). The expected
FIG. 2. Trunnion ball showing coating failure near the bore and hardness for chrome plating is approximately 65 HRC.
trunnion bearing surface. • Nitriding is a thermochemical case-hardening process.
Unlike other hardening processes, material is not
deposited onto the base metal. With nitriding, the
outer surface of the part is hardened, and the hardness
decreases as one goes further into the part. Nitrided
parts can be used up to 1,500°F (816°C).
The overall quality associated with a coating is influenced by
the condition of the base material and its application. There-
fore, a coating should be evaluated through testing to verify its
capabilities. One way to accomplish this is through wear tests at
temperature (FIG. 3).

Centerlines and clearances. A material’s coefficient of ther-

FIG. 3. Ring and block wear coating samples tested at elevated
temperature. The coating held up well to this test. It has a relatively
smooth, uniform wear band that shows minimal signs of galling.
68 NOVEMBER 2019 | HydrocarbonProcessing.com
mal expansion is the average ratio of the change in length per
degree in temperature to the length at a given minimum tem-
perature, expressed as in./in./°F or mm/mm/°C. For example,
when a 316 stainless steel sphere with a diameter of 10 in. and
an average coefficient of thermal expansion of 9.7 × 10–6 in./
in./˚F is heated from 70°F (21°C) to 500°F (260°C), it will ex-
 Valves, Pumps and Turbomachinery

pand to a diameter of 10.042 in. Since this coefficient changes Packing problems. “Live loaded” packing uses springs to ob-
with temperature, that same sphere will expand to 10.096 in. at tain a constant stress in the packing studs and packing rings to
1,000°F (538°C). TABLE 1 shows some coefficients of thermal compensate for small amounts of oxidation, consolidation and
expansion for various materials and temperatures. extrusion. Springs can be placed over the packing studs and
Since different materials have different expansion rates, ma- under the nuts, although larger springs that surround the stem
terial selection impacts operation. An unfortunately common (FIG. 4) provide a more consistent load over time. These live-
and worst-case valve example is 300 series stainless steel trim loaded packing sets benefit from occasional adjustment, with
in a carbon steel (A105) body. Although this combination may best performance occurring with this regular maintenance.
provide an economical solution at ambient temperature, the Determining an appropriate torque for the packing studs is
much higher rate of expansion for stainless steel can result in the critical to the valve’s performance. Ball valves in high-tempera-
trim expanding into the body at high temperatures, leading to ture applications experience flow-induced vibration and ther-
drivetrain binding. A better alternative is to use F6a or Inconel mal cycles as the ball rotates from a closed position to an open
625 trim in a carbon steel body. position. If the bolt torque is too low while the valve is in ser-
The concern with different expansion coefficients is exac- vice, then the packing nuts may loosen and cause a packing leak.
erbated by the fact that not all valve components are at the Excessive bolt torque leads to excessive valve torque, which may
same temperature because thermal gradients within a valve result in the valve failing to operate, or cause a “stick/slip” be-
are common. In high-temperature applications, this often re- havior in a control valve, leading to poor control of flow.
sults in the trim expanding more than the body, which leads to API 622 uses two tests to qualify valve packing up to 1,000°F
drivetrain binding. (538°C). High-temperature corrosion testing uses a fixture
Throttling valves usually open slower, allowing the parts to apply compressive stress to the packing set while soaked in
within the valve assembly more time to equalize. On/off valves 300°F (149°C) water at 650 psi (45 bar) for 35 d, looking for
have a higher burden because a sudden rush of hot fluid occurs stem pitting. A packing material test measures weight loss due
when they go from closed to full open, but smaller bypass valves to oxidation while ratcheting soak temperatures up to 1,000°F.
can be used to mitigate this issue. Packing sets passing these tests can be used in a ball valve test-
ed to API 641 for fugitive emissions, although this test is limited
Stem seal considerations. The inability to use most poly- to 500°F (260°C) due to the use of methane. An alternate inter-
mers and elastomers above 400°F (204°C) presents a challenge national fugitive emissions test, ISO 15848, can go up to a stan-
in seal design. Graphite has become the status quo for most
high-temperature seals despite its limitations. Graphite stem
packing can experience oxidation, consolidation and/or extru-
sion—leading to premature seal leakage.
To minimize oxidation, the temperature of the packing set
should be limited to 850°F (454°C) in oxidizing environments,
and to 1,200°F (649°C) in non-oxidizing services, such as
steam. Keeping the packing rings below this limit can be accom-
plished by using bonnet and stem extensions and/or lantern
rings, both of which serve as insulators. As a rule, any refining
applications over 800°F (426°C) should include coordination
with a packing ring manufacturer.
Consolidation is the filling of internal voids within the pack-
