Phoenix, Arizona 2006 NPRA Q&A and Technology Forum

Arizona Biltmore Phoenix, ArizonaOctober 8 – 11, 2006

Phoenix, Arizona

2006 NPRA Q&A and Technology Forum

Sunday October 8, 2006

2:00 pm – 8:00 pm Registration Northwest Lobby6:00 pm – 8:00 pm Reception Squaw Peak Lawn

Monday October 9, 2006

7:00 am – 5:00 pm Registration McArthur Registration8:00 am – 8:30 am Keynote Address McArthur Ballroom Salon 48:30 am – 10:00 am Plant Automation: McArthur Ballroom Salon 1

Plenary Session8:30 am – 12:30 pm • Crude/Vacuum/Coking Q&A McArthur Ballroom Salon 4(concurrent) • Plant-wide Systems P&P McArthur Ballroom Salon 3

• Design & Operations Safety Session Grand Room10:00 am – 10:30 am Coffee Break McArthur Prefunction Area10:30 am – 12:30 pm Plant Automation: McArthur Ballroom Salon 1

Process Efficiency12:30 pm – 1:30 pm Lunch McArthur Ballroom Salons 5-71:30 pm – 3:00 pm Plant Automation: McArthur Ballroom Salon 1

“Big Shift Change”1:30 pm – 5:00 pm • Gasoline Q&A McArthur Ballroom Salon 4(concurrent) • Crude/Vacuum/Coking P&P McArthur Ballroom Salon 33:00 pm – 3:30 pm Refreshment Break3:30 pm – 5:00 pm Plant Automation: McArthur Ballroom Salon 1

Supply Chain Management

Tuesday October 10, 2006

7:00 am – 5:00 pm Registration McArthur Registration8:00 am – 8:30 am Lifetime Service Awards McArthur Ballroom Salon 48:30 am – 10:00 am Plant Automation: McArthur Ballroom Salon 1

Security Issues8:30 am – 12:30 pm • Hydroprocessing Q&A McArthur Ballroom Salon 4(concurrent) • Gasoline P&P McArthur Ballroom Salon 310:00 am – 10:30 am Coffee Break McArthur Prefunction Area10:30 am – 12:30 pm Plant Automation: McArthur Ballroom Salon 1

Process Safety (Part I)12:30 pm – 1:30 pm Lunch McArthur Ballroom Salons 5-71:30 pm – 3:00 pm Plant Automation: McArthur Ballroom Salon 1

Process Safety (Part II)1:30 pm – 5:00 pm • FCC Q&A McArthur Ballroom Salon 4(concurrent) • Hydroprocessing P&P McArthur Ballroom Salon 3 3:00 pm – 3:30 pm Refreshment Break McArthur Prefunction Area3:30 pm – 5:00 pm Plant Automation: McArthur Ballroom Salon 1

“The Melting Pot”

Wednesday October 11, 2006

7:00 am – 11:00 am Registration McArthur Registration7:00 am – 7:30 am Continental Breakfast McArthur Prefunction Area7:30 am – 9:00 am Plant Automation: McArthur Ballroom Salon 1

Energy Management7:30 am – 11:00 am FCC P&P McArthur Ballroom Salon 39:00 am – 9:30 am Coffee Break McArthur Prefunction Area9:30 am – 11:00 am Plant Automation: McArthur Ballroom Salon 1

Concluding Keynote

Schedule of EventsTable of Contents

1 Introduction

2 Keynote Address

2 Session Information

2 Sponsors

3 Monday Sessions

6 Lifetime Service Awards Presentation

6 Tuesday Sessions

8 Wednesday Sessions

10 Q&A Panelists

14 NPRA Committees

15 Questions 1 - 15

16 Questions 16 - 28








24 Affiliate Directory

Cover photo courtesyof ConocoPhillips

2006 NPRA Q&A and Technology Forum

The 2006 NPRA Q&A and Technology Forumaddresses real problems and challenges that youface at your facility and helps you sort throughsolutions as you discuss them with panelists and in networking with other attendees. Today’s competitive refining environment requires attentionto plant safety, superior technology, innovation, and excellence in operations. Networking withrefiners, petrochemical producers, catalyst andchemicals suppliers, process licensors, engineeringfirms, and other industry experts at the Q&A andTechnology Forum keeps you on top of the latestdevelopments as you cope with demanding business conditions.

Principles & PracticesThe Principles & Practices (P&P) sessions, whichcorrespond to and complement the Q&A sessions,will be ideal for operations superintendents,process engineers and others that can benefit froma session that is focused on practical issues, thefundamentals of good operations, and eliminatingpersistent problems.Crude / Vacuum Distillation and CokingGasoline ProcessesFCCDistillate HydroprocessingPlant-wide Systems

October 8 - 11, 2006

Design & Operations Safety SessionThe Design and Operations Safety Session will present plant safety topics for process engineers,design engineers, and Operations supervisorsand managers. The topics will include recognizingand eliminating hazards, siting structures inprocess plants, and pressure relief systems.

Plant Automation & Decision SupportFor the second year, the Plant Automation andDecision Support Conference is being co-located with the Q&A and Technology Forum so that attendees whose responsibilities overlap betweenprocess engineering, unit operations, process control, and planning will be able to use their conference time effectively. This “conference within a conference” will have 10 separate sessions that will provide a comprehensive arrayof topics for plant automation and process engineering professionals.Plenary SessionProcess EfficiencyBig Shift ChangeSupply Chain ManagementSecurity IssuesProcess Safety (Part I)Process Safety (Part II) – Panel DiscussionThe Melting PotEnergy ManagementConcluding Keynote

Attendees will be able to attend any of the Q&A,P&P, plant automation, or safety sessions. Therewill be one keynote session for all attendees onMonday and the hospitality suites will be open toevery attendee.

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2

Keynote Address

8:00 am – 8:30 am McArthur Ballroom Salon 4

Principles & Practices Sessions

Plant Automation & Decision Support

Session Information MondayOctober 9, 2006

The Principles & Practices (P&P) sessions are discussion-oriented sessions that complement the informationexchange that occurs in the Q&A sessions. Each of the P&P sessions will address the fundamentals of goodoperation and the bedrock principles for the technologies that are commonlyemployed. These sessions will usuallyhave short presentations which will befollowed by a time where attendees canask further questions or present their own particular problems and benefit fromthe collective experience of the otherattendees. The five P&P sessions are:Crude & vacuum distillation and coking Gasoline processes FCC Distillate hydroprocessing Plant-wide Systems (Sulfur Recovery,Cooling Water, NOx ReductionTechnologies, Safety Reviews)

Sponsors

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Screening MeetingCB&I

Panel MeetingGrace Davison

Opening ReceptionBJ Chemical ServicesChevron Lummus GlobalExxonMobil Research & Engineering

CompanyJohnson Matthey Catalysts and TracercoKBC Advanced Technologies, Inc.ProSys, Inc.

Hospitality BrochureSTRATCO, DuPont Refinery Solutions

Monday Morning Coffee BreakAir Products/Technip Hydrogen Alliance

Monday Afternoon Refreshment BreakBJ Chemical Services

Tuesday Morning Coffee BreakPraxair Inc.

Tuesday Afternoon Refreshment BreakCB&I

Wednesday Morning Continental BreakfastOSIsoft

Energy Management WebinarMatrikon

Conference BagsGE Water and Process Technologies

Electronic Session CountersBaker Petrolite Corporation

The NPRA Plant Automation and DecisionSupport Conference is ideal for thoseindividuals who are responsible for plantautomation, process control, planningand scheduling, IT and modeling/simulation. Unlike other plant automationand decision support conferences, thisconference is designed by operatingcompanies for operating companies.

The Plant Automation and DecisionSupport Conference will have ten separate sessions: Plenary SessionProcess EfficiencyBig Shift ChangeSupply Chain ManagementSecurity IssuesProcess Safety (Part I)Process Safety (Part II): Panel DiscussionThe Melting PotEnergy ManagementConcluding Keynote

William HonnefSenior Vice President of

Sales and MarketingVeraSun Energy Corporation

Congress has decided that fuels in the U.S. will include renewables such as ethanol and biodiesel and has established minimum renewables volumes for the next several years. Bill Honnef of VeraSun will describe theethanol supply outlook, the industry’schallenges in distributing and blending it nationwide, and the prospects for a cellulosic ethanol production process thatis competitive with current processes.

