Operations and Process Technology Summit

2017 American Fuel & Petrochemical Manufacturers OPERATIONS AND PROCESS TECHNOLOGY SUMMIT

Conference Daily Published by DAY ONE | #AFPMSUMMIT17 ® HYDROCARBON PROCESSING Sunday/Monday | October 1/2, 2017

Weathering the storms INSIDE THIS ISSUE 3 Schedule of sessions and special events and promoting innovation 7 Five unique ways to improve revamp projects CHET THOMPSON, President, American Fuel & Petrochemical Manufacturers Fluor explores how harnessing the knowledge of industry subject Welcome to the AFPM Op- Not only have we improved lives around the globe matter experts (SMEs) improves erations & Process Technology through our products, but we continue to innovate, ad- productivity and predictability Summit, and thank you for join- vancing our industries through modern technology and ef- ing us this year in Austin, Texas. ficiencies. By investing billions of dollars in research and 8 Improve visibility, increase The past five weeks have been development, and utilizing our collective ingenuity and in- profitability with planning difficult and challenging for our dustriousness, we have developed new processes that have and scheduling Gulf Coast associates, employ- reduced emissions and made the air cleaner now than it has Navigating unpredictable and ees and facilities, and for the mil- been in 50 years. risky environments with AspenTech lions of people impacted by Hur- Fuels and petrochemicals are largely responsible for 13 Overcoming the “lost decade” ricanes Harvey and Irma. AFPM many of humankind’s major advancements over the last of ICS security remains committed to continue 100 years, and our industries will continue to be at the Claroty’s Cofounder Galina Antova its efforts to help in the recovery. center of future innovations for generations to follow. The discusses how industry must Hurricane Harvey ripped through the epicenter of US work that we do is instrumental in advancing our indus- better prepare for cyber security fuels and petrochemical production, knocking offline 25% tries, which is why this conference is so important. I assure threats on the horizon of US refining capacity and approximately 80% of ethyl- you that AFPM will take every opportunity to advocate ene production. Yet, in a matter of only a few weeks, our for, and give voice to, the essential role that fuels and pet- 16 What is APC 2.0? industries were well on their way to being fully operation- rochemicals play in improving modern life. Companies are moving away al. That is a testament to the preparedness and resilience This year marks the 70th anniversary of the Summit, and from model-based multivariable of our industries, as well as to our dedicated and skilled we want to extend our sincerest thanks to the many people tools to more agile advanced workforce. This did not happen by accident—we were that have made this event possible over the years, and for process automation, prepared and enacted critical safety procedures, while developing another program that you are sure to find infor- says APC Performance working closely with first responders and the federal gov- mative and beneficial. 18 List of exhibitors, hospitality ernment to ensure that any disruptions to the fuel supply Again, welcome, and thank you for attending and showing suites, meeting rooms map would be minimized. your support for our industries and the great state of Texas.• Commemorating 70 years of industry advocacy For 70 years, AFPM’s Q&A and mittee on petroleum refining capacity of US automobile demand post-WW2, “Chris” McDowell, appeared on the Technology Forum—now the Op- to the National Petroleum Council on demand for fuels grew rapidly, and panel in 1978, and has continued to erations & Process Technology Sum- July 8, 1947, reported a total US re- refineries had to add capacity and be- participate in Summit planning and mit—has played an important role in fining capacity of 5.65 MMbpd (with come more reliable and efficient. other activities for almost 40 years! leading the discussion of issues, trends an operating rate of 91%). Of the 141 The first mention of a “panel of Only Warren Letzsch, with more than and challenges facing the refining and refineries operating in 2017, 82 were authorities” discussion at an AFPM 42 years of participation, has a longer petrochemical industries, as well as built prior to 1947, and the total num- meeting was in 1947. This panel dis- tenure on the committee. addressing specific operating issues ber of refineries in 2017 is about a cussed catalytic cracking at the 1947 Aside from small adjustments to and problems within the industry. quarter of the number in 1947. Refin- AFPM Annual Meeting in San Anto- the panels for Q&A and more specif- The 2017 Summit represents 70 eries are now much larger and have a nio, Texas. Note: AFPM was called ic Q&A sessions for plant managers, years of providing an open forum for total 2017 capacity of 18.62 MMbpd the Western Petroleum Refiners As- the forum did not make many chang- industry professionals to network, col- (with an operating rate of 96.6%), ac- sociation (WPRA) at that time. Until es until the Principles and Practices laborate and share technical informa- cording to a report from the Energy 1961, the Q&A was held in El Dora- (P&P) sessions were added in 2004 tion and best practices among peers. Information Association (EIA). do, Kansas—legend has it that the lo- to complement the Q&A sessions. Since the first Q&A in 1947, the With the innovation of fluid cata- cation was chosen because there were The P&P sessions were implemented refining industry has grown by leaps lytic cracking, improved catalyst tech- few, if any, distractions to prevent at- to reinforce fundamental principles and bounds. The report of the com- nology in the 1940s and the expansion tendees from the sessions. and proven operating practices of re- After 1961, the Q&A began mov- finery and petrochemical processes ing to different locations around the for a target audience of mid-career country and attendance grew accord- and junior process engineers and op- ingly, reaching the 1,200–1,300 range erations staff. in the 1970s. The Q&A panels ex- In 2005, the Plant Automation and panded over the years to more than 20 Decision Support Conference was co- panelists, who sat on the stage for two located with the Q&A, and the “Tech- and a half days and answered submit- nology Forum” was formed. Attend- ted and floor questions. Today, four ees whose responsibilities overlap disciplines are broken up into four between process engineering, unit op- separate panels. erations, process control and planning One thing that has not changed were now able to use their conference since 1947 is that the strength of the time more effectively. For the last few Q&A lies in the diverse exchange of years, we have added a Young Lead- ideas from competitors, operating ers segment, where we offer a three- While technologies and our industries have changed over the past 70 years, the companies, suppliers and customers, hour session and a special networking attendees’ and presenters’ willingness to educate and collaborate with one another and the networking among the at- has remained a key reason for the conference’s long-term success. Source: AFPM. tendees. The first woman, Christina  See 70 YEARS, page 3 Let’s do The Right Catalyst the math. System for You

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A joint venture of Grace and Chevron 70 YEARS, continued from page 1 event for less experienced industry The more things change, the more ter materials, enhanced maintenance professionals to attract and bring they remain the same. The topics of methods and improved equipment. them back to the Q&A and, more im- discussion at the Q&A over the last For 70 years, this conference has portantly, retain them in our industry. 70 years have been very similar. Dis- been—and remains—the leading The industry has changed greatly cussions about fluid catalytic crack- technical venue for the exchange of over the last 70 years (e.g., intense ing, crude quality, coking, alkylation, information, ideas and best practices competitive pressures have resulted catalysts, reforming and hydropro- in the petrochemical and refining in- in numerous small refinery closures cessing—among other long-time sub- dustries. The Summit would not have and a reduction in the number of in- jects—have dominated the decades. lasted and remained strong without dependents in the business). Those As technologies have developed and the buy-in of the professionals in our same pressures have led to mergers the industry has become more effi- industry, and the attendees’ and pre- and acquisitions that have changed cient, asset reliability and plant avail- senters’ willingness to educate and the shape of the industry. The growth ability have improved through bet- collaborate with one another. • of some independent refiners through acquisition, and the recent emergence of “super majors,” have concentrated refinery capacity in fewer companies, SCHEDULE OF SESSIONS leaving small refiners to survive in regional markets. Adding to the pres- AND SPECIAL EVENTS sures of the marketplace have been environmental rules for gasoline, diesel SUNDAY, OCTOBER 1, 2017 Chairman of the NPRA ALLAN MUSE, fuel and refinery emissions that have 3–6:30 p.m. Registration and badge pickup Manufacturing Committee in 1972, required capital expenditures that re- 5–6:30 p.m. The Summit Kickoff Networking Event opens that year’s NPRA Q&A session duce the amount of capital available on refining technology. Source: AFPM. for profit-improving projects. MONDAY, OCTOBER 2, 2017

7 a.m.–6:30 p.m. Registration DOWNLOAD THE 2017 OPERATIONS & PROCESS 7–8 a.m. New Manager Morning Mixer TECHNOLOGY SUMMIT INTERACTIVE MEETING MOBILE 8–8:55 a.m. General session APP AND PUT THE CONFERENCE PROGRAM AND 9–10 a.m. Concurrent Sessions: EXHIBITOR DIRECTORY IN THE PALM OF YOUR HAND. • Cybersecurity • Operational Planning, Control and Automation Technologies The interactive app will allow you to: • Principles & Practices—Emerging Leaders Town Hall • View schedules, locate and explore sessions, access speaker information, • Q&A and Discussion Session—Gasoline Processes find networking events and access hospitality directory 10–10:15 a.m. Coffee Break • Create your own personal schedule for easy conference attendance • View the exhibit hall floor plan and review the exhibitor directory 10:15 a.m.–12 p.m. Concurrent Sessions cont. • Access the attendee list 12–2 p.m. Lunch in Exhibit Hall • Send private messages to fellow registrants • Post updates to sessions, keynotes and exhibitor booths and obtain 2–3:30 p.m. Concurrent Sessions: up-to-date event details • Cybersecurity • Interact with a real-time feed of all event activity that showcases which • Operational Planning, Control and Automation Technologies sessions are trending, and the most popular photos and discussion topics • Principles & Practices—Gasoline Processes • Comment on our activity feed about real-time events at the meeting • Q&A and Discussion Session—Hydroprocessing • Learn about our sponsors 3:30–3:45 p.m. Refreshment Break Download today! Or search “AFPM OPTS17” in the app store. 3:45–5:15 p.m. Concurrent Sessions cont. Your unique initial password for accessing the App is “opts17”. 5:15–6:30 p.m. Reception in Exhibit Hall If you experience password issues contact [email protected]. TUESDAY, OCTOBER 3, 2017

7 a.m.–5 p.m. Registration

Published by Hydrocarbon Processing 8–10 a.m. Concurrent Sessions: as three daily editions, October 1/2, • Cybersecurity October 3 and as an electronic edition • Operational Planning, Control and Automation Technologies • Principles & Practices—Hydroprocessing on October 4. If you wish to submit • Q&A and Discussion Session—Crude/Vacuum Distillation and Coking a press release, please contact 2017 OPERATIONS AND the editor via email at 10–10:15 a.m. Coffee Break PROCESS TECHNOLOGY SUMMIT [email protected]. 10:15 a.m.–12 p.m. Concurrent Sessions cont. 12–2 p.m. Lunch in Exhibit Hall Publisher Advertisers: 2–3:30 p.m. Concurrent Sessions: Catherine Watkins AFPM...... 19 • Cybersecurity Athlon Solutions...... 11 • Operational Planning, Control and Automation Technologies AFPM Contacts Axens North America Inc...... 9 Diana Cronan • Principles & Practices—Crude/Vacuum Distillation and Coking BASF SE...... 13 • Q&A Session—FCC Rebecca Adler Criterion Catalyst & Technologies, L.P...... 5 Editor EMGC...... 17 3:30–3:45 p.m. Refreshment Break Mike Rhodes Grace...... 2 3:45–5:15 p.m. Concurrent Sessions cont. Haldor Topsoe Inc...... 7 Contributing Editors Hydrocarbon Processing Subscription...... 14 5:30–6:30 p.m. Women in Refining Networking Event Ashley Smith Hunter Buildings...... 15 Reception open to registered women only. Lee Nichols Johnson Matthey Production Manager Process Technologies Inc...... 20 WEDNESDAY, OCTOBER 4, 2017 Angela Bathe Dietrich 7:30–10 a.m. Registration Hydrocarbon Processing 2 Greenway Plaza, Suite 1020 8–9:30 am Concurrent Sessions: Houston, TX 77252-77046 • Cybersecurity 713-529-4301 • Principles & Practices—FCC • Principles & Practices—Fostering Profitability 9:30–9:45 a.m. Coffee Break www.HydrocarbonProcessing.com 9:45–11 a.m. Concurrent Sessions cont.