ing ring and the packing box chamber that occur during initial
assembly of the packing rings. Additional consolidation can oc-
cur over time as the graphite rings continue to densify under
load and temperature.
Consolidation can be minimized by using high-density
graphite rings, designing to an appropriate packing stress and
using an assembly procedure focused on compressing each
graphite ring to its target stress, as opposed to compressing the
stack of rings simultaneously.
Extrusion occurs when portions of the graphite rings are
pushed out of the packing box because of loads produced by the
packing studs and/or pressure from the process fluid. It is nec-
essary to minimize clearance between the stem and the body/
bonnet to limit the amount of extrusion—a difficult task, con-
sidering that these materials thermally expand at different rates.
If the clearance is too large, the rings will extrude. If the clear-
ance is too small, the stem rubs or binds on the body/bonnet.
Carbon rings or metal washers can be implemented above and
below the packing set to minimize extrusion.
Hydrocarbon Processing | NOVEMBER 2019 69
 Valves, Pumps and Turbomachinery
dard temperature class of 752°F (400°C) with helium, although
higher temperatures could be tested upon agreement between the
manufacturer and purchaser. Other minerals, such as mica or ver-
miculite, can be used as packing up to 1,800°F (982°C) and, un-
like graphite, will not pit stainless steel valve stems. Coordination
with a packing vendor is necessary for these special applications.
Body gasket considerations. Static seals have a little more
freedom in design. Gaskets can be made from graphite or metal,
and graphite gaskets can be flat sheet or spiral wound. Flat-sheet
gaskets are compressed and enclosed between two metal surfac-
es. A spiral-wound gasket is semi-metallic, comprising a spirally
wound V-shaped metal strip and a graphite filler material (FIG. 5).
Spiral-wound gaskets used between pipe flanges typically
come with an inner and outer ring. These rings provide cen-
tering, compression control and augmented gasket stiffness.
Spiral-wound gaskets used inside a valve assembly do not have
inner and outer rings, so these gaskets are considered “specials”
because the metal windings must produce the stiffness once pro-
vided by these rings.
Designing in the proper amount of gasket stiffness without
losing sight of its ability to seal becomes more difficult as the
pressure class and size of gasket increase. Spiral-wound gaskets
FIG. 4. A live loaded graphite packing arrangement for ball valves
uses springs on the valve stem to provide a constant load.
FIG. 5. Cross-section of a spiral-wound gasket showing alternating
bands of stainless steel windings and graphite filler.
70 NOVEMBER 2019 | HydrocarbonProcessing.com
are limited to CL2500 ratings and may be assembled only once.
After that, the gasket has been deformed too much for reuse. To
obtain the proper compression on spiral-wound gaskets, larger-
diameter bolts are required when compared to a bolted joint
that utilizes an O-ring or metal bore rings. For graphitic-type
gaskets, leakage to atmosphere may occur if bolt loads relax.
Metal bore rings (FIG. 6) are self-energized and pressure-en-
ergized seals that offer an alternative to graphite-based gaskets.
The seal ring is clamped between two mating parts, and as the
body halves are drawn together, contact eventually occurs with
the ring.
A controlled compressive load is applied to the ring, such
that permanent deformation is avoided. This type of seal pro-
vides several functional benefits. It is reusable, prevents leakage
during thermal transients regardless of temperature, and has
been successfully used in valves up to CL4500 pressure ratings.
Lab testing. Production tests of shell integrity and seat leakage,
to both ASME B16.34 and API 598 standards, are performed at
ambient temperature and provide insufficient insight into the
operation of a valve at elevated temperatures. This type of verifi-
cation requires testing by the manufacturer in a laboratory.
Testing can involve heating the valve from the outside, either
in a kiln or wrapped in heat tape (FIG. 7), and testing to check
for leakage, torque and part wear. Thermocouples are used at
multiple locations on the valve assembly to ensure that the tem-
perature equalizes throughout.
Tests normally use hot air, helium or methane as the pro-
cess fluid. Steam testing, where the fluid heats the valve from
the inside, may also be used to gauge the operation of the valve
under thermal shock, as would be experienced in operation.
Although this may better represent the temperature gradients
in operation, the steam can act as a lubricating fluid, which may
reduce measured torques.
Industry tests can also be used to gauge high-temperature
operation. API 641, ISO 15848-1 and Shell 77/300 all measure
fugitive emissions at elevated temperature, with the latter also
looking at seat leakage across the temperature range. API 607
and API 6FA fire testing evaluates seat and external leakage,
operability and cavity pressure after the assembly is exposed
to flame for 30 min.
Regardless of the test, lab environments are different than
actual applications because the test fluids are less corrosive and
FIG. 6. Metal bore seal ring clamped between two valve body halves.