MondayOctober 9, 2006

3

PresiderSteve Elwart, Ergon Refining

Keynote“Open Operations and Maintenance”Alan Johnston, President, MIMOSA

Business Drivers To UpgradeAutomation Systems Solomon Associates

Plant Automation & Decision Support:Plenary Session

8:30 am – 10:00 amMcArthur Ballroom Salon 1

PresiderJon Finch, Flying J

Control & Management of HighlyStressed Cooling SystemsGE Water & Process Technologies

Amine Plant/SRU/TGT/SWS: Basic 101 OverviewHuntsman

SCR and SNCR: Basic 101 Class –Overview, Design, ApplicationsGE Energy

How to Conduct an Effective Pre Start-Up Safety ReviewAcuTech Consulting Group

This year’s safety session includes presentations on recognizing hazardsand control methods to eliminate them,an update of API’s RecommendedPractices 752 for siting temporary structures in operating plants, and thedesign and use of process pressure relief systems and blast overpressurestudies.

Factors that Influence Vapor CloudExplosion EnergyJatin Shah, Principal Consultant, Baker

Engineering and Risk Consultants, Inc.

No Hazard Left BehindRonald Meyers, Safety Engineer,

Georgia Gulf

Blowdown Drums and Atmospheric Relief SystemsPatrick Berwanger, Founder and Former

President, Berwanger, Inc.

Techniques for Hazard RecognitionDavid F. Coble, President, Coble, Taylor &

Jones Safety Associates

Update of the API Facility Siting Task Force Work on ‘Placement of Portable Buildings’Willis Jernigan, Director, Health & Safety,

Koch Industries

Plant-wide Systems Principles & Practices

8:30 am – 12:30 pmMcArthur Ballroom Salon 3

Design & Operations Safety Session

8:30 am – 12:30 pmGrand Room

Crude & Vacuum Distillationand Coking Q&A


PanelistsKevin Black, ConocoPhillipsGreg Cantley, Marathon PetroleumDon Fruge, CITGO PetroleumAlan Goliaszewski, GE Water and

Process TechnologiesShri Goyal, Shell Global Solutions Conrad Jenson, Holly Refining &

Marketing

See page 15 for questions.

4


Identification and Capture ofKnowledge at Risk – What the Refining Industry is Doing John Paul Havener, Solomon Associates

The Performance Pentagon: Learningand Knowledge Management toOptimize Operations and ProcessesRoger J. DeSanti, Professor, University of

New Orleans, Louisiana State Univ.

How do you help people maintain, foster,and grow in their responsibilities? The five components necessary for effectivelearning and training will be discussed asthey relate to gaining information andknowledge for the purposes of transfor-mation and optimization in the workplace.

Planning the Lifecycle of theAutomation SystemMarjorie Ochsner, Senior Product

Manager, Honeywell Process Solutions

A number of factors are important to consider when planning the life cycle ofautomation systems. This session will discuss various approaches and optionsfor upgrades and migrations of agingDCS systems and other automation infrastructure. An analysis of the advan-tages and disadvantages of differentapproaches will be performed. Casestudies based on real-world projects will be discussed to highlight specificscenarios and analyze the results thatwere achieved. The planning and imple-mentation process will be emphasized to identify specific success factors.

Plant Automation & Decision Support: “Big Shift Change”

1:30 am – 3:00 pm McArthur Ballroom Salon 1

PresiderSteve Williams, Aspen Technologies

Implementation of ManufacturingIntelligence Within an EnterpriseMonitoring System at Saudi Aramco George Bauer, IndX Software

Using Dynamic Simulation to Validate Design and OperationMajeep Jain, Engineering Specialist,

Jaleel Valappil, Engineering Specialist,Vibhor Mehrotra, Engineering Supervisor, and Amudha Valli, Engineering Specialist, Bechtel Corporation

Increased demand for oil and gas hasrenewed interest in the technical devel-opment of refineries and gas plants withan emphasis on streamlining operationsand improving process design which hasled to tighter bounds on process design.Dynamic simulation is a proven tool forevaluating basic design of a plant duringits evolutionary phase and simulatingplant response under normal and criticalsituations. Dynamic simulations can alsobe used to perform controllability andoperability studies.

This paper discusses engineering studiesperformed at Bechtel to validate processdesign and operation of an atmosphericdistillation unit with a diluent rectifier col-umn. A high fidelity dynamic model of theprocess plant was developed and usedto study operability and controllability forvarious transient scenarios. Additionalcontrol strategies were tested and recom-mended to complement the existing con-trol systems. Early operational guidelineswere established based on these studies.

Plant Automation & Decision Support: Process Efficiency

10:30 am – 12:30 pm McArthur Ballroom Salon 1

Large-Scale Adaptive MultivariableControllers Eliminate Step Tests andMaximize Plant PerformanceUmesh Mathur, President, Advanced

Control Engineering Services,Robert D. Rounding, Control Engineer,

BP North American Gas SPU,Daniel R. Webb, Plant Manager, INEOS

Olefins & Polymers USA,Victor L. Rice, V.P. Advanced Control &

Optimization, Plant Automation Services, Inc.,

Barry Burr, Bryan Research & Engineering, and

Robert Conroy, Fluidity Engineering Solutions

A discussion of manifold benefitsobserved from use of an adaptive multi-variable, model-predictive control (MPC)approach in two major light hydrocarbonplants; both projects were executed withabsolutely no step tests. Operatoracceptance has been exceptional.

Multivariable Control Without Step Testing, A Recent Implementation for BP in the UKRoland Sims, APC Consultant, PAS,David Lawrence, Instrument Technical

Authority, BP, andVictor Rice, VP APC&O Business, PAS

The session will present how a multivariable control was installed at a BP facility in the UK. The goal of the project was to install a multivariable control while minimizing plant disturbanceduring implementation of the project. The process of implementation will beillustrated showing exactly what stepswere taken to minimize plant disturbance.The BP CATS project will be presentedwhere not only was step testing notrequired, but where the commissioningprocess went very smoothly.

5


PresiderKevin Proops, Flint Hills Resources

Desalting And Overhead System CorrosionNalco

Vacuum Unit Design:Dry or Wet?Process Consulting Services

Coke Drum Reliability, Design and ReplacementCB&I

Delayed Coker Structure Safety Flint Hills Resources

Coker Expansion OptionsFoster Wheeler USA

Crude/Vacuum Distillation and Coking Principles & Practices

1:30 pm – 5:00 pm McArthur Ballroom Salon 3

Gasoline Processes Q&A

1:30 pm – 5:00 pm McArthur Ballroom Salon 4

PanelistsA.S. Basu, Indian OilAngelo Furfaro, UOP Ken Jinkerson, Western RefiningSteve Mathur, Chevron ProductsJohn Quanci, Sunoco Kerry Rock, CDTECH


PresiderCliff Pedersen, Suncor Energy

Optimization of Feedstock LogisticsManagement and BlendingCristiano Pinto de Costa, Logistic and

Custody Transfer Engineer, COPESUL,Gilberto Müller, Automation Process

Control Engineer, COPESUL,Érica R.P. Claro, Automation Senior

Process & Control Engineer, COPESULGastão D. C. Moraes, Automation Senior

Process & Control Engineer, COPESUL,Arturo Cervantes, Senior Consultant,

Optience

COPESUL will describe optimization ofraw material supply operations includingships receiving material, intermediatestorage allocation, pipelines programmingand control, blending and integration with planning and production schedulingoptimization tools.

Oil and Gas Supply Chain Global Competitiveness: A Country in the BalanceMaria Victoria Riaño Salgar, Project

Manager, Ecopetrol S.A., andAndrew R. Nelson, Resolution Product

Manager, Matrikon Inc.

Ecopetrol undertook a major initiative toenhance its competitiveness in interna-tional markets which involved a majorrework of its business and financial sys-tems to adopt industry best practices.One of the key strategies was to put inplace a volumetric system to be the single source of validated volumetricinformation across the entire supply chain.

The steps taken by Ecopetrol greatlyimproved its knowledge of the state ofthe business, enabling tighter control ofcosts, more effective optimization ofinventories and an enhanced ability todeal with external entities. The result ismore effective control and greater com-petitiveness in national and internationalmarkets.

Petroleum Supply Chain ManagementChallenges and SolutionsGreg Janecek, Director, Business

Development Petroleum Oil & Gas,Aspen Technology, Inc.

As a result of tightening supply of crudeand finished products, most oil compa-nies today have some initiatives in placeto streamline their supply chains (by bet-ter planning and execution) and developcompetencies to manage challenges likesupply chain disruptions. This paper willpresent a case study showing what typesof solutions companies are seeking, thereasons for these solutions, the anticipat-ed benefits and the overall impact to thework process.

Plant Automation & Decision Support:Supply Chain Management

3:30 pm – 5:00 pmMcArthur Ballroom Salon 1

6

Hydroprocessing Q&A


PanelistsMike Dabkowski, Sunoco Ted Hallen, Haldor TopsoeTom Kiliany, ExxonMobil Refining and

SupplyGarry Kirker, Valero Energy David Roland, Marathon PetroleumJames Turner, FluorPaul Zimmerman, UOP


TuesdayOctober 10, 2006

The Peter G. Andrews Lifetime ServiceAward honors members who have madelong lasting contributions to the valueand vitality of the NPRA Q&A meeting.Recipients of this award have served as Q&A panelists, screening committeemembers, and, most importantly, activeparticipants in the dialogue that is fundamental to the meeting. During their careers, the recipients have demonstrated a willingness to pass ontheir knowledge and expertise to future generations in this forum, have made significant contributions to the meeting’squality, and have emphasized the importance of sharing knowledge in making continuous improvements.