2017 Operations and Process Technology Summit | American Fuel & Petrochemical Manufacturers Sunday/Monday, October 1/2, 2017 3 2017 SUMMIT PANELIST BIOS

Brant Aggus, Becht Engineering Darin Foote, CHS, is an Operations Superintendent at the CHS Inc. refinery in Laurel, Montana. In addition to his role in operations, he has held roles in Noaman Al-Fudhail, Aramco, began his career with Saudi Aramco in the Ras refinery LP modeling and process engineering, and managed a 2-MM-hour, Tanura Refinery as a hydrocracker Process Engineer and grew to hold a number site-wide turnaround. Mr. Foote has spent 17 years working in the areas of leading positions. As part of Saudi Aramco’s training program, Mr. Al-Fudhail of crude/vacuum, FCCU, solvent extraction and fired heaters. Prior to joining spent a year and a half working with UOP, performing design and technical support CHS, he worked for Flint Hills Resources and John Zink Co. in various roles. for hydrocrackers and diesel hydrotreaters. He has recently served as the Senior He earned a BS degree in chemical engineering from Brigham Young University Operations Representative for the hydrocracker and diesel hydrotreater at Saudi in Provo, Utah. Aramco’s Jazan Refinery, working with the project management team and the EPC contractor during the units’ detailed design phase. He is now the Superintendent Errol Johnson, Motiva, is the process engineering Team Lead for Motiva of refinery engineering at Saudi Aramco’s Riyadh Refinery, overseeing and leading Enterprises in Port Arthur, Texas. His responsibilities include supervising process all engineering resources and activities for the refinery. Mr. Al-Fudhail graduated engineers who provide technical support to all hydrocracking, hydroprocessing, from the University of Washington with a BS degree in chemical engineering. reforming and base oil units for the site. Previously, he worked for Valero Energy as a Process Engineer covering a wide range of petroleum refining areas. Sanjay Bhargava, KBC, is a Principal Consultant/Senior Advisor working in Mr. Johnson earned a BS degree in chemical engineering from the University the downstream operations/solutions group and in business development for of Texas A&M–College Station and an MBA degree from the University of large multi-refinery and petrochemical profit improvement and energy reduction Texas A&M–Corpus Christi. He has more than 12 years of experience in the projects. He has more than 28 years of experience in the oil and gas industry, petroleum refining industry. and has performed consulting work in more than 50 refining and petrochemical complexes worldwide. Recently, he led plant-wide, best practices-based Bryan Kinderman, Clariant, has served as Clariant’s Sales Director for operational excellence programs—spanning organizational alignment, business the refining business, responsible for North and South America, since 2015. work processes and procedures, workforce capability development, sustained Previously, he worked for UOP for 15 years. Mr. Kinderman has been working margin improvement, refinery modernization feasibility studies, crude optimization in the refining industry for 28 years across multiple businesses in the oil and gas and safety reliability improvement projects—in Latin America and India. Prior industry, from upstream drilling, midstream and refining. He graduated from to that, he served as Operations Manager for KBC’s North Asia hub in Beijing, the Colorado School of Mines in 1989 with a BS degree in chemical engineering, China, and has managed several refinery and petrochemical profit improvement, and earned an MBA degree from DePaul University in 2000. integration (RPI) and implementation projects (PIP), energy reduction programs (SER), and reliability and operational planning improvement programs in the US, Eric Légaré, Andeavor, is Process Development Manager at the Andeavor China, India, Brazil, Japan and Thailand. Mr. Bhargava has spent more than Martinez Refinery in Martinez, California. He is responsible for the development 15 years working as an FCC and alkylation specialist in several refineries of refinery capital projects that support turnarounds, regulatory, income and worldwide. He earned dual MS degrees in the US: an MS degree in chemical sustaining projects, as well as developing new project management tools engineering and an MBA degree in finance. to improve the efficiency of the FEL process while promoting stakeholder engagement in the project development process. Prior roles during his 12 years Bryan Dinkel, Marathon Petroleum, is an FCC Technologist for Marathon with Andeavor include supervision of the refinery’s operations engineers and Petroleum Co. (MPC) in Texas City, Texas, and provides operational and technical management positions in process engineering and operations. Mr. Légaré has support to the seven FCCUs within the MPC system. Mr. Dinkel has 14 years of 24 years of industry experience, and holds a BEng degree in chemical refining experience, and has been in this role at Marathon for more than 4 years. engineering from McGill University in Montreal, Canada. His previous roles with BP included various process and project engineer roles, FCC/alky site Consultant and Technical Services Supervisor. He earned a Darwin Logerot, Prosys Inc., is a Senior Consulting Engineer at ProSys Inc., BS degree in chemical engineering from Texas A&M University. a global process control software and engineering consulting firm located in Baton Rouge, Louisiana. Since joining ProSys in 2006, he has become one of the Geoff Dubin, Axens North America, is a Technology Manager at Axens company’s leaders in the areas of state-based control, alarm management and North America covering olefins and light oil hydroprocessing technologies. model predictive control. Prior to joining ProSys’ consulting team, Mr. Logerot Mr. Dubin has been with Axens for 14 years and has held several positions had more than 30 years of experience in the process chemical industry in a within the company, with experience covering process engineering, energy variety of chemical engineering roles, including process design, operations and optimization, project management and business development. In his present project management. He has had successful tenures at companies such as role as Technology Manager, he is responsible for technology positioning and Exxon Chemical, Ethyl Corp. and ENGlobal Corp. Mr. Logerot graduated from licensing for the fields he covers, as well as providing technical guidance to Louisiana State University in Baton Rouge with a BS degree in chemical other departments in the organization. Mr. Dubin earned a BS degree in engineering in 1973. He earned his Professional Engineer (P.E.) designation chemical engineering from the University of Delaware. from the Louisiana Professional Engineering and Land Surveying Board in 1981.

Hector Gamboa-Arizpe, CITGO Petroleum Corp., works as a Strategic Sarah Long, Navajo Refinery, is a process engineer for HollyFrontier Navajo Planning Engineer at the CITGO Corpus Christi Refinery (CCR), developing and in Artesia, New Mexico. She holds a BS degree in chemical engineering, designing process solutions for mid-to-large capital projects across the facility. with an emphasis in biological engineering and mathematics, from He has 15 years of industry experience in petroleum refining, and has worked Texas Tech University. as a process engineer for several key refinery processes, including delayed coker, sulfur plant and amine treating systems; a crude/vacuum unit; several MEROX Alex Maller, Technip units; and several hydrotreaters. He has held various subject matter expert (SME) roles in corporate technology teams that aim to synergize the sharing of process William Ross McDaniel, KP Engineering LP, is a Senior Process Engineer knowledge across CITGO’s operating facilities. He was part of a team that at KP Engineering LP. He has 14 years of professional experience focused on recently improved the sulfur removal capacity of CCR to satisfy more stringent consulting refineries on crude, vacuum and hydrotreating revamp projects. Tier 3 gasoline emissions standards. As part of that effort, three of CCR’s His experience involves all levels of front-end design, including conceptual/ MEROX units were expanded and CCR’s gasoline hydrotreater was revamped feasibility studies, refinery optimization studies and feed studies leading to to accommodate 25% more charge. Mr. Gamboa-Arizpe holds a BS degree EPC projects. Additionally, his experience includes assisting clients directly with in chemical engineering from the Massachusetts Institute of Technology. turnarounds, new startups and small projects onsite. Mr. McDaniel received a BS degree in chemical engineering from the University of Lamar, and is Michael Federspiel, W. R. Grace & Co., is a Chief FCC Technologist in a registered Professional Engineer in the state of Texas. Grace’s global customer technology group. Based outside of Chicago, Illinois, Mr. Federspiel provides support for Grace customers in the Americas, Asia David Pappal, Valero, began his career in the refining industry, joining and the Middle East. He has more than 19 years of experience in FCC design, Mobil Research and Development Corporation in 1974, where he worked development, commissioning, technical service, operations management, and for 27 years in a variety of research, development and technical support catalyst sales and service. He earned a BS degree in chemical engineering assignments. Prior to Mobil’s merger with Exxon, Mr. Paooal lead the R&D, from the University of Wisconsin–Madison. equity technical support, and technical and marketing support

4 Sunday/Monday, October 1/2, 2017 American Fuel & Petrochemical Manufacturers | 2017 Operations and Process Technology Summit 2017 SUMMIT PANELIST BIOS

for hydroprocessing licensing activities at Mobil. After leaving Mobil, he joined Akzo-Nobel Catalysts as Worldwide Development Director for hydrocrackng catalysts, where many new hydrotreating and hydrocracking catalysts were successfully deployed in the industry. Upon joining Valero in September 2003, Mr. Pappal was promoted to Refinery Technology Director in the strategic development and technology section in San Antonio, Texas. His responsibilities included technical support for Valero’s hydrotreating and hydrocracking assets, with a particular focus on the implementation of technology from idea inception through commercial unit startup. Tier 2 and Tier 3 gasoline compliance projects, ULSD implementation and strategic WINNING projects commercializing hydrocracking technology were successfully completed. A major accomplishment was the design, construction and startup of two world-scale, two-stage distillate selective hydrocrackers. ADVANTAGE

Ramamoorthy Ramachandran, Bharat Petroleum, is Director (refineries)—and a member of the board—of Bharat Petroleum Corp. Ltd. TM (BPCL), a Fortune Global 500 company and one of India’s leading oil companies, with a significant presence across the entire petroleum value chain. Prior to his present role, Mr. Ramachandran was the Managing Director of Bharat Oman Refineries Ltd. a JV company with Oman Oil. He has more than 35 years of experience in refinery operations, projects, technical services, corporate affairs and ERP. As Director, he is also responsible for overseeing the JV and subsidiary companies of BPCL in the refining business, as well as its R&D, international trade, pipelines, central procurement organization and group refineries information services.

Alexander Sabitov, Phillips 66, is the Senior Reforming and Isomerization Engineer for Phillips 66’s refining business improvement group. He provides day-to-day technical support for the reforming, isomerization, aromatic extraction and S Zorb process units, and leads the development of short- and long-term opportunities to maximize returns by improving naphtha processing assets. He began his career with UOP in 1996 as an R&D Development Engineer, and worked in various functions with UOP technical services and naphtha technology business development departments until joining Phillips 66 in 2015. Mr. Sabitov graduated with an MS degree in chemical engineering from Ufa Oil Technological University in Russia.