free of the particulates that may induce wear. Thermal gradients
are nonexistent or less than what will be experienced in service.
As a result, field trials are recommended to prove the solution
prior to application on a large scale.
Other considerations. Pressure-temperature ratings are given
for common materials in ASME B16.34, with the temperature of
the shell assumed to be the temperature of the fluid. Although a
valve nametag may list a maximum temperature, this may relate
only to the shell integrity and does not guarantee proper opera-
tion at that temperature. It is important that the end user commu-
nicate to the supplier the range of temperatures at which the valve
must operate, and not just specify a pressure class and material.
The need for external coatings is questionable in high-tem-
perature applications, with the most benefit being realized by
steel valves during shipping and plant downtime. Steel valves
will rust at ambient temperatures, but not at high temperatures.
During shipping, installation and startup, these valves are at
low temperature and may be exposed to moisture, causing rust.
Wet spray and powder coats are limited to approximately 300°F
(149°C). Inorganic zinc coatings, with or without silicone top
coats, provide galvanic corrosion protection to steels at temper-
atures up to 1,000°F (538°C) and are a popular choice. Consid-
ering the complex relationship of base material, base coats and
top coats, advice should come from the coating manufacturer.
Bracket designs intended for high temperature must have a
higher factor of safety to account for larger actuators, while also
accounting for lower bracket, bolting and coupling strength at
elevated temperatures. The distance from the valve to the actua-
tor or manual operator must be adequate to protect elastomers
and personnel. These applications often use insulation around
the pipe and valve body to minimize heat loss.
Whereas a standard actuator with nitrile seals and polymer
bearings may be rated only to 200°F (93°C), high-temperature
constructions with fluorocarbon elastomers and metal bearings
may extend the range up to 350°F (177°C). Even if the actua-
tor can handle higher temperatures, accessories such as airsets,
FIG. 7. A valve wrapped in heat tape and insulation and instrumented
with multiple thermocouples.
Valves, Pumps and Turbomachinery
boosters, positioners and solenoids may need to be remotely
mounted in a cooler area.
Recommendations. Many refinery processes call upon engi-
neered ball valves to operate at high temperatures where elas-
tomers and polymers cannot be used. These valves can operate
successfully when a holistic approach is taken during the design,
including the selection of materials, actuation and accessories.
Even with attention to these details, the severity of these appli-
cations requires a program to test and verify performance.
End users specifying and purchasing these types of valves
can use the information presented in this article to improve
their ball valve and vendor selection process.
JASON JABLONSKI is the Director of Rotary Engineering at
Emerson Automation Solutions, and has 20 yr of experience in
the design, testing and manufacturing of process control
equipment. He received his BS degree in mechanical
engineering from Iowa State University and his MBA degree
from the University of Texas at Dallas. Jason is a Project
Management Professional, Agile Certified Practitioner and
member of the API Subcommittee on Piping and Valves.
WADE HELFER has 22 yr of industry experience in the design
and evaluation of control and isolation valves for a variety of
industries, and is an expert in rotary valve seals, butterfly valve
flow dynamics and high-temperature valve design. He
completed his BS degree and graduate coursework in
mechanical engineering from Iowa State University and is the
Rotary Technologist at Emerson Automation Solutions,
responsible for developing and evaluating new technologies.
TENDER SALE & ONLINE AUCTION
SYNGAS MANUFACTURING
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of Falconara Marritima (AN) Italy
INCL. AIR SEPARATION UNIT incl. air compressor installation “Sulzer”
(1997), cap 240.930 Nm³/hour; nitrogen installation “Borsig/Renk”;
oxygen installation “Sulzer”; booster installation; gasification area
incl. gasification plant; carbon extraction plant; gas cooling hydrolysis
plant; absorption area; sulphur recovery area incl. sru plant, tail gas
treatment plant; grey water treatment area incl. gwt plant; sour gas
treatment plant;
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Hydrocarbon Processing | NOVEMBER 2019 71
 Water Management
W. PERPICH, Veolia Water Technologies,
St. Petersburg, Florida
Sustainability and the water management
company’s role
Water is key to the hydrocarbon processing and chemical
processing industries. Yet, it is not an infinite resource, which
creates operational, financial and regulatory risks. The true
cost of water can include insurance and litigation costs and dis-
posal costs, plus the capital expenditures (CAPEX) and oper-
ating expenses (OPEX) of water infrastructure.
Sustainability is top of mind, especially in the areas of raw
water availability, freshwater minimization and wastewater re-
cycle and recovery. A major global hydrocarbon and chemical
processing company stated the importance of water manage-
ment on its 2018 corporate sustainability report. This com-
pany is seeking to continuously improve its development and
implementation of water management strategies, taking into
consideration local factors such as quality and availability at
each plant.
Understanding the mass balance of a facility’s water con-
sumption is a critical first step in creating water management
strategies. This global HPI/CPI company understands how
water sustainability is a major component of resource manage-
ment. It continuously works to improve its understanding of
water consumption, including when and how much at each
area of the facility. Using a water tool developed by IPIECA,
the global oil and gas industry association for environmental
and social issues, the company identified that 37% of its major
operating sites are in potentially water-scarce areas.
FIG. 1. Wastewater recycle and reuse at HPI/CPI facilities is becoming
a trend. Treated wastewater can be recycled for use onsite or in other
beneficial areas such as cooling tower makeup, service water, boiler
feedwater and, in some cases, irrigation.
72 NOVEMBER 2019 | HydrocarbonProcessing.com
Water management companies can play a valuable role in
helping the HPI/CPI industry with water sustainability in the
areas of recycle and reuse, zero liquid discharge, consulting ser-
vices and system design. Operators will benefit by mitigating
operational, regulatory and reputation risks.
This article discusses the ways in which one water manage-
ment company is helping the HPI/CPI industry, including a
particular global partner, with water management.
Benefits from water management services. By reducing
their demand for freshwater and also more efficiently manag-
ing wastewater, HPI/CPI operators can significantly reduce
their water footprint. Water management companies can
provide site-specific recommendations based on water needs
assessments, treatability studies, audits, piloting and lab test-
ing. They offer technologies and services, such as primary and
secondary oil/water separation, biological treatment, clarifi-
cation, recycle and reuse, sludge handling and treatment, and
zero liquid discharge.
Wastewater recycle/reuse minimizes freshwater intake and
is becoming a trend in drought-stricken areas, and as waste-
water discharge costs increase. The treated wastewater can be
recycled for use onsite or for cooling tower makeup, service
water, boiler feedwater and, in some cases, irrigation (FIG. 1).
Water management strategies for hydrocarbon processing
can be adopted from upstream oil and gas operations. In the
upstream market, for instance, the oil and gas industry is in-
corporating non-potable water sources as alternatives to fresh-
water for completions. Historically, produced water has been
regulated as a waste for disposal. Stakeholders now recognize
that produced water can be reconditioned as a source of sup-
ply for oil and gas activities.
Regulators, the industry, and the public and private sectors
all support treatment innovation for this emerging reuse trend.
Technologies such as water softening can stabilize frac sup-
ply water for recycle. Other technologies combine a high-rate
softening process with ceramic membrane technology to treat
frac flowback and produced water for reuse as frac water. These
types of technologies can also be used to treat produced water
for injection to achieve enhanced oil recovery and to treat pro-
duced water for steam generation.
Benefits of water reuse technologies include:
• Reduced freshwater demand, disposal costs,
truck traffic and emissions
 Water Management