Presider Jerry Lane, BP

Unit Monitoring Best Practices: Critical Variables in Catalytic ReformingChevron

Principles and Practices Used inCatalytic Reformer OptimizationT-Squared Technologies

Principles and Practices to Manage Chloride on a Catalytic Reformer StabilizerFrontier Oil

Key Considerations for a Reforming Unit RevampUOP

Design and Operation of NHT Strippers to Protect Catalytic ReformersRoddey Engineering

2006 NPRA Q&A Peter G. Andrews Lifetime Service Awards


Gasoline Principles & Practices


PresiderBlake Larsen, Western Refining

Three Basic Steps Towards Cyber Security in Your Process Control EnvironmentRick Kaun, Senior Security Consultant,

Matrikon Inc.

Since most control systems do not allowfor the deployment of pure IT-based bestpractices it is up to the process controlasset owners to come up with creativeand intelligent ways of securing their systems on their own. Through extensivework with many clients in the processcontrol space, we have come up with anumber of solutions that will help moveprocess control environments towardsbetter cyber security. This presentationexamines three different case studieseach of which offers a different approachto security. The specific topics and benefits of these examples range fromthe power of planning and measuringyour environment to the basics of asecure architecture and the ability toaudit and log all remote access into your process control environment.

I3P UpdateBen Cook, Sandia National Laboratories

Presentation on Cyber Security from a Federal LevelMarcus Sachs, SRI International

Plant Automation & Decision Support:Security Issues


Roger O. Pelham

Brian Moyse

7

PresiderRich Bowman, TOTAL Petrochemicals

Abnormal Situation Management UpdateDave Strobhar, Beville Engineering

Abnormal Situation Prevention In More Complex SystemsRavi Kant, Principal Engineer, Emerson

Process Management, andRoger K. Pihlaja, Principal Engineer,

Emerson Process Management

Abnormal situations include unexpectedequipment and process unit malfunctionsthat result in significant anomalous operating conditions. The concepts andapplications of abnormal situation prevention (ASP) will be extended to more complex systems and unit operations which involve multilevel collaborative diagnostics.

Alarm Management – More Than a Nuisance. A Business Improvement OpportunityBill Sheldon, Advanced Process Control

Engineer, Chevron Phillips Chemical Company LP

Alarm management is often consideredto be an issue of “safety” alone. While it is definitely a safety concern, alarm management can also be a great way to improve the bottom line!

This presentation offers an additional perspective on alarm management activities and provides sound businessjustification for the implementation ofalarm management practices while promoting sound and prudent safetypractices that act as a proper foundationfor any alarm management initiative.

State Handling in Automation TechnologiesMik Marvan, Product Manager, Alarm

Management Solutions, Matrikon Inc.Rohit Patwardhan, Product Manager,

Control Asset Optimization, Matrikon

Industrial processes are inherently complex and exist in many states.Distributive control and supervisory sys-tems are changing to better address thisreality. This workshop will delve into thetopic of state handling using automationtechnologies in the domains of regulatorycontrol, advanced process control, andadvanced alarming methods.


Plant Automation & Decision Support:Process Safety (Part I)



Panel Discussion on Process SafetyBob Gale, Emerson Process

Management Eddie Habibi, PASMik Marvan, MatrikonKevin Staggs, Honeywell Process

Solutions

Operating company panelists and additional panelists to be announced.

Plant Automation & Decision Support:Process Safety (Part II)


8


PresiderBrent Stratton, Valero Energy

Hydrogen Generation Technology /FundamentalsAir Products & Chemicals

ULSD Implementation UpdateLYONDELL-CITGO Refining

Design/Operational Considerations for Hydrotreater Revamps for ULSD OperationFluor

Hydroprocessing Catalyst Activity /Deactivation Mechanisms andManagementAdvanced Refining Technologies

HydroprocessingPrinciples & Practices


PresiderPaul Millner, Chevron

ARRIS – Architecture for RefineryReal-time Interoperable Systems Michael V. Brooks, Chevron

Self Organizing Networks: Discovering a New Emerging Wireless Technology Dan Daugherty, Emerson Process

Management

Strategic Implementation of Wireless TechnologiesBrent E. McAdams, FreeWave

Technologies, Inc.

The evolution in wireless technologieshas opened the door to a new class of plant automation architecture thatoffers adopters a significant strategicadvantage. Driven by significant andmeasurable cost savings in engineering,installation, and logistics, as well as dramatic improvements in the frequencyand reliability of field data collection,automation experts and IT professionalsare presented with an opportunity todeliver a major, positive impact to theirrespective company’s bottom line.

This paper will explore the attributes ofvarious wireless technologies, whichinclude security, the elimination of wiring,power management and the ability toembed wireless into existing OEM technologies. Additionally, this paper will discuss the requirements of typicalapplications and deployment options that match capabilities with applicationneeds and then examine alternatives in which wireless architecture can interface with existing systems for thepurpose of preserving investments inexisting infrastructure.

Plant Automation & Decision Support:“The Melting Pot”


FCC Q&A


PanelistsDave Brosten, Shell Global SolutionsAlan English, KBC Advanced

TechnologiesMark Gregory, Flint Hills ResourcesZiad Jawad, Shaw Stone & WebsterDennis Kowalczyk, Grace DavisonKen Peccatiello, Valero Energy


WednesdayOctober 11, 2006

Presider Dave Mendrek, Murphy Oil

FCC Unit Industry SurveyMurphy Oil and UOP

Catalyst Section Key EquipmentHealth MonitoringFlint Hills Resources

Main Column and Gas Con SectionKey Equipment Health MonitoringMurphy Oil

Performance Optimization DiscussionKBR and Shell Global Solutions

Performance Optimization ExamplesValero Energy, KBR, and Shell Global Solutions

FCCPrinciples & Practices


9


The State of the Refining IndustryToday and the Roles thatManufacturing and Process Control Play in ItSteve Cousins, Lion Oil

Plant Automation & Decision Support:Concluding Keynote


WednesdayOctober 11, 2006

PresiderAnne Keller, Jacobs Consultancy

Energy System Real Time OptimizationDerya Uzturk, Senior Engineer,

ExxonMobil Research and Engineering Company,

Howard D. Franklin, Senior Engineering Associate, ExxonMobil Research and Engineering Company,

John M. Righi, Senior Engineer, ExxonMobil Research and Engineering Company, and

Apostolos T. Georgiou, Senior Engineering Associate, ExxonMobil Research and Engineering Company

An energy system real-time optimization(ERTO) application is an online computerprogram consisting of a model of the utility system, a mathematical optimizer, agraphical user interface, and an interfaceto the plant process control system. The objective of the application is todetermine and implement the energy system operating targets which minimizesthe cost of utilities. ExxonMobil hasdeveloped significant experience delivering ERTO applications to refineries.ExxonMobil’s experience at theirRotterdam Refinery will demonstrate how the technology can be applied.

An On-Line Advisory System forOptimizing Refinery Utility SystemsDavid F. Wilson, Flint Hills Resources, Abraham Jimenez, Flint Hills Resources,Jose de Souza, Aspentech, Inc.

Flint Hills Resources’ Corpus ChristiRefinery implemented Aspen Utilities toprovide an on-line advisory system foroptimizing utilities operations decisions.The paper will describe the goals andobjectives of the project, some of theimplementation experience and somerecommended best practices for implementing and sustaining similar systems.

Industrial Energy Management byUsing an On-line ToolDavid Nelson, Chief Financial Officer,

Nelson & Roseme, Inc.,Susana Benedicto, Process Engineer,

Repsol YPF,Diego Ruiz, Chief Operating Officer,

Soteica Europe, andCarlos Ruiz, Director, Advanced

Applications, Soteica Europe

Repsol’s La Coruña Refinery is a highconversion site with coking and FCCunits. The energy system is based on five steam headers and two cogenerationplants producing steam and electricity.Electrical deregulation and mandatedCO2 emissions reductions have provided challenges. This presentationdescribes the tasks performed usingmodern on line information system tools(Visual MESA) to assist with the energysystem management. A full model of theenergy system has been done, includingall of the constraints.