Lyle Schoellkopf, Advanced Refining Technologies

Kyle Sharon, Valero Energy Criterion’s newest generation in catalysts continues to advance our technology to the pole position. With R&D expertise and innovation Kevin Solomon, Athlon second to none, the CENTERA GT™ high performance catalyst helps refiners keep on winning! Criterion continues to increase performance Patrick Sugg, UOP, has 23 years of service at UOP, and serves as a and quality, this leap forward with CENTERA GT adds to our industry Services Manager for multiple US sites. He has made contributions across leading line of SENTRY™, ASCENT™ and ZEOLYST™ catalysts. Our the project lifecycle, from technology development and engineering to catalysts protect and perform, adding value with customized refining commissioning and ongoing service support. Mr. Sugg’s technical focus solutions for even the most complex needs. has been on petrochemicals and reforming units that utilize continuous catalyst regeneration systems. SENTRY: Ultimate protection from feed poisons and pressure drop Hydrotreating: Performance in quality meeting strict fuel standards JEREMY THEISS, MARATHON PETROLEUM, has been a Technical and maximizing advantaged feeds Service Manager for Marathon Petroleum Corp.’s Detroit, Michigan Hydrocracking: Increasing the quality and yields for high value refinery for two years. He has 15 years of experience in the refining products processing heavier feeds industry working in various roles for Marathon Petroleum. His previous roles include Process Engineer, Operations Supervisor, Economics and With world-class technical customer service, Criterion continues to Planning Engineer, and Product Control Manager. Mr. Theiss earned race ahead for catalyst performance and value. We look forward to a BS degree in chemical engineering from the University of Cincinnati. working with you.

Steve Tragesser, KBR, has 33 years of industry experience, 26 of which have been with KBR. In his role as Chief Technology Engineer, he is responsible for the implementation of technology on FCC and alkylation projects, including grassroots and revamps. His other roles at KBR have included FCC Technology Manager, supporting marketing efforts for FCC grassroots and revamp projects. He also worked in FCC technical service, providing troubleshooting and startup support on grassroots and revamp projects. Mr. Tragesser has participated in more than 23 FCC grassroots and revamp startups, and has worked in FCC process design for many Leading minds. Advanced technologies. grassroots and revamp projects, as well as studies. He previously worked at Stone and Webster as Technology Manager, and for Akzo Nobel (Albemarle) early in his career. He earned a BS degree in chemical engineering from the University of Texas in 1984.

www.CRITERIONCatalysts.com

2017 Operations and Process Technology Summit | American Fuel & Petrochemical Manufacturers Sunday/Monday, October 1/2, 2017 5 Process engineers, discrete entities and the nature of reality RAVI AGLAVE, Siemens PLM

Some of the most significant dis- nature of reality from such discrete using models based on the fundamen- counts for collisions, cohesion, adhe- coveries in the 19th and 20th centuries elements and their transport. Devel- tal behavior of particles. Joseph-Louis sion, custom contacts, particle shapes, pointed to very similar observations oping fundamental models for dis- Lagrange gave us the framework of granular flow properties and particle- in numerous fields: every quantity crete behavior provided the necessary looking at flow from a different frame particle interactions. Depending on that appeared to be continuous was understanding and tools to recreate of reference, which was essential in application and modeling needs, a discovered to be discrete. Light con- the apparent continuity in the observ- the development of solutions of such one-stop tool is now available to bet- sists of photons; matter is comprised able phenomenon. discrete flows (FIG. 1). ter understand particulate flows. of atomic and sub-atomic particles; Particulate materials—consisting of Of course, numerous other scien- Many companies are deploying the energy levels of electrons consists such discrete units or elements—are tists contributed by including com- this unique capability and reaping the of quantas; digital information flows very common in the chemical and pro- plex physical behaviors such as mo- rewards, including: in bits; and even hereditary informa- cess industry. While designing or trou- mentum, mass and energy transfer • Coal Milling Projects (CMP): tion is transferred in smaller discrete bleshooting equipment, an understand- with surrounding fluid, friction, colli- In partnership with Aerotherm, units called genes. Most scientific ing of the bulk behavior of particles is sion, drag, wetting and cohesion with CMP recently maximized the efforts revolved around building the needed. Such reality can be built by other particles as well as erosion, throughput of pulverized coal and abrasion or boundaries. Deriv- to their burners while reducing ing from the basis of molecular dy- pressure drop using simulation. namics, the discrete element method The lower operating cost of (DEM) has made several advances in the resulting fan design and recent years to emerge as a prominent the reduced wear from the numerical analysis method of indus- particles (FIG. 2) resulted in trial equipment. a 21% average throughput improvement and an increase An integrated environment. Tradition- in maximum throughput from ally, designing particulate processes 22 tph to 30 tph. With this, involved thumb rules and expensive CMP improved the existing experimentation, leading to processes design, resulting in improved that were not fully optimized for max- mill product output, lowered imum life, distribution and efficiency fan resistances, reduced internal at a low-energy usage and cost. wear and air heater leakages, A solution has been developed and lower power consumption. that is the first to have full integra- • ArcelorMittal: In partnership tion of flow and particulate model- with Aerotherm, ArcelorMittal ing from within a single integrated reduced erosion by 30% in environment. For lean particle flows, particle separators in its steel Lagrangian modeling methods are plant. By using the DEM FIG. 1. Designing or troubleshooting equipment can be improved by using models available in STAR-CCM+® software technology to create a digital based on the fundamental behavior of particles. from Siemens PLM Software, while twin of the ash extraction unit the Discrete Element Model (DEM) in a steel plant, the location handles denser flows. Process en- and severity of erosion were gineers can now use a single tool to accurately predicted and the simulate realistic, non-spherical par- design was modified. ticle shapes of varying sizes, accu- These examples show the benefits rately model particle motion and con- of a coupled DEM-CFD and/or the tact, utilize compatibility with other Lagrangian approach to designing advanced physics models and reduce particulate flow processes. Taking this expensive testing, all with a single li- one step further, the in-built Design cense and from a single graphic user Manager in STAR-CCM+ and design interface (GUI). exploration tool HEEDSTM software The Lagrangian particle model help engineers use intelligent search (LMP) solves discrete phase trajecto- algorithms to automatically explore ries through a continua for low-par- the design space and determine better ticle volume fractions predicting the process designs and solutions more turbulence effect on dispersion where quickly. With such tools available, FIG. 2. Particle flow simulation in a coal mill classifier with STAR-CCM+. contact mechanics are not important. there has never been a better time to (Image courtesy of Aerotherm) The DEM, on the other hand, ac- be a process engineer.•

AFPM FEATURED EVENT: NEW MANAGER MORNING MIXER AFPM is excited to introduce a new event this year: and for which they may not have been well prepared. the New Manager Morning Mixer, held Monday morn- For example, “How would you handle an employee ing from 7–8 a.m. that chronically calls in sick?” The answers can be se- This is a new event for those who are about to or have rious—such as, “Have a discussion with the employee just entered into a formal supervisory or managing role. expressing your concern over their health”—or they can Whether you are comfortable and well-trained or ner- be not-so-serious—such as, “Buy the employee a case vous and have lots of questions, come meet like-posi- of chicken noodle soup and give it to them during their tioned peers who can share with you their experience next performance review.” Or, they can be both. While and help you boost your team’s performance. interesting, answering the questions is not the goal of the This new manager networking session is a breakfast session: the most important part of this event is to get with both informal networking and a “speed network- people talking to each other and building their networks. Monday morning’s New Manager ing” event that centers around an activity called, “How As new managers, they probably don’t have the answers! Morning Mixer is both a breakfast and would you handle…?” In that event, attendees will be The new event is open to those who have been man- informal networking event for those paired off and given some prepared questions and per- agers/supervisors for 5 years or less and those who will who are in, or will be assuming, new haps answers to those questions. The questions should become managers/supervisors in the next year. We look managerial and supervisory roles. be some that a new manager/supervisor is likely to face, forward to seeing you Monday morning! •

6 Sunday/Monday, October 1/2, 2017 American Fuel & Petrochemical Manufacturers | 2017 Operations and Process Technology Summit Five unique ways to improve revamp projects MAUREEN PRICE, Fluor

As refiners and petrochemical companies are in costly flare system retrofits and avoiding the tanks could be lifted and demolished challenged to deliver improved results with re- new permitting requirements (FIG. 1). without repairing the cracks, resulting in duced budgets, the industry is becoming more 3. Maximize utility of existing equipment. a cost savings of $100 MM. open to innovation and ideas that improve produc- Revamps require ingenuity and innovation These are just five of the countless examples tivity and predictability. to get the most utility out of existing of SMEs delivering value for this industry. This While state-of-the-art technology is important, equipment with the least capital investment. conference provides a valuable opportunity for harnessing the knowledge of industry subject mat- Stan Lum, a hydrotreating technology the industry to come together and share best prac- ter experts (SMEs) to examine challenges with a expert, helped configure a revamp of the tices and improvements. Harnessing the knowl- fresh perspective is just as vital. A minor invest- preheat system upstream of a naphtha light edge of the industry’s SMEs will position the re- ment in time can result in major cost and schedule hydrotreater. This approach allowed heavier fining and petrochemical industry for success in savings, as evidenced in these five case studies: boiling-range feedstock to be processed years to come. • 1. Support scope modifications. On a recent without needing to retrofit the fired heater revamp project, using Fluor’s distillation or expand the heater permitted duty, expert, Henry Kister, for oversight and reducing the cost and schedule. guidance, Fluor made simple but effective 4. Take advantage of industry standards. improvements to improperly configured Developing custom designs can create hot vapor bypass controls for tower unnecessary delays in fabrication and cost. pressure in two separate columns On a recent project, mechanical SMEs (a depentanizer and a debutanizer). performed a detailed elastic/plastic finite These relatively modest scope element analysis. This analysis confirmed modifications resulted in significant that the vendor-fabricated injection operational benefits, including improved compressor with a wall thickness below stability and product quality. the design minimum was acceptable 2. Remove existing system constraints. for full design pressure and full corrosion Revamps are often constrained by existing allowance. This approach avoided a overpressure protection and relief systems. seven-month project delay. Fluor leveraged Jesus Cabrera’s expertise 5. Take a hard look at “requirements.” in relief system design and dynamic On a recent project, a contractor needed simulation modeling to evaluate and to demolish 30 tanks and stated that the eventually validate the performance of cracks in the tanks needed to be repaired an existing relief valve for future prior to lifting and demolishing the tanks. FIG. 1. Validating the performance of an existing conditions, saving potentially $1 MM Fluor SMEs were engaged and proved that relief valve system saved $1 MM in flare system retrofits.

New revenue stream for refineries will come from excess fuel gas

by Jens Michael Poulsen, [email protected], Haldor Topsoe

Sour Refinery fuel gasses (RFG) are considered low-value gases composed of Fig. 1 Conventional fuel gas system off-gases from a variety of sources within the refinery. They are problematic due to their composition containing high levels of sulfur species and olefins which makes them an environmental liability.