• Removal of hardness, silica, iron, barium and strontium, nating from a number of industrial processes. Most companies
which can scale equipment have the goal of developing a strategy to implement treatment
• Removal of particulates (oil, solids, bacteria) methods for each wastewater type, based on the best technol-
and creation of an absolute barrier, minimizing ogy available.
downstream carryover The author’s company routinely investigates zero liquid dis-
• High system recovery rates of greater than 98%. charge (ZLD) options globally to eliminate liquid discharge
and recover virtually all the water in wastewater streams for
Industrial client support. One water management company reuse. The company also provides water audits/consulting
is working with large hydrocarbon and chemical companies to services that include investigating multiple wastewater streams
identify solutions to economically reduce water usage. Global and suggesting system designs. Audits and recommendations
HPI/CPI companies should consider water reduction efforts consider project scope, availability of labor, electrical transmis-
early in project planning. The driver is different for each proj- sion capacity and capital cost estimates for budgetary purposes.
ect, depending on location and water availability (FIG. 2). Rare- A number of different water recovery options exist, including
ly is a “standard” solution available. Companies understand membrane (reverse osmosis) concentration (FIG. 3), falling
that optimal water reduction solutions will vary significantly film evaporation and forced-circulation evaporation. Recom-
based on water chemistry. mendations are made based on operating cost projections, per-
Water technology management companies ask the client’s formance and the feasibility of electrically driven evaporation.
project coordinators about potential water reduction configura- Industrial plants often receive makeup water that does not
tions during the screening stage, often before details are known meet normal requirements for cooling tower purposes. This
about water quality in the regions where the work is being done. can increase cooling tower operation and maintenance costs,
They leverage previous installation configurations and costs to and negatively impact system components. Water management
highlight the different technology options. and technology companies can help these plants meet future
By developing and implementing local water management
strategies, the referenced company is working with businesses
to lower freshwater consumption during operations. Since
2011, some oil and gas companies actually report having low-
ered freshwater use by 20%. As previously mentioned, major oil
and gas companies are recognizing that 30%–40% of major op-
erating sites are in areas with water scarcity potential. They are
pursuing site-specific management strategies, such as deploying
water conservation technologies, using alternative water sourc-
es, recycling industrial wastewater and using lower-quality water
sources. For example, the use of secondary or tertiary municipal
wastewater will have constituents of concern that other feedwa-
ter sources may not (e.g., nitrates, chlorine or chloramine).
Oil and gas companies are continuously investigating waste-
water mitigation strategies for “typical” wastewater types origi-