Plant Automation & Decision Support:Energy Management


Greg Cantley is the Crude & VacuumDistillation Technologist for MarathonPetroleum Company and is activelyinvolved with the expansion, optimization,and troubleshooting of Marathon’s elevencrude and vacuum units. Greg startedhis career in Ashland’s ProcessEngineering Department in Catlettsburg, KY performingprocess design work for all of the Ashland refineries. Later he joined Marathon and transitioned to troubleshooting andoptimization of refinery distillation towers throughout theMarathon refinery system.

Greg holds a BSChE from West Virginia Institute ofTechnology.

Alan English is Senior Staff Consultantfor KBC Advanced Technologies inParsippany, NJ. Al has nearly 30-yearsexperience in process engineering,R&D, troubleshooting, technologylicensing, model development anddesign. He has provided consultingservices on more than 40 FCC units worldwide, and advisesclients on process optimization, design review, catalyst selec-tion, troubleshooting and monitoring programs. He is alsochairman of the FCC Process Technology Group which isresponsible for developing FCC and alkylation technologywithin KBC. Before joining KBC in 1995, Al held research,process engineering and operations positions with Gulf,Chevron and Sun.

Al holds a BSChE from Lehigh University, a MS in technologymanagement (EMTM ) from Stevens Institute of Technology,and a PE license in PA. Al is the author or coauthor of 12 publications and holds 3 patents in FCC technology.

Don Fruge is the Process Design andStrategic Planning Manager at CITGOPetroleum’s Lake Charles, LA refinery.He presently supervises the refinery’slaboratory and all refinery process engineering, which includes unit monitoring and troubleshooting; catalystand chemical evaluations; energy management and optimization; turnaround planning and support; and profitabilityinitiatives. Prior to this position, Don served as LogisticsManager, Senior Process Design Engineer, Operations FieldEngineer, Operations Engineering Section Supervisor,Economics Engineer, and Process Engineer.

Don holds a BSChE from McNeese State University.

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NPRA Q&A Panelists

A.S. Basu is Technical Head of Indian OilCorporation’s Mathura Refinery where herecently led the pre-commissioning andstart-up activities for the diesel hydrotreat-ing, hydrogen and Penex units in 2005.Basu has 30 years of experience encom-passing Operations, Technical Services,Planning, Safety and Environmental Protection at Indian Oil’svarious refineries. Basu has also worked at Indian Oil’s NewDelhi headquarters where he was responsible for productionplanning and distribution of petroleum products throughout acomplex, nationwide retail network. Basu is a recognized FCCexpert with both hands-on and technical service experience.Some of his significant contributions include conceptualizationand formulation of proposals for adapting Indian Oil’s refineriesto changing fuel quality requirements.

Basu is a graduate of India’s Chemical engineering school,Jadavpur University.

Kevin Black is Senior Consulting Engineerfor ConocoPhillips, Carson, California. Inhis current position he is responsible forproviding day-to-day process engineeringand technical support for the vacuum distillation and coking Units. Kevin joinedConocoPhillips in 2002, following assign-ments in process engineering, operations, project management,purchasing as well as technical management with Shell Oil,Unocal, TOSCO and Phillips Petroleum.

Kevin holds a BSChE from North Carolina State University andis a Registered Professional Engineer in California.

Dave Brosten is an Advisor in Shell Oil’sCentral Support for FCC Operations inHouston, TX where he is responsible fortroubleshooting unit problems, catalystoptimization and selection, and hardwareoptimization. Dave has also been involvedin several major FCC revamp projects toupgrade units to close-coupled riser designs with high perform-ance strippers and improved regeneration. Dave has spent hisentire career at Shell Oil refineries supporting the catalyticcracking technologies, providing direct process support toFCCU’s and FCC revamp projects. Dave has two patents in theFCC area.

Dave holds a BSChE from Montana State University.

Angelo Furfaro is Senior Manager ofPetrochemical Operating TechnicalServices in the Process Technology andEquipment group of UOP. He is responsi-ble for providing technical support to UOPlicensees in all aspects of Platforming/Isomerization/Aromatics and AromaticsDerivatives/Olefins/Detergents and Petrochemical technologies,including establishing operating procedures; optimizing unitperformance; troubleshooting; and coordinating engineeringrevamps. Since joining UOP, Angelo has held positions inExperimental Design and Development, Field OperatingServices, Separations & Aromatics Operating Technical Services,Platforming Operating Technical Services, and as Manager ofboth Platforming and Aromatics Operating Technical Servicesand has experience in a wide variety of refining process units.

Angelo holds a BSChE from the University of Colorado, Boulder.

Alan Goliaszewski is Senior ResearchTechnologist for GE Water & ProcessTechnologies in The Woodlands, TX. Overthe past 14 years, Alan has been active inresearch and technical service activities forrefinery process additives and fuel addi-tives. He has held the position ofHydrocarbon Process Group Leader and has led activities for abroad range of refinery issues including fouling control, corro-sion inhibition, H2S scavenging, alkylation, and phase separa-tion including desalting, antifoaming, and solids settling. Prior tothis assignment, Alan spent six years in the Unique MoleculeDiscovery Group for GE in Trevose, PA.

Alan holds a BS degree from St. Joseph’s University, and MSand PhD degrees in Chemistry from Princeton University.

Shri Goyal is Shell Oil’s Advisor of Cokingand Heavy Oils Processing where he provides worldwide technical support and“best practices” development includingsafety, reliability, troubleshooting, monitor-ing, optimization, expansion and projectdevelopment. He also leads Shell Oil’sCoking TechNet group. Shri joined Shell Oil in 2000 after 20 years with Amoco where he worked on crude units, FCCUs,hydrotreaters, deasphalters and delayed cokers. He holds 11 US patents in refining processes.

Shri holds a BSChE from IIT, New Delhi, MSChE from IIT,Bombay and a PhD ChE from the University of Utah. He also holds diplomas in Ceramics Engineering, Engineering Administration and Business Management.

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Mark Gregory is the Engineering andReliability Manager at Flint HillsResources’ Pine Bend, MN refinerywhere he is responsible for all of thetechnical support groups (SeniorProcess Engineering, Fixed EquipmentEngineering and Inspection, Instrumentand Electrical Engineering, and Maintenance) and the ProjectGroup which is responsible for the facility’s capital andexpense spending. In his 25-year career with Flint HillsResources he has held positions at the Pine Bend and CorpusChristi refineries including technical service for the FCC/Alkylation/Coker/Hydrotreating areas and as AssistantOperations Manager for the FCC/Alkylation/Crude/HDC andCoker areas.

Mark holds a BSChE from Michigan Technological University.

Ted Hallen is Senior Staff Engineer for the Hydroprocessing Group atHaldor Topsoe. Ted’s experienceincludes 37 years in the process indus-tries, with over 17 years at Unocal withresponsibilities in operations, projectexecution, development, and technolo-gy sales and licensing. Ted’s last position at Unocal was in the Process Technology and Licensing Business Group asRegional Sales Manager. Ted has been with Haldor Topsoe for 11 years in sales management and engineering positions.He is currently a Senior Staff Engineer where he functions as a consultant for other engineers, interfaces with the manufac-turing and research organizations within the Haldor TopsoeGroup as well as handling some selected sales responsibilities.

Ted holds a BSChE from the University of Utah.

Ziad Jawad is an FCC DesignSpecialist for Shaw Stone & Websterwhere he is responsible for processengineering in reliability and optimiza-tion FCC revamp projects. He previous-ly spent 7 years as an OperationsSupport Engineer at the Delaware CityRefinery. His responsibilities included process monitoring,troubleshooting, optimization, project design, and turnaroundsupport. He has experience in the areas of FCC, Alkylation,Polymerization, Isomerization, and Amine / Caustic Treating.

12

NPRA Q&A Panelists

Dr. Garry Kirker is Director of Hydro-processing for Valero Energy Corp.where he is responsible for the devel-opment of new hydroprocessing projects, expansion of existing units andoptimization of Valero’s hydroprocessingassets. He has worked in the refiningindustry for over 25 years and his professional experienceincludes over 22 years with Mobil and ExxonMobil in refiningtechnology leadership positions focusing on hydroprocessing,including hydrotreating, hydrocracking and gas-to-liquids technologies.

Garry holds a Ph.D. in Physical Inorganic Chemistry from IowaState University in the Kinetics and Mechanisms of CatalyticSystems.

Dennis Kowalczyk is a NationalTechnical Sales Manager with GraceDavison. He is responsible for coordi-nation of FCC catalyst & additive salesand technical service activities in theEastern United States and Canada. Hehas extensive experience in FCC cata-lyst evaluation, FCC unit optimization, FCC reactor effluentstudies, and process studies designed to select new FCCtechnology for unit revamps. Prior to joining Grace Davison,Dennis spent 19 years at Refining Process Services (RPS) asDirector of Operations and 5 years with the Gulf Oil Corp.Dennis co-founded RPS as a consulting company dedicatedto providing specialized independent technical and consultingservices to the petroleum refining industry. At RPS, Denniscreated TheFCCNetwork.com, a web site devoted to the subject of fluid catalytic cracking. He also co-developed and presented a number of training courses for FCC andpetroleum refining.