In a conventional RFG system, see fig. 1, an amine wash will remove H2S, but does not extract the 100’s ppm of other sulfur species. Also, a hydrogen reformer cannot accept several % olefins. Fig. 2 Hydrotreating concept for desulfurization of sour fuel gases Refinery industry trends such as: • regulations for low sulfur gasoline and The fuel gas system can however easily be refinery fuel gas, not only into clean fuel, diesel, modified to purify the gasses, resulting in but also bring it to a level where it can be • reduced sulfur bunker fuel, low sulfur emissions and value-adding hy- used as valuable feedstock for catalytic • more heavy and sour crude regulations, drogen feedstock. production of hydrogen, methanol, sup- clearly indicate that RFG are growing in A hydrotreating (HDT) concept for desul- port fuel for Claus sulfur units or other volume. furizing extremely sour fuel will turn your consumers of sulfur-free alkanes

SPONSORED CONTENT

AFPM_h_horiz_1.indd 1 11-09-2017 11:46:52 2017 Operations and Process Technology Summit | American Fuel & Petrochemical Manufacturers Sunday/Monday, October 1/2, 2017 7 Improve visibility, increase profitability with planning and scheduling PATRICK GARRETT, AspenTech

Planners and schedulers must way to adequately represent a very and multi-core processing. This re- narios, which allows them to make navigate unpredictable and risky complex reality. By adopting the fol- sulted in a major advantage over the the best decisions on how to run the environments. The ongoing period lowing best practices, planners can competition, as this process would refinery during disruption, and pro- of crude oil price volatility is an ex- achieve optimal results: previously take up to 36 hr. vides them with the tools to return to ample of the new normal, accompa- Planning with sustained profit- ideal operations quickly. Schedulers nied by fluctuating feedstock pricing, ability in mind. This includes se- Building the schedule. The refining can also compare plan and schedule hyperactive commodities trading, lecting the correct parameters from industry is relatively unpredictable results vs. actuals to better under- extensive currency movements, and the hundreds of plant and market by nature, and schedulers are faced stand where production gaps exist. acute shifts in demand and supply variables to create a model that with stricter product specifications, Finally, schedulers should have patterns. To ensure optimal perfor- takes into consideration factors such market and regulatory requirements an advanced blending solution avail- mance, companies must focus on op- as prices, yield, energy consump- that can impact profit margins. Hav- able to maximize margins and re- erational excellence and build flex- tion and other economic drivers. ing a comprehensive, refinery-wide duce product quality giveaway. The ibility into their operating plans. One Typically, this map would be a lin- schedule can lead to significantly purpose of any refinery is to refine way to do this is through planning ear program model to represent the more stable operations and reliabil- crude into different blendstocks that and scheduling technology. complexity of real refinery and/or ity. One US refining company report- are eventually blended into saleable Global shale plays have increased olefins operations. ed that it reduced operational target products, such as distillates, gasoline the range of options for refiners. Ac- Solving the optimization prob- changes by 70% in its refineries that or fuel oils. As blend complexity in- cording to Rystad Energy, the US is lem reliably. Once the model is built used scheduling technology. creases and additional constraints are now home to more oil reserves than to the right level of accuracy, includ- The first step to achieving this is introduced, having the right tools is Saudi Arabia or Russia. Depending ing non-linear relationships, the tool through a collaborative environment. crucial for schedulers to create an on the source, new feedstocks can be must be tested. New features in some By bringing all schedulers and their optimal blend recipe. lighter or heavier than crudes that are advanced optimization programs al- activities onto a single platform, re- traditionally used, requiring changes low planners to detect false positives finers can streamline their workflow A tall order, but not impossible to in refinery configurations. Fortunate- (local optima) by solving cases from and achieve a greater view of the en- fulfill. With change as a constant, ly, planners and schedulers now have a number of starting conditions. This tire petroleum supply chain. Sched- the shortage of experienced work- access to technology that optimizes greatly increases confidence in the uling automation software enables ers in the refining and petrochemical existing assets. Advanced software results and prevents lost profits by crude and product schedulers to industries is a growing concern. A helps navigate complex decisions, avoiding local optima. work from the same schedule. This crucial need for leaders with diverse and accurate planning and advanced Analyzing the solution for ro- enhances communication between business experience drives many scheduling tools ensure that margins bustness. The largest barrier to im- functions and improves visibility companies to rotate new engineers can be maintained despite numerous plementing contingency planning lies into the refinery’s activities, which and managers through planning and changes and challenges. in running the vast number of cases can ultimately increase profitability. scheduling roles. Proficiency with it requires. The best companies in the Organizations that implement best-in-class planning and schedul- Understanding the plan. Most refin- industry are investigating the use of best-in-class scheduling technology ing technologies are mandatory for eries (FIG. 1) operate within rela- cloud computing to test more cases often find their teams empowered to refiners to be competitive. With the tively thin margins, meaning that any in less time. For example, a leading make decisions faster and have more right innovation, refiners can now error can be detrimental to profitabil- refining company in the Asia-Pacific time for improvement projects. With improve visibility across the entire ity. Decisions must be made with a region was able to solve 800 cases in the planning and scheduling soft- petroleum supply chain and increase mathematical optimizer as the only 90 min. with advanced optimization ware, refiners can run different sce- profitability.•

FIG. 1. Best-in-class planning and scheduling technologies improve visibility across the entire petroleum supply chain and increase profitability.

8 Sunday/Monday, October 1/2, 2017 American Fuel & Petrochemical Manufacturers | 2017 Operations and Process Technology Summit EIA: Changing quality affects decisions

According to a recent report by the where it can be processed. Sour crude formations in the Lower 48 states, higher than heavier crude oils, be- US Energy Information Association oil requires more complex refinery which contain primarily light-density cause light crude oils require less (EIA), growth in global liquid fuels processing to meet low-sulfur fuel crude oil. refinery processing to produce high- supply since March 2017 has been specifications and to avoid damage to As the relative availability of light value products, such as gasoline and driven by increases in the produc- refinery units. and heavy crude oils has changed, diesel. Lighter crude oils are also con- tion of historically higher-priced light Processing heavy-sour crude oil price spreads between light and heavy sidered more valuable because not all crude oils. This growth has more than requires additional refinery units— crude oils have narrowed. Relatively refiners have the equipment necessary offset recent declines in the produc- including crackers, cokers and hy- light crude oils are typically priced to process heavier, denser crude oils.• tion of medium and heavy crude oils. drotreaters—to yield light products. Sour As these production trends continue, These additional units increase re- 5.0 price differences between certain finery complexity, but also allow the US crude oils are narrowing, and refinery refiner more flexibility to select types Hondo Monterey Canada 4.5 Mexico operation decisions are changing. of crude oils to purchase and run Venezuela When comparing the qualities of through their refineries. Saudi Arabia different crude oils, two of the most Because the price of crude oil and 4.0 Iran UAE important attributes are sulfur content refinery complexity are major factors Former Soviet Union and density (FIG. 1). EIA defines crude that affect profitability, a wider price 3.5 Western Canada select Ecuador UK oil with less than 1% sulfur as sweet differential between heavy and medi- Maya Nigeria Malaysia and crude oil with greater than 1% sul- um crude oils and light crude oils ben- 3.0 fur as sour. Density is measured in API efits more complex refineries. In 2017, Arab heavy gravity, an inverse of the petroleum the price differential between medium Merey 2.5 liquid’s density relative to water. API and heavy crude oil and light crude oil

gravity ranges from heavy, or high, has gotten smaller, reducing the com- % Sulfur content, Dubai Mars 2.0 density (less than 25° API) to light, petitive advantage of some more com- West Texas Sour (Midland) Iran Heavy or low, density (greater than 35° API). plex refineries, the EIA report says. Arab Light On the US Gulf Coast (USGC), the Voluntary production cuts from 1.5 Iran Light premium for Louisiana Light Sweet OPEC members since November Urals (LLS) crude oil over heavy Maya 2016 have reduced the global supply 1.0 Oriente crude oil from Mexico narrowed from of medium- and heavy-quality crude $9/bbl in March to $5/bbl in August. oil. In addition, crude oil production West Texas Sour Intermediate 0.5 North Sea Brent In the Midwest, the premium for light outages in Canada and declines in Louisiana Light Sweet Eagle Ford Bonny Light Bakken condensate crude West Texas Intermediate (WTI) production from Mexico and Ven- Tapis over heavy Western Canada Select ezuela are further reducing the total 0.0 Sweet 10 20 30 40 50 60 (WCS) also narrowed from $13/bbl in amount of medium and heavy crude March to $10/bbl in August. oil available to refiners. Heavy Density, API gravity Light Differences in sulfur content also Much of the increase in US crude affect the price of crude oil and oil production has come from shale FIG. 1. Density and sulfur content of selected crude oils, %.

350x245_right_page_PubCorporate_crops_v2.pdf 1 15/02/2017 08:55:51

CMJ

2017 Operations and Process Technology Summit | American Fuel & Petrochemical Manufacturers Sunday/Monday, October 1/2, 2017 9 Improve FCC yields from contaminated feeds using boron-based nickel passivation KITTY CHA, BASF Corporation

The drive to improve refinery mar- timony or specialty alumina) or, more Specialty aluminas are a commonly on the success of BoroCat, BorotecTM gins leads to the processing of heavi- recently, boron-based technology. used option in residual FCC catalysts was launched in 2017 and caters to re- er, more contaminated crude. Conse- for trapping Ni by keeping it in a high- finers processing variable-quality or quently, the presence of contaminants FCC Ni passivation technologies. er oxidation state, reducing overall H2 mild- to moderate-resid feedstocks. in fluid catalytic cracking (FCC) Nickel passivation using antimony and contaminant coke production. The At a refinery that processes mild- feedstock is also increasing. One of (Sb) compounds has been in use for efficacy of this route is limited by the resid feedstock, Borotec was com- the contaminants, nickel (Ni), depos- more than 40 years. It has been shown very low mobility of Ni and the im- pared against another supplier’s pre- its on the FCC catalyst and catalyzes that Sb injection alone can reduce the mobile nature of the alumina trap. It mium bottoms upgrading technology. dehydrogenation reactions, producing dehydrogenation effect of Ni by 20%– is known that Ni deposition on resid- In this commercial trial, Borotec en- unwanted hydrogen (H2) and contam- 40%. After injection, an immediate, ual FCC catalysts typically follows a abled the refinery to: inant coke. These effects typically di- sharp reduction in dry gas production gradient, where higher amounts of Ni • Decrease contaminant minish the profitability and operability and delta coke is typical. Apart from accumulate on the outer stages of the delta coke of the FCCU. So, strong demand ex- passivating Ni, Sb can also poison catalyst particle. Since Ni tends to be • Improve activity retention, ists for improved Ni passivation tech- carbon monoxide (CO) combustion concentrated on the peripheral surfaces at similar vanadium and nology. Nickel passivation is especial- promoters and increase nitrogen oxide of a residual FCC catalyst, it can be sodium levels ly beneficial when the FCCU operates (NOx) emissions. The Sb pickup by trapped by alumina only within suffi- • Significantly improve bottoms at the wet gas compressor (WGC), the FCC catalyst can vary depending cient proximity. Therefore, the lack of upgrading and liquid yields the regenerator temperature limit, or on several factors, impacting its effec- mobility for both alumina trap and con- (FIG. 1 and TABLE 1) the air limit. By alleviating these con- tiveness on Ni passivation. Further- taminant Ni within the catalyst particle • Improve propylene straints, a substantial increase in prof- more, the use of Sb is not permitted limits alumina’s ability to passivate Ni. and butylene yields, after itability is immediately possible by in some FCCUs due to environmental BASF set out to develop the next gen- catalyst optimization. increasing either the FCCU through- and safe handling concerns. For most eration of Ni passivation technology. While the initial Borotec perfor- put or the severity. Ni’s effect can be FCCUs that can use Sb, further pas- mance exceeded that of the competi- reduced using passivators (such as an- sivation of Ni is still needed. Boron-based technology. A unique tive catalyst, BASF was able to further solution to passivate Ni using boron optimize the catalyst to give higher 2.7 chemistry is the heart of BASF’s Bo- C3= and C4=, resulting in a $0.23/bbl ron Based Technology (BBT) plat- profit improvement over the competi- 2.5 form. Multiple spectroscopic studies tive catalyst. This successful com- have shown that by using boron-based mercial trial verified Borotec’s abil- 2.3 technology, Ni can be kept in a more ity to improve performance, leading 2.1 electron deficient (i.e., less reducible) to higher yields of valuable products state, inhibiting its potential to par- and lower bottom-of-the-barrel yields LCO/BOT vol/vol 1.9 ticipate in dehydrogenation reactions compared to competitive technolo-