FIG. 3. Membranes (reverse osmosis concentration) can be a water

recovery option for HPI/CPI companies. Recommendations are made
by water management companies after analysis of operating cost
projections, performance needs and feasibility.

FIG. 4. Cooling tower operation and maintenance costs can be

FIG. 2. Global HPI/CPI companies should consider water reduction high. Water management companies can recommend strategies for
efforts early in project planning. The driver is different for each project, facilitating delivery of consistent, high-quality makeup water, and can
depending on location and water availability. develop cooling tower blowdown discharge and reuse solutions.

Hydrocarbon Processing | NOVEMBER 2019 73

 Water Management
high-quality water demands. These include strategies for facili-
tating delivery of consistent high-quality makeup water, and
treatment strategies to meet future requirements. Water tech-
nology companies can also help develop cooling tower blow-
down discharge and reuse solutions that are both environmen-
tally compliant and economical (FIG. 4).
For example, high-rate clarification for raw water, and cool-
ing tower blowdown treatment for reuse, are other areas of
consideration. A proprietary, high-rate softening technology
FIG. 5. A proprietary, high-rate softening technology lowers the
raw water footprint. The system combines microsand-ballasted
coagulation, flocculation and lamella settling to treat raw water
and wastewater.
Statement of Ownership, Management and Circulation (Required by 39 U.S.C.).
1. Title of publication: HYDROCARBON PROCESSING
2. Publication number: ISSN 0018-8190
3. Filing date: September 27, 2019
4. Issue frequency: Monthly
5. Number of issues published annually: 12
6. Annual subscription price: $399.00
7. Complete mailing address of known office of publication:
Gulf Publishing Company, P. O. Box 2608 (2 Greenway Plaza, Suite 1020,
77046), Houston, Harris County, Texas 77252-2608.
8. Complete mailing address of the headquarters or general business
offices of the publishers: Gulf Publishing Company, P. O. Box 2608
(2 Greenway Plaza, Suite 1020, 77046), Houston, Texas 77252-2608,
Contact person: Suzanne McGehee; Telephone (713) 520-4473.
9. Names and complete addresses of publisher, editor and managing
editor: Publisher—Catherine Watkins, 2 Greenway Plaza, Suite 1020,
Houston, Texas 77046; Editor—Lee Nichols, 2 Greenway Plaza, Suite
1020,
Houston, Texas 77046; Executive Editor—Adrienne Blume, 2 Greenway
Plaza, Suite 1020, Houston, Texas 77046.
10. Owner: Gulf Publishing Holdings LLC, 2 Greenway Plaza, Suite 1020,
Houston, Texas 77046.
11. Known bondholders, mortgagees and other security holders owning
or holding 1 percent or more of total amount of bonds, mortgages
or other securities: Gulf Publishing Holdings LLC, 2 Greenway Plaza,
Suite 1020, Houston, Texas 77046.
12. Tax Status has not changed
13. Publication title: Hydrocarbon Processing
14. Issue date for circulation data below: September 2019
15. Extent and nature of circulation: Average, Actual
A. Total number of copies (net press run): 19,980, 17,462
B. Legitimate paid and/or requested distribution:
1. Outside County Paid/Requested Mail Subscriptons stated
on PS Form 3541—10,882, 10,242
2. In-County Paid/Requested Mail Subscriptions stated
on PS Form 3541—0, 0
74 NOVEMBER 2019 | HydrocarbonProcessing.com
lowers the raw water footprint. The system (FIG. 5) combines
microsand-ballasted coagulation, flocculation and lamella set-
tling to treat raw water and wastewater. The system then sends
water to reverse osmosis (RO) pretreatment (membrane or
multimedia filters) and then RO/demineralization systems,
and finally to the reuse point.
Meeting sustainability challenges. Water technology
companies help HPI/CPI clients better manage their freshwa-
ter usage, as well as wastewater recycle and recovery. As a re-
sult, these clients not only become more sustainable, but also
improve operations and the bottom line.
As water becomes scarcer and more expensive, and as en-
vironmental regulations change, water technology compa-
nies can help clients choose the best and most cost-effective
solutions.
WILLIAM (BILL) PERPICH is a Director of Business Development
for Veolia Water Technologies. He has more than 25 yr of
experience in environmental engineering, focusing on physical/
chemical and biological treatment of industrial process water
and wastewater systems. He holds a BS degree from the
University of Wisconsin—Stevens Point, with an emphasis
in wastewater treatment and solid/hazardous waste
management. For the past 5 yr, Mr. Perpich’s role at Veolia Water Technologies
has involved business development for the oil and gas sector, including refineries,
chemical and petrochemical plants. He specializes in identifying and implementing
the best technologies that provide clients with cost-effective, reliable,
environmentally friendly and compliant solutions.
3. Sales through dealers and carriers, street vendors,
and counter sales, and other paid or requested distribution
outside USPS—7,639, 5,969
4. Requested Copies distributed by other mail classes through
the USPS—18, 15
C. Total paid and/or requested circulation (sum of 15B1,2,3 and 4):
18,539, 16,226
D. Nonrequested distribution (by mail and outside the Mail):
1. Outside County nonrequested Copies Stated on PS Form 3541—
0, 0
2. In-County Nonrequested copies Stated on PS Form 3541—0, 0
3. Nonrequested copies distributed through the USPS by
Other Classes of Mail—0, 0
4. Nonrequested Copies Distributed Outside the Mail—806, 758
E. Total Nonrequested Distribution (sum of 15d): 806, 758
F. Total distribution (sum of 15C and E): 19,345, 16,984
G. Copies not distributed: 635, 478
H. Total (sum 15F and G): 19,980, 17,462
I. Percent paid and/or requested circulation (15C/F x 100):
95.8%, 95.5%
16. Electronic Copy Circulation: Average, Actual
A. Requested and Paid Electronic Copies: 13,115, 15,369
B. Total Requested and Paid Print Copies (Line 15c) +
Requested/Paid Electronic Copies: 31,654, 31,595
C. Total Requested Copy Distribution (Line 15f) +
Requested/Paid Electronic Copies: 32,460, 32,353
D. Percent Paid and/or Requested Circulation: 97.52%, 97.66%
17. This statement of ownership will be printed in the November 2019
issue of this publication. Publication required.
18. Signature and Title of Editor, Publisher, Business Manager, or Owner
I certify that the statements made by me above are correct and complete.
/s/ Catherine Watkins, Publisher
 Water Management
J. DALEBROUX, Emerson Automation Solutions,
Shakopee, Minnesota; and B. ALEYNIK,
Chicago, Illinois