Dennis holds a BSChE from West Virginia University and is aLicensed Professional Engineer in Pennsylvania.

Steve Mathur is the Sulfuric and HFAlkylation Team Leader and ProcessExpert for Chevron Global Refining inRichmond, CA. He is responsible forsupporting all Chevron alkylation andolefins business units worldwide includ-ing troubleshooting operations andevaluation of new technologies. He began his career with anExxon affiliate and worked for Champlin and Sunoco beforejoining Chevron 15 years ago.

Steve holds a BSChE from the Indian Institute of Technology,Roorkee and a MSChE from the University of Detroit.

Conrad Jenson is the OperationsManager for Holly Refining andMarketing Corporation’s Woods Cross,UT refinery. He has 16 years of refiningexperience with both engineering andoperations assignments includingCrude, SDA, FCC, HF Alkylation, andSulfur Recovery units. Prior to joining Holly, Conrad held theposition of Production Team Leader at the ConocoPhillipsSweeny refinery.

Conrad holds a BSChE from the University of Utah.

Ken Jinkerson is Director ofOperations for Western Refining. In his29 years in the refining industry hisassignments have included Manager ofTechnical Services and Manager ofEconomics and Planning and he hasworked for Shell Oil, Pester Refining,Derby Refining, Coastal Corporation and Mapco.

Ken holds BSChE and MSChE degrees from the University ofMissouri at Rolla.

Tom Kiliany is Complex Engineer forExxonMobil Refining and SupplyCorporation in Torrance, CA. Tom isresponsible for technical guidance of the hydrocracker, FCC feedhydrotreater, naphtha pretreater andreformer, distillate desulfurizer, hydro-gen production, and sulfur recovery units. With 27 years ofexperience at ExxonMobil, Tom has had assignments inprocess development, catalyst research and development, aswell as technical service. The technical service assignment ledto grassroots startups of new technology in the Far East andMiddle East.

Tom holds a BSChE in Chemical Engineering, with distinction,from Pennsylvania State University and a MSChE from VillanovaUniversity. He has received a total of 18 U.S. and foreignpatents.

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Ken Peccatiello is a Director of FCCTechnologies for Valero EnergyCorporation in San Antonio, TX. Kenhas over 28 years experience in FCCoperations and technology includingfive years as ChevronTexaco’s world-wide FCC expert providing best prac-tice development and implementation, I&T support, operationalsupport, project development and implementation, and trainingof personnel. He has also worked for WR Grace’s technicalservice division and as Technical Superintendent at their LakeCharles, LA catalyst manufacturing facility. He began his careerwith Amoco Oil in 1977 at the research facility in Naperville, ILwhere he was involved with multiple FCC studies and the developmental stages of FCC resid processing. He laterbecame Operating/Process Engineer for FCCU’s #1 and #2 at the Amoco Texas City, TX refinery.

Ken holds a BSChE from the Illinois Institute of Technology.

Dr. John Quanci is the Manager ofProcess Technology for SunocoRefining & Supply. The ProcessTechnology group consists of theprocess specialists who are responsiblefor supporting and leading the evalua-tion, transfer and implementation oftechnology for all Sunoco locations as well as optimization andtroubleshooting activities. John has led the reforming, isomeriza-tion, hydroprocessing and cleans fuels groups in R&D, refinerytechnical departments, and process engineering asset supportgroups. John has worked in the petroleum industry for morethan 15 years in the U.S. and overseas as well as several yearsexperience in the electronics specialty chemical industry.

John holds a BSChE from Cooper Union and M.A. and PhDdegrees in Chemical Engineering from Princeton University.

Kerry Rock is Director of Technologyfor CDTECH in Houston, TX. He is cur-rently responsible for directing technolo-gy development and marketing processtechnologies to the refining and petro-chemical industries. He has over 35years experience in the oil and gas,refining, chemical, and petrochemical industries which includesresearch and development, process design and managementof projects for dehydrogenation, desulfurization, gasoline refor-mulation, fuel ethers, methanol, hydrogenation, oil and gas pro-duction, transportation and processing, biomass gasification,flue gas desulfurization and environmental emissions control.

Kerry holds BSChE and MSChE degrees from the University ofHouston.

David Roland is the Technical ServiceManager for Marathon PetroleumCompany at the Catlettsburg, KY refinery where he is responsible for the refinery optimization, process engineering and process controlgroups. During his 19 years withMarathon he has held positions in refinery technical service,capital budget development, linear program modeling, controls, and operations planning at the Detroit and Garyvillerefineries and at Marathon headquarters in Findlay, OH.

Dave holds a BSChE from the University of Michigan and aMSChE from Wayne State University. He is a licensed profes-sional engineer in the State of Michigan.

James Turner is Director II, ProcessTechnology & Engineering for Fluor inHouston, TX. His 18 years with Fluorincludes experience in process designof new refinery units and revamps andhis technology expertise lies inhydrotreaters and hydrocrackers, refinery configuration, hydrogen management, clean fuels regulations, distillation, and ammonium bisulfide corrosion inhydroprocessing processes.

James holds a BSChE from Texas A&M University and is aregistered professional engineer in Texas.

Paul Zimmerman is a senior hydropro-cessing specialist in the Catalysts,Adsorbents, and Specialties group for UOP LLC. He is responsible for providing technical support for UOPhydroprocessing catalysts includingoptimization, troubleshooting, and operating procedures. Paul has held hydroprocessing positions at UOP in Development, Field Operating Services,and Operating Technical Services. Prior to UOP, he worked for Unocal’s Processing Technology and Licensing group inResearch and Development conducting hydrocracking pilot plant studies for new catalyst commercialization andprocess improvements.

Paul holds a MSChE from the University of Idaho.

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NPRA Committees

NPRA Q&A Screening CommitteeThe Q&A Screening Committee is a forum whereNPRA members can discuss operations in therefining and petrochemical industries with specialemphasis on process technology. The Q&AScreening Committee and panelists met on June 27-29 in The Woodlands, TX, where theCommittee selected 113 questions deemed mostinteresting and beneficial to the conference fromthose submitted. If you submitted questions whichare not adequately covered by the selected questions, you may still present them from thefloor during the appropriate session of the Q&A session. The following are members of the2006 Screening Committee:

Matthew Baebler, Tesoro CorporationDave Bartholic, Bar-Co Processes Joint VentureVito Bavaro, Criterion Catalysts & TechnologiesSandie Brandenberger, ConocoPhillipsDavid Brossard, Chevron CorporationKen Bruno, Albemarle CatalystsTim Campbell, Axens North AmericaMichael Capone, Praxair Robert Carpenter, GE Water & Process Tech.Bill Cates, Hunt Refining CompanyKen Chlapik, Johnson Matthey CatalystsGeri D’Angelo, Advanced Refining TechnologiesBob Davis, R.E. Davis Chemical CorporationLarry Denk, AggrekoDaryl Dunham, ConocoPhillipsGary Everett, LYONDELL-CITGO RefiningCJ Farley, BASF CatalystsJon Finch, Flying J Angelo Furfaro, UOP Joey Hagmann, Placid Refining CompanyStephen Haik, Motiva Enterprises Fred Hill, Marathon Petroleum Company David Hunt, Grace DavisonJeff Johns, Chevron CorporationCheryl Joyal, BP Daniel Kennedy, Pasadena Refining SystemGarry Kirker, Valero Energy CorporationLarry Kraus, Albemarle CatalystsLawrence Kremer, Baker Petrolite CorporationLarry Lacijan, UOP Jerry Lane, BP Warren Letzsch, Shaw Stone & WebsterLarry Lew, Chevron CorporationGlenn Liolios, STRATCO-DuPontLinda Lord, Western Refining CompanySam Lordo, NALCO CompanyBob Ludolph, Sunoco Aris Macris, KBRTariq Malik, CITGO Petroleum CorporationRon Marrelli, Holly Refining & MarketingChris McDowell, Tesoro CorporationHarvey McQuiston, Shaw Stone & WebsterDavid Mendrek, Murphy Oil USARik Miller, ConocoPhillipsMichael Mills, GE Water & Process TechnologiesPaul Moote, Sinclair Oil CorporationBrian Moyse, Haldor Topsoe A/SDonald Mulraney, CB&IDan Neuman, Tricat IndustriesJoe Niedecken, Valero Energy CorporationMart Nieskens, Shell Global Solutions Kenneth Peccatiello, Valero Energy CorporationRoger Pelham, Pelham ConsultingRandy Peterson, STRATCO-DuPont

Kevin Proops, Flint Hills ResourcesKerry Rock, CDTechBob Roddey, Roddey Engineering Services, Inc.Gene Roundtree, ExxonMobil Research &