and lowering the formation of H2 and gies. The improved metals tolerance 1.7 Other supplier contaminant coke. BBT also presents provided by Borotec allows improved Borotec additional benefits. Unlike Sb, boron crude flexibility for refiners that en- 1.5 74 76 78 80 82 84 does not increase NOx emissions in the gage in crude spot buying to maxi- Conversion, vol% FCCU. As boron is mobile under FCC mize profits. conditions, its efficacy in Ni passiv- To date, the ability of BASF’s Base/Another supplier Borotec Delta ation is greater than that of specialty BBT to effectively passivate Ni and Conversion, wt% 80 80.5 0.5 alumina, as it migrates within the cata- improve profitability has been dem- lyst to passivate Ni. onstrated in more than a dozen refin- LPG, wt% 16.9 17 0.1 In 2016, BASF introduced Boro- eries. Borotec, the latest innovation Gasoline, wt% 54 54.5 0.5 CatTM, the first FCC catalyst based on from the BBT platform, provides LCO, wt% 14.2 13.9 -0.3 the BBT platform. Since then, Boro- mild- and moderate-resid feed FC- Cat has been successfully implement- CUs more flexibility in crude selec- Slurry, wt% 5.9 5.6 -0.3 ed in refineries all over the world. tion and increased yields of high-val- LCO/slurry, wt/wt 2.4 2.5 0.1 Results have shown that refineries ue products. using BoroCat can process heavier, For more information, and to meet FIG. 1. Borotec FCC catalyst delivered significantly improved bottom conversion more contaminated feedstocks and the BASF team, join them at Tables 1 and liquid yields. improve their profitability. Building and 2 in the exhibition hall. •

DRIVE PROFITABILITY THROUGH DATA ANALYSIS As industry becomes more digitalized, companies have greater amounts of Collaborative Operations brings together people, products, solutions and data at their disposal. The challenge is to make this data meaningful and get services to provide analytic intelligence that can improve efficiencies and it to the right people to enable impactful business decision-making. ABB has reduce risk, enabling a digital business transformation. introduced Collaborative Operations, the newest part of the ABB Ability™ It also enables users to securely integrate and aggregate data from mul- service offering. Using the ABB Ability capability and Cloud infrastructure, tiple sites. This data is automatically analyzed and continuously monitored Collaborative Operations offers true data-driven solutions by providing re- by both customers and ABB experts in connected Collaborative Operations mote connectivity, secure access to process performance information and centers (FIG. 1). technical support, enabling compa- ABB gives personnel and asset safety and reliability the highest priority. nies to collect data, apply predictive Data connections must be safe, but the value of that data should also be pro- analytics, and generate insights that tected. Rather than forfeit safety, value or control to realize the benefits of can help drive profitability. digitization, ABB Ability meets these needs with an innovative, multi-layered Field devices are installed to gath- approach to security. ABB pursues digital security innovation via its Group er data, and analytics are applied to Cyber Security Council, and participates in standardization efforts such as quickly identify, categorize and pri- Plattform Industrie 4.0 and Industrial Internet Consortium. oritize issues. Common communica- In addition to monitoring, the platform provides immediate access to high- tions protocols are established be- level technical experts to quickly resolve issues. ABB experts and customers tween customer sites, ABB technical work in close collaboration, making data-driven decisions in real time to in- FIG. 1. ABB experts and customers centers and customer headquarters for crease operational performance and business profitability. collaborate to make data-driven further financial analysis and for use Processes to avoid repeating the same problems can be developed and repli- decisions in real time. in decision-making processes. cated, enabling the financial impact to be realized across the entire enterprise.•

10 Sunday/Monday, October 1/2, 2017 American Fuel & Petrochemical Manufacturers | 2017 Operations and Process Technology Summit AFPM is “keeping Austin weird”

The slogan, “Keep Austin Weird,” but he felt that it was a prime location Marathon, which draws 20,000 run- by more than 100 bands. has grown from an urban catchphrase that intersected the roads to San Anto- ners from around the world; the Aus- The city is proudly eclectic, and into an underlying, unspoken attitude nio and Santa Fe. Throughout its early tin Food + Wine Festival, showcas- it doesn’t take long for that spirit to that has been adopted by the city’s history, the path to statehood, the Civil ing the city’s innovative cuisine; and spread to its visitors. Austin welcomes vibrant and welcoming community. War, the Great Depression and into countless music festivals, including AFPM with open arms, and we invite Austin is different from the rest of the new century, Austin has remained the Austin City Limits Music Festi- you to get out and soak up the sights, Texas (and the rest of the country), a center of Texas political, cultural val, which welcomes 70,000 fans per sounds and smells of one of the most from its place as the self-proclaimed and economic turmoil and prosperity. day to Zilker Park for performances interesting places in the country. • “live music capital of the world” and Austin offers so many things to do, world-class restaurants, to its diverse see and experience. The city’s arts population of cultures, political lean- scene is known for its creativity and ings and lifestyles. is home to world-class museums like The capital of Texas is one of the the Blanton, with the nation’s largest fastest-growing cities in the country, University-owned collection on ex- as new residents and visitors flock to hibit; and the Harry Ransom Center, the hill country for some of the best featuring the first photograph and the entrepreneurial conditions outside of Gutenberg Bible. Explore the work of Silicon Valley, great weather and an designers, painters, sculptors, writers, outdoor lifestyle. The hiking, biking, photographers, filmmakers, dancers swimming, boating, running, triath- and musicians at a variety of venues. lon and beer-drinking, river-floating Learn about President Lyndon John- communities are especially strong. son and Lady Bird Johnson at the in- Austin also features a collection of teractive LBJ Presidential Library. FIG. 1. Bands like Ben Harper and the Innocent Criminals make Austin the breweries and BBQ joints that rival The city also features numerous “live music capital of the world.” Image courtesy of Austin Music Source. any in the country. activities for the adventurous visitor: Settlers founded the village of Wa- The Escape Game Austin, the IFLY terloo on the banks of the Colorado Austin indoor skydiving facility, bike River in 1837, following the establish- tours, city-wide scavenger hunt ad- ment of the Republic of Texas. Two ventures, and (in keeping with the years later, it was renamed Austin after “weird” theme) Bat Fest, a celebration Stephen F. Austin, the “father of Tex- of the world’s largest urban bat colo- as,” and became the capital. President ny. Each year, two million Mexican Lamar’s decision to place the capital Free Tail bats assume seasonal resi- in such a remote location—and vul- dence beneath the Congress Avenue nerable to attack by Mexican troops Bridge and take to the skies for their and Native American tribes—was un- nightly flight. Austin’s packed yearly popular throughout the new Republic, events calendar includes: The Austin FIG. 2. The Austin skyline at night.

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2017 Operations and Process Technology Summit | American Fuel & Petrochemical Manufacturers Sunday/Monday, October 1/2, 2017 11 Increasing amine system H2S and CO2 recovery efficiency MASSIMO CAPRA, Aggreko Process Services, Europe

A common and critical operation at lution of monoethanolamine (MEA), carbon dioxide (CO2) removal is very suspended solids in the lean amine in- all refineries is hydrogen sulfide (H2S) methyldiethanolamine (MDEA), di- important to increase combustion heat creases, the cooling efficiency deterio- removal from hydrogen (H2)-rich ethanolamine (DEA) or diisopropyl- per scf (standard cubic feet) of natural rates, resulting in higher-temperature streams. This operation is performed amine (DIPA). gas. Natural gas can also supply feed- lean amine fed to the scrubber. The as part of hydrotreating processes The solvent is then processed in a stock for gas-to-liquids (GTL) plants, cooling efficiency is even worse dur- seen with hydrocrackers (HDC) or reboiled regenerator, where solvent and achieving low H2S concentration ing hot summer ambient conditions. hydrodesulfurization (HDS) units, as and H2S are separated to reuse the allows the production of super-clean Foaming, fouling and hot weather con- well as with natural gas sweetening lean amine in the scrubbing operation, liquid fuels. ditions amplify one another’s effects. units. The liquid-gas effluent mixture as shown in FIG.1. MEA solutions are the most effi- Many factors work against having from the fixed bed catalytic reactors is The H2S scrubbing efficiency of cient for H2S and CO2 removal, but enough cooling at the top of the amine characterized by a gas phase contain- the sour gas is critical for the desul- they are also the most corrosive. The unit regenerator, including warmer air ing H2S, the product of the desulfur- furization reaction yield, as well as for corrosion rate increases when MEA and warmer cooling water tempera- ization reaction. The H2-rich gas can limiting the corrosion of the compres- solutions are combined with an H2S- tures. The most common overhead be recycled to the reactor only after sor downstream from the scrubber. rich atmosphere, or with amine’s oxi- cooling arrangement is either a com- removal of the H2S. This operation It is critical to maintain a low H2S dation products generated by expo- bination of a fin-fan and cooling wa- is performed in a scrubber, where the concentration in natural gas operations sure to atmospheric oxygen. ter exchanger, or just a cooling water gas is contacted with an H2S seques- due to its toxicity and environmentally The resulting iron sulfide (FeS) exchanger. Either of these exchanger trating solvent, generally a water so- polluting combustion products. Also, corrosion product imparts poor pas- configurations can become limited. sivation qualities to the steel surface When this is detected, additional ex- Sweet gas Lean amine exposed to corrosion due to its weak changers can circulate more cooling CW adhesion characteristics, compounded water through a closed loop mechani- Air cooler Acid gas by the abrasive nature of the amine cal refrigeration system, allowing unit flow. The final result is an accumula- operators to maintain lower tower tion of solid FeS in the liquid stream, pressure while fully regenerating the Scrubber making the stream even more abra- lean amine. sive and detectable by a rapid change Engineered temporary cooling so- Feed e uent in amine solution color, which is also lutions provide ideal process condi- Sour gas Regenerator an indicator of its status. tions during critical periods of the

Furthermore, considering that H2S year when temperatures average high- Steam in the recycled gas inhibits the desul- er, with no production interruption. furization reaction, particular attention Additionally, the immediate added Rich amine should be paid to fouling of the lean marginal value reduces the need for amine coolers, the regenerator feed- non-productive capital assets acquired