Improved cooling system performance

begins with data
Refineries consume large amounts
of energy and water to refine crude oil
into products. Up to 10% of crude oil’s
energy content is consumed during pro-
cessing, and it takes 1.5 bbl of water to
process one barrel of crude oil. Refin-
ing processes also generate large quanti-
ties of excess thermal energy that needs
to be expelled into the environment
using a once-through or recirculating
cooling system. A once-through system
draws water from a raw water source and
pumps it through process heat exchang-
ers where it absorbs heat and is then sent
back to the source. These systems are
cheaper to construct and consume sig-
nificantly less water than recirculating FIG. 1. Cooling towers are often used to transfer heat from processes to the atmosphere, but
systems, but they may also require more they have high construction, operational and maintenance costs.
water treatment chemicals and pose en-
vironmental risks.
Unless a raw water source is abundant vironment for plant personnel. As shown • Bearings and gears can fail
and readily available, recirculating cool- in FIG. 2, there are many things that can due to misaligned drive shafts,
ing water as much as possible is critical go wrong with a cooling tower. To those and high vibration is common.
not only to reduce the cost of water treat- responsible for maintaining them, there • Vibration data from a cooling
ment, but also to conserve the water sup- are two main areas of concern: tower’s gearbox is difficult
ply. Unlike once-through systems, recir- • Problems with mechanical and dangerous to collect without
culating systems reuse the cooling water components, such as fans, permanently installed sensors.
and employ evaporative cooling towers pumps and valves • Mechanical components are often
(FIG. 1) to transfer heat from the process • Cooling water quality and integrity difficult to access, and thus are
to the atmosphere. Evaporative cooling of the distribution system. undermaintained.
towers have high construction, opera- • Failure of a fan requires a crane
tional and maintenance costs, while con- Problems with mechanical com- to remove and fix or replace,
suming large quantities of water, often as ponents. Cooling towers incorporate a which costs time and money
much as 90% of the total water consump- variety of mechanical equipment—most and is a potential safety hazard.
tion in a refinery. notably pumps and fans—that are sus- By installing wireless sensors on cool-
Cooling water availability is critical ceptible to problems common to rotating ing tower pumps, fans and gear boxes to
for refining operations. It is highly de- equipment, but with a unique set of chal- monitor vibration and temperature, a fa-
pendent on maintaining cooling towers lenges. These challenges include: cility can automate data collection for as-
and the rest of the cooling water system • Cooling tower fans operate under set health evaluation—increasing worker
at peak performance. Equipment failures variable load conditions with safety, saving time and freeing technicians
within a cooling tower can be costly to differing stresses over a prolonged for performing repairs prior to failure and
fix, can potentially lead to unplanned period, putting them at higher risk other higher-level tasks. Furthermore,
downtime, and may create an unsafe en- of structural failure. continuous monitoring can enable con-
Hydrocarbon Processing | NOVEMBER 2019 75
 Water Management
dition-based maintenance, which is more Increasing COC introduces several
effective than time-based maintenance or problems that can impact cooling system
reactive maintenance that addresses a fail- performance, such as corrosion, scale de-
ure after the fact. position, fouling from airborne contami-
nants, microbiological growth and deg-
Cooling water quality. The measure of radation of a cooling tower’s structural
cooling water recirculation is defined as integrity. The severity of these problems
cycles of concentration (COC), which is depends on multiple parameters, such
the ratio of dissolved minerals in the re- as chemical composition of the makeup
circulating water to dissolved minerals in water, cooling tower location, cooling
the makeup water. It can be calculated us- system materials of construction and
ing Eq. 1: operating conditions. In addition, these
problems are interrelated, and address-
COC = ing one may exacerbate the other. For
Total dissolved minerals example, lowering pH of the cooling wa-
in blowdown water (1) ter by adding acid can help control scale
=
Total dissolved minerals deposition, but may intensify corrosion
in makeup water and make controlling certain types of
Evaporation rate + microbiological growth more difficult.
blowdown rate It is critical to establish and main-
tain a program of corrective measures
Blowdown rate to maintain optimal cooling system per-
FIG. 2. Following the chain of effects of a problem shows how a small issue can escalate
if not addressed quickly.
76 NOVEMBER 2019 | HydrocarbonProcessing.com
formance. Concentration of dissolved
minerals and pH of cooling water must
be carefully monitored and controlled
to avoid excessive scale deposition while
maintaining acceptable corrosion rates.
Organic and inorganic contaminants
must be removed through side-stream
filtration and prevented from depositing
on heat-transfer surfaces. Finally, micro-
biological growth must be controlled
with biocides. Some of these microbio-
logical contaminants may include harm-
ful bacteria such as Legionella, which
causes Legionnaires’ disease.
Preventing scale while controlling
corrosion. As COC increases, more wa-
ter evaporates, and additional minerals
enter the system via makeup water. The
recirculating water becomes supersatu-
rated with dissolved minerals and pre-
cipitation begins to occur, resulting in
formation of scale deposits, such as cal-
cium carbonate and magnesium silicate,
on heat-exchange surfaces. While small
amounts of scale can be beneficial for
corrosion protection, if left unchecked,
scale deposits will start to impede heat
FIG. 3. A general-purpose pH sensora is an
appropriate choice for this type of application.
FIG. 4. A conductivity sensorb can control
blowdown cycles when conductivity becomes
too high.