Engineering Glen Scheirer, ExxonMobil Research &

Engineering Jeff Spearman, Barnes and ClickBrent Stratton, Valero Energy CorporationMichael Toole, United Refining CompanySteve Tragesser, KBRLee Turpin, Turpin ConsultingKeith Whitt, Shell Global Solutions Bill Wilson, BP Products North AmericaIrl Zuber, Motiva Enterprises

NPRA Manufacturing CommitteeGary Fuller, Placid Refining CompanyChair

Rick Leicht, National Cooperative Refinery Assoc.Vice Chair

Eric Bluth, Pasadena Refining SystemAl Cabodi, U.S. Oil & Refining CompanyErnie Cagle, Murphy Oil USA, Inc.Jay Churchill, ConocoPhillipsLarry Cunningham, Afton Chemical CorporationSteve Cousins, Lion Oil CompanyJoel Elstein, Flying JRick Fontenot, Lyondell Chemical CompanyPaul Fritz, Sinclair Oil CorporationJim Gillingham, Valero Energy CorporationSteve Jackson, Hunt Refining CompanyVince Kelley, Sunoco Pat Kimmet, CHS, Inc.Greg Kropf, Chevron CorporationDave Lamp, Holly CorporationMike Lewis, Motiva Enterprises Keith Osborn, Coffeyville Resources Joe Coco, Flint Hills ResourcesJaspal Singh, Indian Oil Corporation LimitedStephen Smiejan, Hess CorporationJim Stump, Frontier El Dorado Refining CompanyRoy Whitt, Marathon Petroleum Company

Jeff Hazle, NPRASecretary

NPRA Plant Automation &Decision Support Committee and Associate MembersRich Bowman, TOTAL Petrochemicals USAChair

Blake Larsen, Western Refining CompanyVice Chair

Craig Acuff, Valero Energy CorporationDarrell Bond, Celanese Paul Bonner, Honeywell Steve Elwart, ErgonPhil Hodges, Pasadena Refining SystemDan Mason, ExxonMobil Research & Engineering Paul Millner, Chevron CorporationCliff Pedersen, Suncor Energy Kurt Rickard, Lyondell Chemical CompanyAnne Keller, Jacobs Consultancy Frank Vanderham, Matrikon Doug White, Emerson Process ManagementSteve Williams, Aspen Technology

Daniel J. Strachan, NPRASecretary

NPRA Plant Automation Program CommitteeRich Bowman, TOTAL Petrochemicals USASteve Elwart, Ergon RefiningBlake Larsen, Western Refining CompanyAnne Keller, Jacobs ConsultancyDan Mason, ExxonMobil Research & Engineering Steve Williams, Aspen Technology

NPRA Health & Safety CommitteeWillis Jernigan, Flint Hills ResourcesChair

Bill Walker, Lyondell Chemical CompanyVice Chair

Ray Dixon, Texas PetrochemicalsPast Chair

Bob Bahr, Exxon Mobil CorporationJake Berret, Williams OlefinsRalph Bocian, Ergon-West Virginia Paul Bucknam, Hess CorporationPaul Drydale, Frontier RefiningBill Jones, CITGO Petroleum CorporationFaheem Kazimi, Pasadena Refining SystemFritz Kin, Marathon Petroleum Company Steve Lackey, Sinclair Oil CorporationRock Lowery, ConocoPhillipsBrenda Overton, Air Products and ChemicalsGil Parker, Placid Refining CompanyRandy Patton, Valero Energy CorporationShade Schroeder, National Cooperative Refinery

AssociationEddie Seal, TOTAL Petrochemicals USADick Smullen, HOVENSA Joe Thurm, Sunoco Bill Turnage, Murphy Oil USALarry Whipple, Western Refining Company

Rick Brown, NPRA Secretary

15

Crude / Vacuum Distillationand Coking

Crude Preheat and Desalting1. Have you experienced fouling on the

crude side of preheat exchangers indesalted crude service as a result ofcaustic injection for chloride control?Please discuss your experiences.

2. What processing issues haveoccurred from crude oils containingelements such as arsenic, mercuryand selenium that pose health, safetyand environmental issues? Havethere been any recent improvementsin detection methodologies for heavymetals in crude oil? Have you hadsuccess using the desalter to removeheavy metals from crude oil?

3. What methods are used to removesolids from desalter effluent water?Can you provide design criteria forthese applications?

4. Are there any new technologies formonitoring desalter interface levels?How do they differ from conventionalfloats (internal and external), capaci-tance probes and agar probes? What parameters (service factor,serviceability, etc.) are important inselecting interface level detectors?

5. Many refineries are experiencingproblems with high conductivitycrudes or crude components. Howdo these conductive componentsaffect desalting? What precautionsshould refineries take when process-ing high conductivity crudes?

6. What has been your recent experi-ence with improved heat exchangertechnology (e.g. twisted-tube, helicalbaffle, plate and frame, rod-baffle) inheavy oil and crude preheat servic-es? What methods have been usedto effectively clean these bundles?What has been your experience withchemical vs. mechanical (high pressure water) cleaning? Pleasecompare the cost and effectivenessof each cleaning method.

Opportunity Crudes7. What problems have you experi-

enced processing crudes with high levels of amine-based H2Sscavengers?

8. What is your experience with pro-cessing high calcium content crudes(such as Doba)? What problems dohigh calcium levels cause and whatlevels of calcium can be toleratedwithout operating problems? Whatmitigation strategies have beenattempted (both successful andunsuccessful)?

9. Is there a correlation between highTAN jet fuel metals levels and JFTOTtest failure? Will a mild caustic washimprove stability?

10. What additives used in crude oil production and transportation impactcrude unit operation and reliability?What forums exist to discuss andevaluate impacts of existing and new chemicals used in crude oil production on crude unit operation?

Process11. How have you minimized entrainment

from the vacuum tower flash zone?Please describe the c-factor, wash oil contaminant levels, wash oil rate,and tower internals employed in yourmore challenging applications. Doyou collect the overflash / slop wax?Where is it routed? How do you minimize coking in the slop wax pip-ing, pumps, and meters?

12. What are the available options toboost diesel cetane other than conventional hydrotreating andhydrocracking? Is increasing distillateT90 a practical way to improve poolcetane?

Coker Operations13. What other feedstocks besides

vacuum tower bottoms or FCC slurryare fed directly to the coker (crude,fuel oil, recovered slop oil, etc.)?

14. What is your experience regardingthe maximum operating temperaturefor the coker fractionator bottoms liquid? What is the residence time at this temperature?

15. What is the typical overlap (ASTMMethod D2887, in °F) between theheavy coker gas oil (HCGO) 5% point and the light coker gas oil(LCGO) 95% point? What is yourLCGO D2887 95% target, and whatdetermines it?

Q&A and Tecnology Forum:Questions 1 – 15

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16. What range of energy consumption(MBTU/bbl) is typical for cokers?What process changes provide themost cost effective improvements inenergy efficiency, and what is thebest way to monitor energy consump-tion to ensure optimal performance?Is there a correlation between liquidyield and energy consumption?

17. Have you closed a water balancearound the coker furnace, drum andfractionator? What fraction of thewater comes from steam purges?What has been done to reduce steampurges? What are typical values forsour water production per barrel ofcoker feed? To what coking cycletime does this correspond?

18. To what coke drum outage do youoperate your cokers? Please reference the outage to the face ofthe top center nozzle, as well as thetop weld seam and tangent line. What are the average coke drumvapor velocities and drum diametersfor these outages?

19. If you are producing shot coke, whatis the estimated density of your cokewhile it is still in the coke drum andwhat is its estimated void fraction?

20. Is there a relationship between greencoke’s percent volatile matter (VCM)and calcined coke’s vibrated bulkdensity (VBD)? Does this relationshipchange with coker feed type?

21. In your experience, are coke drumhot spots (blowouts) related to feedproperties and/or coke drum operat-ing conditions? What indicators doyou use to predict hot spots? Whatsteps do you take to reduce theimpacts of hot spots?

22. Have you observed post-switch cokedrum foaming while initially steamingthe coke drums to blowdown? Whatcan cause this to occur, and how doyou minimize foaming?

23. Have you experienced elevated cokedrum vapor temperature (>300°F) atpressures below 5 psig after the cokebed is covered with water? How doyou explain this?

24. What is the most effective way toinject coke drum overhead quench?Should the injection be in the horizon-tal or vertical run of the vapor line?Are spray nozzles effective? What isyour typical frequency for cleaningvapor lines? Where is most of theplugging occurring in your system?

Coker Equipment25. What are your maximum allowed

coker heater tube metal temperaturesand how do you measure tube temperatures? How does metallurgy(5 or 9% chrome, stainless steel orhigh nickel alloy) affect this limit?Have you used ceramic-coated radiant tubes, and if so, has thisextended heater run length?