FIG. 1. In a reboiled regenerator, solvent and H2S are separated to reuse the lean effluent exchanger and the lean amine to minimize the risk of interrupting amine in the scrubbing operation. air cooler. As the concentration of the production. • Protecting automation technology from EMP The possibility of an electromagnet- and industrial testing firm, conducted ic pulse (EMP) knocking out critical test RS105 for EMP radiated suscep- infrastructure is of growing concern tibility on a fully operational Bedrock to global security experts. To ensure system. The test involved repeated that defense technology remains func- 50,000 V/m nanosecond EMP strikes tional in the event of such an attack, to emulate the energy of a high-alti- the US has established Military Stan- tude electromagnetic pulse (HEMP). dard 461 (MIL-STD-461F) and Inter- The Bedrock system performed with- national Electrical Commission 61000 out error and without consequential (IEC 61000) for EMP resistance. damage during and after the test, even While these standards have been used after consecutive test runs. primarily by defense technology, Bed- Like its intrinsic cyber security, rock Automation has recently demon- Bedrock Automation was able to strated compliance for its cyber-secure build EMP resistance into its systems Bedrock control system and its power at the design phase because it started and UPS subsystems for use across from a clean sheet of paper. Bedrock multiple applications (FIG. 1). engineers achieved both cyber secu- When most existing control sys- rity and EMP protection through the tems were designed, EMP was of incorporation of numerous detailed minimal concern. However, it is gain- design elements. This included the ing more attention today, as is con- creation and deployment of a pinless cern about lower-level electromag- backplane, which eliminates the pos- netic interference (EMI). While some sibility of pins as antennae to absorb industrial control systems do protect and disperse energy. against EMI, Bedrock Automation The Bedrock control system pro- has designed in EMP protection resis- vides secure, high-performance DCS, tance as well. PAC, PLC or SCADA RTU function- FIG. 1. Bedrock Automation has recently been certified for compliance with US The Bedrock control system sought ality. The power supplies were de- MIL-STD-461F, demonstrating that its intrinsically cyber secure industrial control MIL-STD-461F to complement the signed to provide secure, EMP-hard- system and stand-alone power supplies can also withstand repeated EMP blasts. intrinsic cyber security built into its ened power and power backup for the The Bedrock UPS.500, shown here, provides an EMP-protected power backup open, secure automation system. Day- Bedrock system, but they can also be for any control system. ton Brown, an independent military used with any control system. •

12 Sunday/Monday, October 1/2, 2017 American Fuel & Petrochemical Manufacturers | 2017 Operations and Process Technology Summit Overcoming the “lost decade” of ICS security GALINA ANTOVA, Claroty

The last decade in the world of IT of these recommendations are simply and investment from government, from York University in Toronto, Canada, network security has certainly present- impractical when considering busi- board rooms, CIOs, CISOs, ICS own- and an MBA degree from the International ed more than its fair share of challeng- ness requirements. As is the case with er-operators, security vendors and Institute of Management and Development (IMD) in Lausanne, Switzerland. es and setbacks. Despite the collective virtually all standards/compliance- ICS equipment manufacturers on the failures in that space, major advanc- type regimes, what is intended as a problems that confront our industry. es in security controls were clearly floor too often becomes a ceiling. We need a reference architecture made. Countless innovations—signif- that delivers the “biggest bang for icant investments in terms of people Trying to force the “square pegs” of IT the buck” and the most rapid increase and money, the birth and evolution of security into the “round holes” of ICS in security readiness. It should be an an industry/sub-industries, a proven networks. IT security tools were not easily and rapidly (i.e., months, not ability to respond to (although not designed for fragile ICS networks. years) implementable framework foresee) emerging threats—indicate a When implemented, approaches like that focuses on risk assessment, real- tremendous amount of positives hid- active scanning, active querying and time monitoring, high-risk vulner- den behind the losses. other “standard IT tools” have crashed ability management, threat intelli- In the world of industrial control PLCs, interrupted uptime and caused gence, advanced endpoint protection systems (ICS) security (operational significant problems. We know of one and rapid response. • technology), despite nearly two de- real-world, recent example where a cades of discussion around nightmar- widely utilized network scanning tool Galina Antova is the Cofounder ish cyberattack scenarios and out- caused an electrical outage. and Chief Business comes, the past 10 years can arguably Development Officer of Claroty. be labeled, “The lost decade of infor- Delaying investment because these Prior to that, she was the mation security in industrial control attacks are presently theoretical. Global Head of Industrial systems networks.” Logically, cybersecurity budgets over Security Services at Siemens, overseeing It can be said that we are no bet- the past decade have been dedicated development of its services that protect industrial customers against cyberattacks. ter off today in terms of cybersecurity to the areas where the bleeding was Ms. Antova was also responsible for leading readiness than we were 10 years ago. occurring. This makes sense and we its Cybersecurity Practice and Cybersecurity The theoretical is becoming reality cannot really fault companies for Operations Center, which provided managed and, unfortunately, we are not pre- investing this way. However, this security services for industrial control FIG. 1. With increasing cybersecurity pared to counter the threat that is just “whack-a-mole” approach to deal- systems operators. Previously, she was with threats on the horizon, the industry over the horizon (FIG. 1). ing with cyberthreats has resulted in IBM Canada, with roles in the Provisioning cannot afford another 10 years to Encouragingly, in the past two woefully underfunded programs for and Cloud Solutions business. Ms. Antova evolve through the same layered, years we have seen an accelerated ICS cybersecurity. holds a BS degree in computer science defense-in-depth strategies. pace of awareness and prioritization being given to ICS security. The Believing that the concept of “air- emergence of new startups in the gapped” networks was ever a reality, sector, the newly found focus of en- or would stand up against business We create trenched security companies, the level and efficiency demands. Networks We create of discussion among chief informa- have been designed so they cannot be chemistry tion security officers (CISOs), board accessed from the outside and with- thatchemistry makes members, etc., shows some promise out interconnectivity to the IT net- amid an otherwise gloomy analysis. work. This sounded good for a time, individualthat makes However, all of this new prioritization but business demands have eradicated refinerscrude oil love and awareness have come as a result the notion of an “air-gapped” ICS fueling the world. of an increasing amount of targeted network. Maintenance requirements, love refined and spillover attacks into this domain. connectivity to the supply chain, re- Where did we go wrong? mote analytics, managing “top floor solutions to shop floor” KPIs, and the desire to Failing to “bridge the gap” between drive predictive analytics have seen IT and ICS (engineering) staff. These “air gapping” become all but obsolete. teams have made strides in terms of working together, but a lack of solu- Maintaining cumbersome, difficult tions built specifically for ICS that do to implement, hard to consume, pre- not jeopardize uptime and safety and vious-generation ICS-specific solu- offer a demonstrable value to both tions. A number of promising ICS- teams has resulted in a closed-door specific cybersecurity solutions have policy in most cases. “I own the shop emerged and failed to gain main- floor. I need to keep production mov- stream traction over the years. Dif- ing. I need to ensure that nothing fails ficulty in implementation (installing that could cause safety concerns for a firewall in front of every PLC) and our teams or the public. No, you are consumption (massive installation NOT putting that in my network.” projects, significant upfront time to configure), and unwieldy/unrealistic Falling victim to the notion that pre- maintenance requirements saw these scriptive commands/standards can promises fail. They simply did not and will be implemented. ICS security understand the unique needs of the focus and developing regulations such ICS consumer. as NERC CIP to mandate security It can be said that a decade was As the globalglobal leader leader in in catalysis, catalysis, we BASF see it as our task to createsunite apparent value foropposites refineries and through to create our true and tangible benefits, both for our customers and the environment. With controls in this domain are a positive lost and that the threats are now at our flexible FCC catalysts and additive solu- our comprehensive experience and pioneering spirit, we step. However, while standards such doorstep. Clearly, we cannot afford developtions coupled products, with services industry-leading and solutions tech for- the petroleum as IEC 62443 have done a very good another 10 years to evolve through refiningnical service. industry When that individualenhance bothsolutions performance and sus- tainability.solve global When problems, catalyst it‘s innovations because empowerat our costu- job outlining controls that can be ap- the same layered, defense-in-depth mers‘BASF, success we create it´s chemistry. because at BASF, we create chemistry plied, anyone who has done hands-on strategies that marked the last decade www.catalysts.basf.com/refining work on these networks knows that in IT security. We need a revolution. they are not easy to apply. While the- First, we must stop “studying” the oretically the right thing to do, many problem. We need immediate focus

2017 Operations and Process Technology Summit | American Fuel & Petrochemical Manufacturers Sunday/Monday, October 1/2, 2017 13 Pursuing reliability and improved profitability

Kevin Solomon, Athlon Solutions’ for the Q&A Hydroprocessing Ses- worked as an engineer and business nies like Google. We must do a better Engineering & Technical Support Di- sions. AFPM and Hydrocarbon Pro- leader for Chevron Texaco. job of showing how important our in- rector, is one of this year’s panelists cessing had our own Q&A discussion One of the big reasons I came to dustry is and how clean it has become with Mr. Solomon prior to the Crude/ Athlon Solutions is because I wanted over the last 10–20 years. Vacuum Distillation & Coking ses- to have fun. It is not a rigid, process- sion to learn more about him, Athlon focused organization. It is nimble, AFPM/HP: What kind of questions Solutions and where they see the in- which lends itself to providing inno- will the Crude/Vacuum Distillation dustry going. vative solutions for customers. & Coking session be addressing Despite being a new name to the this year? AFPM/HP: You are new to AFPM downstream industry, Athlon Solu- Solomon: We have an excellent and Athlon Solutions. Tell us a little tions is full of talented people and panel and great topics, including about yourself and what brought industry know-how. Fewer boundar- discussions on safety, coker units, you to the company. ies than larger organizations allow for desalting, fouling, corrosion con- Solomon: Before I joined Athlon easy collaboration between groups trol, vacuum towers and advanced Solutions in January, I was an Ex- and quick-to-market solutions. In my process controls. If I had to pick one pert Consultant at McKinsey & Co., short time here, I have seen many ex- theme that ties them together, I think where I worked with many organiza- amples of it and the potential for a lot it would be reliability and improved tions to improve their operations. Be- more. That is exciting and fun. profitability. fore that, I worked more directly with The industry is challenged by dif- the industry: I was a Process Excel- AFPM/HP: Your experience is fering types of crude, and that is in- KEVIN SOLOMON is the Engineering lence Leader at Hess Corp., a Tech- broad and includes domestic creasing with heavier crudes, shale & Technical Support Director nical Advisor at GE Water & Pro- and international assignments. oil and opportunity crudes that re- for Athlon Solutions. cess Technologies, and for 23 years I What are the major challenges finers are seeing. They need reliable you see for industrial water technology to manage the differ- and process treatment? ing physical characteristics, and this UPCOMING AFPM GATHERINGS Solomon: From my perspective, means new chemistries, applications AFPM Annual Meeting it is people, and I think that the chal- and engineered solutions. The in- March 11–13, 2018 / New Orleans, Louisiana lenge of finding the right people spans dustry works with an ever-changing the entire oil and gas industry. We all crude slate. Some refiners know how Don’t miss the 2018 AFPM Annual Meeting in New Orleans. The world’s premier refining know we are in an industry that has to deal with the changes, and many meeting will once again assemble key executives and technical experts from refining and huge economic cycles, but we also are just learning to adapt. marketing organizations worldwide, as well as representatives from associated industries. face the challenge of attracting and The Q&A and Discussion Ses- Leading industry experts share valuable insights on major issues, including energy and retaining talent. The workforce is ag- sion on Crude/Vacuum Distillation environmental initiatives, and the latest technological developments impacting refining ing and we are competing with other & Coking will be Tuesday morning and petrochemical industry management and performance. A new topic has been added: Hurricane Harvey—the lessons learned, hurricane preparedness, crisis management, industries for younger talent that per- from 8–10 a.m. Join the Athlon So- shutdowns and startup, best practices, and helping our employees and the community. ceive our industry to be not as high- lutions team at their hospitality suite tech, “hip” or glamourous as compa- Monday night in room 208. •