transfer and significantly increase the
risk of localized corrosion.
In addition, some carbonate deposits
may accelerate delignification of cooling
tower lumber and undermine structural
integrity. Scaling is typically controlled
by blowing down (bleeding off) some of
the recirculated water from the system to
reduce concentration of dissolved min-
erals. This may be sufficient for opera-
tion at low COC, however; at high COC,
reducing alkalinity by adding sulfuric or
hydrochloric acid and dosing chemical
scale inhibitors may be required to con-
trol scale deposition.
Corrosion in a cooling system is a fac-
tor of temperature, pH, concentration
of dissolved minerals, water flow veloc-
ity and extent of microbiological foul-
ing. Three main types of corrosion exist:
general, localized and galvanic. Localized
corrosion is the major concern with these
systems because it may lead to a rapid
metal failure and is often hidden from
sight under deposits.
Corrosion effects are widespread and
often result in unscheduled downtime
and costly repairs. These include:
• Fouling of heat exchangers and
distribution piping by corrosion
products (e.g., rust)
• Leaks in heat exchangers resulting
in contamination of the process
fluid by cooling water or vice versa
• Decrease in heat transfer efficiency.
pH control, along with chemical anod-
ic and cathodic corrosion inhibitors such
as chromates, nitrites, polyphosphates
and bicarbonates, are commonly used
to maintain corrosion within acceptable
limits. Corrosion inhibitors must be care-
fully chosen for the specific metallurgy of
the cooling system.
Controlling fouling and microbio-
logical growth. During normal opera-
tions, cooling water becomes contami-
nated by organic and inorganic matter.
Dosing of dispersants may be necessary
to prevent coagulation or flocculation
of suspended solids, which are drawn
in with the outside air. Warm water also
produces an ideal environment for al-
gae, slime and bacterial growth. If left
untreated, microorganisms form a gel-
like substance called biofilm that allows
them to attach to heat-transfer surfaces
and protects them from biocides. Bio-
film also prevents corrosion inhibitors
from reaching the metal surfaces and
may accelerate corrosion.
To control microbiological growth,
non-oxidizing and oxidizing biocides,
such as chlorine, bromine or ozone, are
typically added on timed intervals. Some
of these are highly toxic and pose a signif-
icant safety risk. Ozone is an effective al-
ternative to traditional chemical biocides
and has the following advantages:
• More effective than chlorine
or ultraviolet light at destroying
bacteria and viruses
• Does not produce harmful
residuals that need to be removed
from effluent water
• Reacts with iron, manganese
and sulfur in the water to form
insoluble metal oxides
or elemental sulfur
• Can be generated onsite,
eliminating the risks of storing
and handling toxic chemicals
• Does not increase corrosion.
Cooling water monitoring. Effective
control of COC and chemical treatment
to maintain water quality requires contin-
uous online measurement of water qual-
ity. Nonetheless, many facilities operate
based on daily or even weekly analysis of
their cooling water. Online monitoring of
cooling water quality can help optimize
cooling system performance and lower
water and chemical usage.
At a minimum, plants should continu-
FIG. 5. Conventional pH sensorsc can be
fouled when suspended solids levels are high,
so a fouling-resistant sensor can be used
to reduce maintenance requirements.
FIG. 6. Where suspended solids levels are
high, a toroidal conductivity sensord may be
necessary to make the measurements used
to reduce the level.
Water Management
ously monitor their cooling water pH and
conductivity, using temperature-com-
pensated pH sensors (FIG. 3) to monitor
the alkalinity of the cooling water, along
with conductivity sensors (FIG. 4) to
monitor the concentration of dissolved
minerals to maintain an optimal COC.
General-purpose pH sensors and con-
tacting conductivity sensors are suitable
for most cooling water systems; however,
for systems with a high degree of fouling,
pH sensors resistant to fouling (FIG. 5)
and toroidal conductivity sensors (FIG. 6)
are recommended.
Measuring free chlorine in cooling wa-
ter provides feedback to the chlorination
system on biocidal efficacy to control
and optimize dosing. To obtain accurate
measurement of chlorine concentration
in the cooling water, a free chlorine mea-
surement (FIG. 7) compensated by a pH
sensor should be used.
FIG. 7. Chlorine necessary to suppress
biological growth can be monitored using
a sensore.
FIG. 8. Ozone treatment to reduce biological
growth is growing in popularity but requires
a specific sensorf to monitor concentration.
Hydrocarbon Processing | NOVEMBER 2019 77
 Water Management
When utilization of a free chlorine
measurement system is cost prohibitive,
an oxidation reduction potential (ORP)
measurement may serve as an alterna-
tive. The effectiveness of chlorine de-
pends on its ability to oxidize water to
produce hypochlorous acid, a strong oxi-
dizing agent. ORP measurement—also
compensated by a pH sensor—may be
correlated to the amount of hypochlo-
rous acid and may be used as a proxy to
a free chlorine measurement for control-
ling the chlorination. If ozone is used to
control biological growth, a dissolved-
ozone sensor (FIG. 8) may be used to
provide a continuous measurement of
ozone concentration to control and op-
timize dosing.
FIG. 9. Measuring total suspended solids
requires a sensorg. Data from this can be used
for regulatory compliance reporting.
FIG. 10. Where it is not practical to add a permanent temperature measurement point, a transmitterh can infer the water temperature without
a process penetration.
78 NOVEMBER 2019 | HydrocarbonProcessing.com
A blowdown stream turbidity mea-
surement (FIG. 9) provides a way to
monitor suspended solids and can be
used to control sidestream filtration and
for reporting of effluent total suspended
solids levels to government regulators.
Cooling water return temperature is
a good indicator of cooling performance
and can be monitored easily with the
temperature sensor incorporated into
most pH or conductivity sensors, elimi-
nating the cost of an additional tempera-
ture measurement point.
Cooling water treatment control.
Since chemical water treatment is one of
the largest variable cost components in
cooling tower operations, automated con-
trol of blowdown and chemical dosing is
important for cost-efficient operation.
In addition to monitoring and com-
municating various cooling water param-
eters, some liquid analytical transmitters
may offer alarm relays, as well as propor-
tional integral derivative (PID) and time
proportional control (TPC) functions.
These functions allow the transmitter
to direct control of the cooling tower’s
makeup and blowdown valves, heaters
and chemical treatment dosing pumps.
PID control can be applied to any of
the sensor measurements connected to
the transmitter, as well as to external ana-
log and digital signal inputs. The output
signal of a PID controller can vary its
output from 0%–100% in response to the
measured variable.
TPC is more commonly known as
duty cycle or pulse-width modulation. It
applies PID control to a relay, rather than
using an analog current output. The TPC
output is defined as the percent of time
that a relay is activated.
The following alarm relay functions
are common for cooling towers:
• High/low concentration:
Primary and secondary measured
variables (such as pH, conductivity
and temperature) can be used
to drive outputs to control
concentrations. These outputs
have an adjustable dead band and
perform on/off control of pumps
and valves. A typical application
is control of blowdown.
• Delay timer: A delay timer can
be used in a concentration control
scheme to delay measurement
following dosing of treatment
chemicals. This ensures enough
mixing time in a cooling water
recirculation loop before
performing a measurement,
preventing unmixed readings that
might cause overshooting.
This function can be utilized
when adding acid or inhibitors.
• Bleed and feed: This approach
is typically used to replace
chemicals lost during blowdown
and involves two or more relays.
Once the bleed relay deactivates,
one or more feed relays activate
for a percentage of the time the
bleed relay was on. Bleed and feed
support continuous monitoring of
blowdown water conductivity to
determine the point of excessive
conductivity. At a programmable
maximum concentration value,