26. Do you have a split feed/dual entryinto your coke drums? Have therebeen problems with feed line plugging and keeping both flowpaths open?

27. What has been your experience withcoke drum switch valves (feed andvapor)? What are the pros and consof ball valves vs. Wilson-Snyderswitch valves?

28. What type of coke drum level detectors have you used and howsuccessful are they?


Notes

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Gasoline Processes

Alkylation29. What are the operational handles

used to increase product octanewhen alkylating propylene and/orisopentane?

30. How have you handled the isobuty-lene diverted from MTBE production?If it has been fed to the alkylation unit,describe the impact on alkylate yield,acid consumption, and octane.

31. What is the current status of solid bedalkylation technology? For thoseworking on this technology, how doesit compare in yield, octane, capitaland operating costs with current alkylation processes?

32. What is the optimum turnaround inter-val for alkylation plants? What bene-fits can be realized if the turnaroundinterval is out of step with that of theFCCU and what modifications needto be made to the alkylation unit toenable “out of step” intervals?

33. API Recommended Practice 751calls for all joints in HF acid service to be inspected at least once everyten years. How do you comply withthis recommended practice? Have you used non-destructive testingtechniques to avoid breaking and re-making flanges?

34. We have seen high corrosion rates inour spent acid degasser and run-down lines due to heated acid. Whatis your experience with operating thedegasser without heating, and isthere any downside to this operation?

35. What recent advancements havebeen made in sulfuric acid alkylationtechnology?

36. Have you had a de-isobutanizer feedline failure in a sulfuric acid alkylationunit? If so, what was the root causeand what steps did you take to prevent future incidents?

Ethanol37. Discuss how ethanol blending

requirements have impacted refiningoperations including: 1) blend formulations; 2) octane balance; 3) driveability specifications; 4) lab testing and procedures; and 5) reformer severities.

38. What needs to be considered torerun gasoline containing ethanol?

Extraction39. Corrosion issues have been encoun-

tered in solvent-based aromaticextraction units where the feeds arederived from naphtha reforming aswell as purchased reformates andthermally cracked naphthas.Purchased feedstocks are likely tocontain oxygen, potentially leading tocorrosion in oxygen strippers as wellas the extraction unit. What are thecorrosion mechanisms and how are they best addressed? Are therereliable methods to check for oxygeningress?

Hydrotreating40. How have you handled fouling/pres-

sure drop problems for the followingcases? 1) processing visbreaker orcoker naphtha mixed with straight run naphtha in a diene saturationreactor upstream of a hydrotreater forcatalytic reformer feed; 2) processingFCC light gasoline mixed with lightstraight run naphtha in a hydrotreaterupstream of a C5/C6 isomerizationunit?

41. How robust/flexible is your FCC gasoline post-treatment unit in termsof accommodating large changes infeed sulfur and/or feedrate?

42. What is a typical octane loss acrossan FCC gasoline hydrotreater?

Isomerization43. What is the commercial availability

of isomerization catalyst that can tolerate feed moisture in excess of100 ppbw? What are the moisturelimits for these catalysts? Describeyour experience with this type of isomerization catalyst.

44. What is the optimum turnaround interval for C5/C6 isomerization unitswhen the catalyst is not replaced?What are the differences betweenchlorided and non-chlorided isomer-ization catalysts? How does the dry out procedure change when chlorided catalyst is not changed outduring the turnaround?


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45. Chlorides can slip into LPG and isomerate streams during start upand unit upsets. Have you providedchloride guards for these streams?Describe your experience.

46. What octane do you actually achievein a once-through C5/C6 isomeriza-tion unit: 1) without deisopentanizingthe feed? 2) with deisopentanizedfeed? What is the maximum octanethat should be achieved in eachoperation?

Reforming47. Is sulfur injection (e.g. DMDS) to

avoid metal-catalyzed coke formationin a continuous catalyst regenerationreformer widely practiced? Describeyour experience.

48. What parameters do you use todetermine when to change the cata-lyst in a catalytic reforming unit? Arethese parameters the same in contin-uous regeneration, semi-regenerated(semi-regen), and cyclic units? In theselection of replacement catalysts forsemi-regen or cyclic units, how doyou decide whether to use Pt/Re catalysts with promoters, balancedPt/Re or skewed Pt/Re catalysts?

49. Comment on the reliability of“Johnson screen” (or other profilewire) internals in fixed bed reactors.What is your experience with repairing these internal parts? What types of repairs have been successfully implemented?

50. Describe any experience you mayhave with gasket failures in the cat-alytic reformer’s reaction circuit. Haveyou identified a type of gasket thatsolved the problem? Please specifythe type of process and the operatingpressure and temperature. Does yourrecommended gasket materialchange if the flanges are insulated?

51. Regarding the sulfiding step doneduring regeneration of a semi-regenreformer: 1) What is the purpose ofsulfiding the catalyst? 2) When in theregeneration procedure should thesulfiding step take place? 3) Whatsulfiding agent is used, andhow/where is the material injected? 4) What are the impacts of too littleand too much sulfiding material? 5) How do you know whether the sulfiding is complete? 6) Should thesulfiding procedure be changed asthe catalyst surface area decreaseswith successive regenerations?

52. What issues do you face when processing naphthas from syntheticcrudes? Specifically, what upgradesmay be required for hydrotreatingand reforming naphtha derived fromsynthetic crude?

53. What materials do you use for a semi-regen reformer’s product separator demister pad? What is atypical life for a demister pad?

54. Describe your experience with deformation of scallops in a semi-regen reformer, specifically related tolifting and/or bowing of profile wirescallops. What symptoms did youexperience while operating or whileregenerating the catalyst that pointedto this issue?


Notes

19

Hydroprocessing

Hydrogen55. Regarding hydrogen recovery,

please describe: 1) best practices for increasing hydrogen recovery; 2) current state-of-the-art in hydrogenrecovery; and 3) your benchmark forpercent hydrogen lost to fuel gas ormass balance closure.

56. What is your hierarchy for managinghydrogen sources for differenthydroprocessing units? What adjustments do you make when thehydrogen demand is greater thanhydrogen supply?

57. What are the mechanisms for steam-methane reformer catalystdeactivation? Are you more likely tosee deactivation in the top, middle or bottom of the reformer tube? What are the indications of this deactivation? How can conditions be optimized to prevent these localized problems?

58. What techniques do you use forsteam-methane reformer catalystloading? Are there others? What aretheir relative benefits?

59. What is the expected life of adsor-bents in pressure-swing adsorption(PSA) units? What contaminantsaffect or shorten life? What methodsdo you use to measure residual life?

Safety & Reliability60. How do you monitor furnace tube

metal temperatures? Compare the relative reliability and accuracy oftube skin thermocouples with that ofthermography.

61. What do you use to blanket yourhydrotreating feed drums? What arethe pros and cons of each blanketingmedium?

62. How do you ensure that emergencydepressuring valves and interlocksare functioning properly during long periods of non use? Are thereon-line methods to determine whether this equipment will operatewhen needed?

Catalyst63. What are the critical criteria for

ULSD catalyst selection? Can catalystselection be done by modeling aloneor is pilot plant testing required? How do you predict catalyst stability /deactivation?

64. What are the most common contaminants in ULSD feedstocks?What are the relative impacts ofarsenic, silicon, sodium, and othermetals? Are the effects of these contaminants the same for cobalt/molybdenum (Co/Mo) and nickel/molybdenum (Ni/Mo) catalysts?

65. Describe your experience with commercial regeneration of the newer Type II catalysts. What activityrecovery did you achieve?

66. ULSD catalyst suppliers reportedexpansion plans in 2005. What is thestatus of these announced plans andhow will they affect catalyst supplyand lead times for ordering catalyst?

ULSD67. How has ULSD catalyst performed

relative to predicted performance?What monitoring tools are you utilizing to optimize unit performanceand determine end-of-run for ULSDcatalyst?

68. Describe your experience producingULSD in a single bed or an under-sized reactor.

69. Are you using a hydrocracker to produce ULSD? If so, how is it integrated into your operation?

70. How do you handle cracked stocks in ULSD units? Please discuss thepercentage of cracked stocks in yourULSD unit feedstock. Describe yourpractices for “phasing in” crackedstocks in an ULSD unit.


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71. How have the qualities/properties ofFCC light cycle oil (LCO) changedfollowing implementation of highseverity FCC feed hydrotreating? Is it easier or harder to process theLCO into ULSD?

72. Have you used hydrocracking catalyst in the last bed of an ULSDunit to improve performance such asdesulfurization or aromatic saturation?Describe your experience.

73. How do you handle off-spec productwhen producing ULSD? Are off-specproducts immediately routed to different tankage or are other optionsconsidered? When making thesedecisions, are you relying on lab data or an on-line analyzer?