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14 Sunday/Monday, October 1/2, 2017 American Fuel & Petrochemical Manufacturers | 2017 Operations and Process Technology Summit Turnkey sulfur treatment meets regulatory specs, boosts value

Sulfur removal remains an on- when existing equipment is down for ited future catalyst and corrosion is- In addition, the new liquid naphtha going challenge for midstream and maintenance or when product vol- sues. The refiner was able to increase stream generated an incremental downstream operators, particularly umes fluctuate. the overhead rates in an already lim- profit of $3 MM/month. By separat- as increasingly complex sulfur com- In addition to successfully remov- ited system, thus meeting the Reid va- ing these streams, the refiner debottle- pounds—many that cannot be re- ing sulfur compounds from light hy- por pressure (RVP) requirements for necked the tower capacity, which en- moved by traditional chemical scav- drocarbon streams, the services avoid the heavier naphtha streams. hanced overall process efficiency by engers—enter the processing stream. having to sacrifice product value or EXALT sulfur extraction services 20%. Satisfied with these results, the Adding to the challenge, the US octane levels simply to reach the re- delivered a turnkey solution that en- refiner decided not to move forward Environmental Protection Agency quired sulfur spec. The solution also abled the refiner to bring the propane with long-term plans to install a hy- (EPA) recently implemented its Tier frees up existing hydrotreater capacity stream back on-spec and recover rev- drotreater, thus avoiding a substantial 3 gasoline sulfur reduction standards, for more complex production streams, enue of more than $1.5 MM/month. CAPEX investment. • requiring operators to reduce the aver- while avoiding the capital and operat- age sulfur content in gasoline from 30 ing expenses associated with install- 100 ppm to 10 ppm. ing additional hydrotreater systems. 90 While the installation of a hydrotreater provides a long-term so- Proving its potential. Refiners have 80 lution, it also requires years of de- used the sulfur extraction services to velopment lead time and a major bring their complex process streams 70 capital investment. Other alternatives into spec, while realizing significant include purchasing sulfur credits to revenue gains. In one example, a US 60 meet Tier 3 compliance or choosing Gulf Coast refinery faced several chal- 50 to process more expensive streams, lenges in producing on-spec naphtha Percent which avoids more complex sulfur and propane as a result of reactive 40 compounds altogether. sulfur contamination. The propane Baker Hughes, a GE company had to be sold at a discount because 30 (BHGE), has developed a more effi- it failed the D-1838 copper corrosion cient and economical solution with its specification due to the presence of 20 TM EXALT sulfur extraction services. reactive sulfur. In addition, valuable 10 Designed to help operators achieve naphtha was being lost into the pro- their required sulfur removal metrics pane stream, causing the light naphtha 0 Total Total Methyl Ethyl Carbonyl Carbon Dimethyl and improve product value, the ser- to be downgraded. sulfur mercaptan mercaptan mercaptan mercaptan disulﬁde sulﬁde vices provide a turnkey, cost-efficient Reviewing the various solutions to Standard caustic treatment EXALT chemistry treatment and flexible solution that incorporates remove sulfur contaminants and bring a proprietary combination of chemical streams on-spec, the refiner considered FIG. 1. Sulfur extraction performance. treatment and mechanical processing. installing a hydrotreater. However, the $50-MM capital investment, coupled Collaboration drives success. BHGE with ongoing operating expenses, representatives first work with an prompted the operator to contact operator’s personnel to develop a BHGE for an alternative solution that site-specific extraction solution. This required less lead time and investment. begins with an upfront survey so the Following a system survey, BHGE team can better understand the sys- recommended EXALT sulfur extrac- tem and compositions of the different tion services, a combination of sulfur streams being processed. The analy- removal chemistries and mechanical sis results help determine the optimal equipment designed to improve sulfur- HUNTER: Providing the best quality custom treatment to meet program objectives. chemical contact efficiency in the pro- The services’ sulfur extraction pane stream. This comprehensive treat- blast-resistant buildings to meet your needs. chemical technologies are industry ment separated the light naphthas and proven for removing heavier, com- heavier sulfur compounds, resulting in HUNTER, the global leader in the production of modular, blast- plex sulfur compounds more effec- a new light liquid naphtha stream. resistant steel buildings, is uniquely equipped to custom design tively than traditional chemical pro- After treatment, results showed and manufacture buildings around your specifications. grams. When it becomes necessary to more than 98% removal of the total drive the reaction further and boost sulfur compounds, including reduced HUNTER has been setting the standard in the design and construction of high, medium and low response buildings since 1999, and offers an expansive list of custom features, extraction efficiency, BHGE partners levels of methyl mercaptan, carbonyl including, but not limited to: with Vapor Point to implement pat- sulfide and carbon disulfide—com- ent-pending mechanical solutions in pounds that could not be removed by n Multi-Module Complexes n HVAC (Roof Mount/End Mount n Bolted Connections Split System) conjunction with the chemical treat- caustic treatment alone (FIG. 1). This n Varying Blast Overpressure and n Positive Pressure ment. The mechanical equipment is treatment did not affect the character- Duration Levels n NFPA 496 Compliance mobile for easy installation and is istics of the product, such as color or n High, Medium or Low Response n Special Filtration Packages n leased rather than purchased, which Blast Designs Data and Communications Wiring volatility, and the propane successful- n Class I Division 2 Electrical n Gas Detection eases CAPEX constraints. This turn- ly passed the copper corrosion tests. n Special Exterior Coatings n Fire Detection/Protection key solution allows for temporary, This solution helped reduce other ex- n Custom Interior Finishes n Fire Suppression n n contingency-based sulfur extraction traneous contamination, which lim- Windows in Doors CSA Compliance n Windows in Exterior Walls n API RP 752/753 Compliant n Upgraded Insulation Packages n Forced Entry/Ballistic Resistant n Custom Flooring Buildings (FE/BR) AFPM CONTINUES TO SUPPORT THE INDUSTRY n Special Equipment/Furnishings IN HARVEY’S WAKE Hurricane Harvey has affected operations at 21 Gulf Coast refineries (representing 25% of US capacity), squeezing supplies and putting upward pressure on fuel prices. While the temporary, lower refinery output reduced shipments, substantial US inventories of refined products have aided in the Design / Manufacture / Customization / Installation / Site Services / Leasing recovery. The US crude and fuel supply and distribution system is dynamic 14935 Jacinto Port Boulevard / Houston, Texas 77015 / +1 281.452.9800 and resilient, and AFPM commends the industry for its tireless efforts and 10690 Briggs Drive / Inver Grove Heights, Minnesota 55076 / +1 651.764.8292 leadership during these difficult times. We will continue to advocate for the industry that we are proud to represent. • HunterBuildings.com

2017 Operations and Process Technology Summit | American Fuel & Petrochemical Manufacturers Sunday/Monday, October 1/2, 2017 15 What is APC 2.0? ALLAN KERN, APC Performance LLC

Large-matrix, model-based multi- Behold the matrix! Probably the most economics and process interactions “speed limits;” approaching targets variable control (call it MPC or APC important and enduring contribu- the first thing they learn, and opera- and constraints in a steady first-or- 1.0) has been the dominant advanced tion of the model-based era to pro- tors are unlikely to move up to the der manner; avoiding overshoot and process control (APC) technology in cess automation will prove to be the console or supervision without learn- oscillation; and taking extra precau- industries, such as oil refining, chem- matrix (not models). The matrix has ing these operational aspects. This is tions, where appropriate, to preserve icals and petrochemicals, for close to emerged as the natural way to define common knowledge among operating and ensure process stability at all three decades. essential aspects of the multivariable teams, so building an optimizer into times. This is quite a different state- The virtues and successes of MPC nature of almost any process. It cap- the APC solution to produce it on a ment from, and ultimately directly aside, it has also earned a reputation tures available handles, important real-time basis is largely superfluous, conflicts with, traditional error-min- as an ownership challenge in many constraints, useful interactions and adding substantially to APC com- imization control performance crite- areas, including cost, maintenance, optimization potentials in an intui- plexity and ownership burdens with- ria, which is based on process models. support and performance. While MPC tive format, and serves as a guide to out adding commensurate new value. Experience has shown that opera- may always be the preferred solution operations and as a specification for A better paradigm is to let opti- tors are perfectly willing to sacrifice in select applications, many end- automation. The matrix (FIG. 1) puts mization results flow down from the automatic control—place loops in users have been moving away from all parts of an operating team (con- business layer to the control layer, manual and circumvent (degrade or MPC as an everyday tool, even if the trol engineers, process engineers and whether via the computer system or switch off) APCs—where opera- technology to backfill that gap (call it operations personnel) on the same the chain of command (this is com- tional performance is not met. To APC 2.0) has yet to fully emerge. page to align their efforts for more mon, in any case). The business layer achieve greater success, APC 2.0, Experience makes it increasingly effective operations. Industry owes has much more of a global optimiza- both single-loop and multivariable, clear that industry needs a multivari- a large debt of gratitude to APC 1.0 tion horizon (more complete infor- must come to grips with operational able control tool that is much more for bringing the concept of the matrix mation) and results do not normally process control performance criteria agile—more operation-friendly in to the forefront of process operation change in real time. (FIG. 3). every respect—to catalyze renewed and automation technology. The essential role of APC is to progress in advanced process auto- Meanwhile, models have proven honor these optimization results in Agility is the word. All of this information. Thirty years of the APC 1.0 to be very unreliable, and as much a the live process environment where mation suggests a more agile APC paradigm have left many companies vulnerability as a strength. Building the related process values (not the 2.0 solution and paradigm: thinking that large-matrix, model- an APC solution based on model- optimization targets themselves) • Costs that fall within normal based, multivariable control and op- based control theory front-loads the are subject to change in real time. operating budgets timization must all go together, and solution with many ownership chal- This optimization paradigm is more • Schedules that meet modern that you cannot have one part with- lenges. It remains to be seen, after streamlined, eliminates redundancy manufacturing precepts— out the others. However, experience 30 years, whether that burden is sus- and enables each layer to focus on its days or weeks rather than now shows that alternative solutions tainable or ultimately outweighs the essential role (FIG. 2). months or years are actually quite possible and even benefits of using models in the first • Support requirements that readily available within existing place. Fortunately, experience and Operational control performance. fall within the scope of modern control system capabilities. emerging technologies also suggest While virtually every aspect of mod- existing in-house control Going forward, the emerging APC that models may actually be dispens- ern process control technology is engineers 2.0 paradigm will differ from APC able to the job of reliable closed- rooted in the concept of models, it • Performance that meets 1.0 in key aspects: loop control. turns out that control performance with operations’ expectations • APC 2.0 will feature a matrix, is one area where industry does not and approval but not necessarily models Automation rules! In most industrial want a model-based solution. Indus- • Technology that falls • Focus will shift to control-layer process operations, the optimization try wants operational performance. within existing control automation and business-layer solution (i.e., the target operating This has been another long, slow les- system capabilities (think optimization point), just like the matrix (i.e., the son of APC 1.0, and an even longer function blocks). • Operational performance will operating window), is well-known a one for single-loop PID control! To the extent that this paradigm has become the new norm (after priori by the operating team. Process Operational performance, in a nut- yet to fully emerge, industry would 75 years of Zeigler-Nichols). engineers are likely to make process shell, means having preset process do well to make this its target. •

Constraints 51AI110 51AI115 51AI116 51AI125 51PC105 51PDI104 Handles NAP90 KERO90 KEROFLSH DSL90 PRESSURE TOP DP Feed Business planning Global 51TC102 heater +1 and optimization Bottom 51FC103 steam +1 Pump- –1 51FC128 around –1 OPT Operating team +1 51TC106 Top temperture +1 +1 +1 OPT real-time knowledge +1 51FC112 Kerosine draw +1 OPT +1 51FC122 Diesel draw OPT Process control and automation Local 51HC128A PA bypass +1 +1 FIG. 2. The APC 2.0 paradigm eliminates redundancy and empowers each layer FIG. 1. Example matrix and its fundamental elements. to focus on its core area of expertise and responsibility.