bleeding of blowdown water is
triggered. Subsequently, pumping
to feed additional makeup water
chemicals is enabled to account
for lost blowdown water. Through
level control, makeup water is
added in proportion to the volume
of water lost through blowdown
and evaporation.
• Totalizer-based relay activation:
This approach feeds chemicals
for a preset period every time a
programmed volume of liquid
has been added or removed.
The relay energizes when the
volume has been reached and
remains energized for a fixed time.
The process repeats once the
volume has been reached again.
The scheme uses pulse inputs
from a flow meter or 4-20
mA current input from a flow
transmitter to calculate a volumetric
total flow. A typical application is
chemical dosing control.
• Interval timer: When a sensor
needs to be cleaned or the process
requires adjustment, an interval
timer turns on to begin the cycle.
When the interval time has
expired, the analyzer deactivates
the “hold” mode on the assigned
measurement and the relay is
energized for the on-time period.
• Date and time activation:
This relay feature allows
programming of relays to activate
on an assigned day of the week
and time of day or night for an
assigned interval, functioning like a
sprinkler timer. The programmable
timeframe cycle is typically two
weeks. A typical application
example is daily biocide dosing.
Evaluating condition and perfor-
mance. In addition to liquid analyti-
cal measurements used for monitoring
and control of cooling water quality
and COC, continuous measurements of
other parameters—such as flow, tem-
perature, level and pressure—at various
points throughout the cooling system
work together to monitor performance
and further optimize efficiency. Typical
points of measurement include:
• A cooling tower’s exhaust air
temperature
• Ambient air dry-bulb and wet-bulb
temperatures
• Cooling water supply and return
temperatures
• Level measurements in water
and chemical storage tanks
• Water flowrates
• Pressure differential across heat
exchangers.
The data generated by these instru-
ments can be recorded and analyzed by
preconfigured applications to continu-
ously monitor the cooling tower and its
related equipment health. This can en-
able:
• Tracking and optimizing cooling
tower efficiency
• Monitoring and optimizing water
and chemical usage
• Monitoring heat exchanger
performance
• Monitoring rotating equipment for
condition-based maintenance to
mitigate asset failures
• Alerting operators when something
abnormal is detected
• Training operators to act on this
new information and to update
procedures as needed.
Wireless products are supported by,
and are fully compliant with, the IEC
62591 standard, making this kind of mon-
itoring much easier and less expensive
than with wired instruments. All the types
of instruments necessary for monitoring a
cooling tower are available with either na-
tive WirelessHART transmitters or with
adapters to connect to WirelessHART net-
works. This makes installation easier, and,
if added to existing networks, the cost is
especially low. Some things to consider:
• Surface-mounted temperature
sensors do not require thermowells,
and are able to accurately measure
water temperature through the
pipe wall (FIG. 10).
• If it is practical to use conventional
temperature sensors, a single
transmitter (FIG. 11) can send
data from up to four sensors
on one wireless signal.
• Vibration and bearing temperature
sensors can be added to fan and
pump motors and gear boxes to
warn of developing mechanical
problems.
• Wireless pressure sensors may
be installed on the inlet and outlet
of a heat exchanger to measure
differential pressure and to
Water Management
FIG. 11. Some temperature transmittersi can
send data from up to four sensors on one
channel.
monitor fouling.
• Liquid analytical transmitters
can connect to a WirelessHART
network with an adapter.
All these elements working together,
guided by data gathering and analytical
apps, can improve cooling tower perfor-
mance and plant profitability.
NOTES
a
Refers to the Emerson Rosemount 3900 general-
purpose pH/ORP sensor
b
Refers to the Emerson Rosemount 400 contacting
conductivity sensor
c
Refers to the Emerson Rosemount 396P/396PVP
pH/ORP sensor
d
Refers to the Emerson Rosemount 228 toroidal con-
ductivity sensor
e
Refers to the Emerson Rosemount 499ACL free
chlorine sensor
f
Refers to the Emerson Rosemount 499AOZ
amperometric ozone sensor
g
Refers to the Emerson Rosemount T1056 Clarity
II turbidimeter
h
Refers to the Emerson Rosemount X-well technology
i
Refers to the Emerson Rosemount 848T wireless
temperature transmitter
JASON DALEBROUX is a Director of
Product Management for Emerson’s
Automation Solutions business
in Shakopee, Minnesota. He is
responsible for Rosemount liquid
and combustion analysis products.
He holds a BS degree in mechanical
engineering from Michigan Technological University
and an MBA degree from the Carlson School of
Management, University of Minnesota.
BORIS ALEYNIK co-authored this
article, but is no longer employed by
Emerson. He was formerly part of
the team responsible for Rosemount
liquid analysis products. He holds
a BS degree in mechanical
engineering from Iowa State
University and an MBA degree from the Kellogg
School of Management, Northwestern University.
Hydrocarbon Processing | NOVEMBER 2019 79

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ADVERTISER INDEX
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Ashcroft Instruments ..................................... 55
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Hoebiger ...................................................... 35
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Publicitas Singapore Pte Ltd HP Marketplace ..............................................81
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Hydrocarbon Processing Subscription ............. 29
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Linde.............................................................19
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