HARVEY’S EFFECTS FELT FAR FROM THE FLOOD ZONES The aftermath of Hurricane Harvey is disrupting plans for crucial main- Target tenance at refineries thousands of miles away. Demand usually slows at Error minimization this time of year, enabling repairs and the installation of new equipment Operational at plants normally in continuous operation. At least 13 refineries from Louisiana to Montana with a combined 3.27 MMbpd have delayed maintenance for weeks or months to take advantage of strong margins, while FIG. 3. The passenger plane changing altitude illustrates why “operational others lack the personnel who were dispatched to help repair and restart performance” criteria are more appropriate for industrial process operation than storm-hit facilities along the Gulf Coast. • traditional model-based error minimization.

16 Sunday/Monday, October 1/2, 2017 American Fuel & Petrochemical Manufacturers | 2017 Operations and Process Technology Summit Advantages of sulfuric acid alkylation technology confirmed ARVIDS JUDZIS JR., ROMAIN LEMOINE and JACKIE MEDINA, CB&I

Maintenance inspections were con- more to start up shortly, and eight damental fouling and corrosion issues This strategy ensures that the re- ducted at two commercial CDAlky® awarded in the last 14 months. These would certainly have been evident. actor effluent is dry, greatly reducing units, licensed by CB&I. Findings recent awards are from major refiners, The reduced corrosion rates and ab- corrosion rates and associated main- confirmed significant advantages of including one in North America. sence of fouling observed at both Sin- tenance costs and safety risks. It also this sulfuric acid (H2SO4) alkylation Shandong Sincier shut down its cier and Haiyue are attributable to the provides for an alkylate product that technology over conventional tech- FCCU for a planned turnaround. innovative design of the CDAlky reac- has an extremely low sulfur content, nology. In particular, corrosion rates Since the FCCU was the source of tors, which not only allows the refiner clearly an advantage in a Tier 3 world. and fouling propensity are greatly olefin feed for the CDAlky unit, the to cost-effectively break the low tem- The advantages of operating at colder reduced with CDAlky technology. Its refinery took the opportunity to also perature barrier for enhanced prod- reactor temperatures on corrosion rate, innovative reactor design enables the inspect the alkylation unit that was a uct quality, but also to eliminate the alkylate quality and acid consumption refiner to “break the low temperature year and a half into its run. No signs alkylate product post-treatment sec- rate have been well documented. barrier” compared to conventional of corrosion, damage, pitting or hy- tion. With conventional sulfuric acid To meet the CB&I team and learn sulfuric acid technologies, provides drogen (H2) grooving were found. alkylation technology, this section can more about the advanced CDAlky sul- for an easy separation of the acid and The DIB column was not opened due cause downstream corrosion and foul- furic acid alkylation technology, visit hydrocarbon phases, eliminates the to time constraints. ing problems. Without post-treatment, the company’s hospitality suite Mon- need for post treatment of the alkylate Ningbo Haiyue shut down its the need to handle large waste streams day night in room 406. • product, and produces a dry reactor CDAlky unit in July 2017 due to local is also eliminated, thereby reducing effluent for the downstream fraction- safety regulations that require an in- its environmental footprint. ation system. spection of newly commissioned units The amount of acid leaving the re- CB&I’s CDAlky technology has after three years of service. Absent the actor is limited by the reactor’s novel been in commercial operation since regulation, the unit was running very design, which increases acid utiliza- March 2013, when the first unit, with well and would not have required a tion while operating at low tempera- a capacity of 5 Mbpd (thousands of shutdown. The inspection revealed tures. The acid droplet size is con- barrels per day) of alkylate, started at no visible signs of corrosion or foul- trolled by the use of an optimized Shandong Sincier Chemical Co. Ltd. ing in the reactor section, coalescers proprietary packing system rather in China. The second CDAlky unit to or fractionation system. Furthermore, than a rotating impeller, providing for be inspected, in operation since July no issues were found with any pump an efficient and easy separation of the 2014, is also located in China at Ning- seals, and all proprietary equipment acid-hydrocarbon phases, which elim- FIG. 1. The inspection revealed no bo Haiyue. This unit has a capacity of was in good condition and required no inates acid carryover entirely. The visible signs of corrosion or fouling in the 15 Mbpd of alkylate. replacement. FIG. 1 shows the reboiler unit operates in an acid-to-olefin re- reactor section, coalescers, fractionation CB&I has now licensed 13 CDAlky bundle for the DIB column. After three gime that minimizes the formation of system or the reboiler bundle for the units, with three in operation, two years of operation, underlying or fun- stable, hydrocarbon-soluble sulfates. DIB column, shown here.

SAVE Gas Processing and World Oil are bringing the Eastern Mediterranean THE DATE Gas Conference (EMGC) back to Nicosia, Cyprus. Now in its ﬁ fth year, EMGC is the region’s premier conference for companies operating in WHEN: this rapidly evolving energy hub. March 21–22, 2018 The two-day conference will center around a high-level technical WHERE: program featuring speakers from leading operating and service Nicosia, Cyprus companies. Join the conversation and network with your peers at EMGC! WEBSITE: EMGasConference.com

Sponsorship opportunities are available! ORGANIZED BY: For more information, please contact: Hortensia “Tish” Barroso, Business Development Manager at [email protected]

2017 Operations and Process Technology Summit | American Fuel & Petrochemical Manufacturers Sunday/Monday, October 1/2, 2017 17 HOSPITALITY SUITES LIST OF EXHIBITORS

This is a directory of the companies that host hospitality functions at the Operations EXHIBITOR NAME BOOTH NUMBER and Process Technology Summit. Open hours are determined by the individual host in compliance with AFPM’s policy not to conflict with regularly scheduled association Advanced Refining Technologies...... 34 sessions and activities and to close by 1 a.m. Air Products...... 8 AIS Software...... 15 COMPANY LOCATION DAY Albemarle Corporation...... 44 Advanced Refining Technologies TBD Mon., Tues. Arkema, Inc...... 33 Albemarle Corporation Room 210 Mon. Athlon Solutions...... 36 Baker Hughes, a GE company...... 41 Athlon Solutions Room 208 Mon. BASF Corporation...... 1/2 Axens North America Room 504 Mon. Catalyst & Chemical Containers...... 31 CB&I Room 406 Mon. CB&I...... 13 CRI Catalysts/Criterion Catalysts/ Room 408/409 Mon., Tues. ChemTreat...... 10 Shell Global Solutions Chevron Phillips Chemical Company LP...... 3 Dorf Ketal Chemicals LLC Room 208 Sun. Clariant Corporation...... 46 The Dow Chemical Company TBD Sun., Mon. Criterion Catalysts & Technologies LP...... 28 DuPont Clean Technologies Room 404 Sun., Mon. Crystaphase...... 9 Haldor Topsoe Inc. Room 211/212 Mon., Tues. DuPont Clean Technologies...... 24 Eurecat U.S...... 37 Honeywell UOP Room 213 Sun., Mon., Tues. Forum Energy Technologies...... 5 Johnson Matthey/Tracerco Room 502/503 Sun., Mon., Tues. Gayesco-WIKA...... 38 Reactor Resources LLC Room 407 Mon. GE Water & Process Technologies...... 30 TechnipFMC Process Technology Room 209 Sun., Mon. Haldor Topsoe Inc...... 20 W. R. Grace & Co. TBD Mon., Tues. Honeywell...... 6 Hunter Buildings & Manufacturing LP...... 45 Functions held in rooms are on the 2nd, 4th and 5th floors as indicated by the first digit in Intertek Pilot Plant Services...... 40 the room number. Suites are held on the sleeping room floors and numbers can be found Johnson Matthey...... 25 on the AFPM Mobile App or the Hospitality Notice Board in the AFPM Registration area. JV Industrial Companies...... 29 KBR Technology & Consulting...... 39 Matheson...... 32 MEETING ROOMS MAP Merichem Company...... 42 Nalco Champion...... 48 New Gas Technologies Synthesis (NGTS)...... 17 Pall Corporation...... 12 Petroval Inc...... 4 Porocel International LLC...... 22 Prosep USA...... 11 Prosys Inc...... 14 Quantum Technical Services...... 47 Refined Technologies...... 21 Richard Industrial Group Inc...... 26 Sabin Metal Corporation...... 43 Saint-Gobain NorPro...... 27 TechnipFMC Process Technology...... 19 The Dow Chemical Company...... 23 VEGA Americas, Inc...... 7 W. R. Grace & Co...... 35 Wood Group...... 18 Woven Metal Products...... 16

Exhibitor information is provided solely for the use of attendees to search for products and services offered by exhibiting companies. Use of this information for solicitation purposes of any kind, by anyone other than a registered attendee, is strictly prohibited.

18 Sunday/Monday, October 1/2, 2017 American Fuel & Petrochemical Manufacturers | 2017 Operations and Process Technology Summit AFPM 2018 Meetings

POWERING AHEAD Annual Meeting March 11 – 13 New Orleans Hilton IN 2018 New Orleans, LA

International Petrochemical Conference March 25 – 27 Grand Hyatt San Antonio, TX

International Base Oils and Waxes Conference March 25 – 27 Grand Hyatt San Antonio, TX

Security Conference April 23 – 25 Omni Royal Orleans New Orleans, LA

Labor Relations/ Human Resources Conference April 26, 27 Omni Royal Orleans New Orleans, LA

National Occupational & Process Safety Conference May 15, 16 Grand Hyatt San Antonio, TX

Reliability & Maintenance Conference May 22 – 25 Henry B. Gonzalez Convention Center San Antonio, TX

Cat Cracker Seminar August 21, 22 Royal Sonesta Houston, TX

Operations & Process Technology Summit October 1 – 3 Atlanta Marriott Marquis Atlanta, GA

Environmental Conference October 14 – 16 Marriott Rivercenter San Antonio, TX

www.afpm.org/conferences

AFPM_2018_QA_ShowDaily_Ad_v1.indd 1 9/7/17 12:37 PM breakthrough catalyst technology

Johnson Matthey’s breakthrough catalyst technology, CATACEL SSR, a high performance structured catalyst for steam reforming, delivers greater capacity and longer catalyst life than traditional pelleted catalysts.

Our CATACEL SSR technology is proven to ease operating limits on the reformer and increase throughput through reduced tube wall temperature, lower pressure drop, decreased energy consumption, and improved carbon resistance.

Our technical support team will work with you to assess your needs and determine if CATACEL SSR technology is a good fit for your operation.

UK Tel +44 (0)1642 553601 Fax +44 (0)1642 522542 US Tel +1 330 298 7005 www.jmprotech.com