74. Does the actual (post start-of-run)hydrogen consumption in your ULSDunit(s) match the design conditions?Have you had to rebalance yourhydrogen system?

75. What methods are you using todetect leaks in feed/effluent heatexchangers in ULSD hydrotreateroperation? What preventive measuresare you taking to minimize leaks?


Process76. When processing unusual feedstocks

such as aromatic extracts from lubeoil processing, de-asphalted oils(DAOs), low-metal resids, etc. inhydroprocessing units, what issueshave come up (e.g. poly-nuclear aromatics condensation, excessivehydrogen consumption, severe deactivation, etc.)? What reliable correlations or analyses are availableto characterize unusual feedstocks,predict their hydrogen consumption,yield pattern, and product quality, etc.?

77. What do you do to take a hydropro-cessing unit to a “safe condition” forinterruptions that you expect to bebrief, e.g. a power outage that maylast a few hours? What do you do fora smooth recovery to full operationalstatus? What do you do differentlywhen the interruption may last 3-4days or more?

78. What options are available for lowpressure hydrotreaters (total pressure< 500 psig) for production of ULSDand low aromatics products? What isthe quantity and quality of the LCOthat can be processed in these lowpressure units?

79. What experiences have you had withhigh pressure drop in a reactor’slower bed? What were the likely causes? Do you have any effectivetechniques for preventing it?

80. Are you using real-time optimization(RTO) of hydrotreater/hydrocrackeroperations based on on-line analyses of feed and product qualities? Do you adjust operatingconditions based on catalyst activity/deactivation modeling?

Notes

21

FCC

Environmental81. In order to achieve a flare-less

start-up, how and when do you startup the wet gas compressor prior tointroducing feed to the unit. Whatstream do you use and how do youcontrol it?

82. To what extent does electrostatic precipitator (ESP) performancedecline over the operating cycle interms of opacity trends and dailyfines collection? Can a performancecurve be generated assuming constant conditions (similar upstreamprocessing, no change in regeneratorcyclones performance, and wellmaintained insulator purge)?

83. Our side-entry regenerator densebed has three temperature indicators(TI) whose readings are over 100°Fapart (colder near the spent catalystinlet). The unit has a modern air gridand a dense phase “ski jump” spentcatalyst distributor. We use the aver-age bed temperature in heat balancecalculations. Typical temperatures are1230-1315°F in the bed, 1290-1335°Fin the dilute phase, 1350-1400°F atthe cyclone outlets and 1405°F in theflue gas. Flue gas NOx is very lowwith less than 0.5 vol% O2 in thestack. What are the incentives for better bed temperature measurementand for reducing afterburn (and bed maldistribution)? What are theincentives for improving the spentcatalyst distributor design? Will oxygen enrichment improve or worsen temperature differentials?How can we minimize the risk ofincreasing NOx emissions if we make any modifications?

84. What is your experience with controlling FCC stack NOx emissionsduring partial burn operation? Pleasecomment on low-NOx CO boiler burn-ers, additive/catalyst applications,operating variable adjustments, andflue gas NOx conversion equipment.

85. Selective catalytic reduction (SCR)units have recently been added toreduce NOx from the FCC stack.What issues may limit the SCR unitfrom matching the 5-year cycle lengthfor the FCCU?

86. What are some design considerationsfor FCC flue gas scrubbers (FGS) to reduce the impact of excessivecatalyst loading that might occur during unit upsets? What monitoringequipment and operating practiceshave you employed to reduce the risk of acidic conditions downstreamof the FGS?

Catalyst87. Some ZSM-5 additives are designed

to maximize propylene productionwhile others maximize butylene. Whatrange of C3 vs. C4 ratio have youobserved with these additives?Describe the zeolite chemistry that iscontrolling the C3 vs. C4 selectivity.

88. How successful have you been inreducing FCC naphtha sulfur levels inthe FCC riser and reactor? What lev-els of FCC naphtha desulfurizationhave you achieved? How do keyreaction variables affect FCC naphthasulfur levels? What types of catalysttechnology are used for FCC gasolinesulfur reduction and what benefitshave you achieved?

Equipment89. What are the causes of catalyst fines

deposition in high velocity sections offlue gas systems (orifice chambers,third-stage separators, underflownozzles, and expander casings)? Are there specific operating parameters or catalyst/additive properties that are more likely toresult in fouling of this type?

90. What methods are you using to keeppower recovery expander bladesclean? Have you tried on-streamchemical cleaning? How effective arethese methods and what are some ofthe associated problems?

91. The addition of wet flue gas scrub-bers and possibly selective catalyticreduction (SCR) units increase thebackpressure on CO boilers or wasteheat boilers. What are the issues thatmust be considered if forced draft orinduced draft fans are added to keepthe existing boiler from being modi-fied? Have you chosen to install fansin this service? (Poll the audience)

92. Please describe your recent experi-ence with the use of ceramics in highvelocity areas for erosion resistance.In which equipment have ceramicsbeen used and how did it perform?

93. What types of isolation valves do you recommend for spent catalystunloading and for third-stage separator fines underflow?

94. What metallurgy do you recommendfor the spent catalyst unloading line?Please describe any failures that you may have experienced and their root causes. What operatingcontrols are necessary to eliminatethe failures and what is the best wayto monitor them?


22

95. The main fractionator bottoms slurrysettler typically has a pressure safety valve (PSV) for over-pressureprotection. Is this PSV sized to relievepressure from water vaporization that might occur during start-up asthe system is heating up?

96. What performance benefits have yourealized from installing structuredpacking in an FCC catalyst stripper?What operating difficulties have youencountered? How many turnaroundcycles has the packing been in serv-ice and what was the condition of thestructured packing when inspectedduring a turnaround?

97. What experience have you had withcoking of shell side bundles in FCCdebutanizer gasoline reboilers? Whatwas the reboiler inlet temperature ofthe heating medium and is there acritical temperature which has provento mitigate the coke formation? Doyou have any experience changingtube material from carbon steel tochrome (or other metallurgy) whichhas reduced coke formation?

98. Have you tried refrigerated cooling ofthe main fractionator overhead vapor(after air and water cooling) to unloadthe wet gas compressor? For whatcircumstances would you recom-mend refrigerated cooling? What isthe lowest practical overhead receiv-er temperature?


Process99. What procedures have you

employed to “pressure bump” theFCC reactor and/or regenerator during operations to dislodgeobstructions in cyclone dip legs ordischarge valves? Are any specialconsiderations required during aregenerator pressure bump if a flue gas expander is located downstream of the regenerator?What considerations are necessaryfor the main column overhead system when performing a reactorpressure bump?

100. What best practices have youemployed to ensure that FCC naphtha is on-spec for corrosion(copper and/or silver strip) immediately following start-ups from turnaround or outages?

101. What best practices have youemployed to ensure that LPG is on-spec for sulfur and mercaptansimmediately following start-ups fromturnarounds or outages? Are thereadditional best practices for thetreaters?

102. What are the potential causes ofexcessive foaming and carryover inLPG liquid-liquid amine contactors?

103. For cycle oil with a gravity close to that of water, conventional coalescing technology has beenineffective for adequate water separation. Are there advanced coalescer designs available for this application or is a different drying method more appropriate?

104. What key parameter affects the 90-day color stability of untreatedFCC light cycle oil? Which analyticalmethod is most reliable for predict-ing the color stability of this stream?What treatments are available andhow much improvement can beexpected?

105. Have you seen an increase in sourwater cyanide content or in incidentsof carbonate stress corrosion cracking in FCC units processinghydrotreated or low sulfur feeds?How does the sulfur to nitrogen ratio in the feed impact cyanide formation? How do you monitor thecorrosion potential?

106. What are typical phenol levels in thesour water from a FCCU and howcan the phenol be minimized?

107. Describe your experience process-ing extraneous naphtha streams inthe FCCU. What types of streamscan be upgraded? What factors areconsidered to determine the bestinjection point: pre-feed nozzle;mixed with feed; upper nozzle; stripper; or gas plant?

Notes

23


108. Describe your experience process-ing aromatic extracts generatedfrom Furfural and/or NMP extractionunits during the manufacture of lubeoil basestocks? Does crude originhave any impact (e.g. vacuum gasoil (VGO) and vacuum resid (VR)derived from Arab Mix / high sulfurMiddle East crude)? What is theimpact of the Furfural and/or NMPextraction on delta coke? What is theimpact on fouling in the main frac-tionator bottoms circuit? Are thereany reliable correlations to charac-terize feeds in these situations andpredict the impacts? In your opinion,should these types of materials beprocessed in the FCC?

109. What are the possible causes ofcoke formation in the first 10 feet ofthe riser above the feed injectionpoint? How is coke formationimpacted by feed distillation andriser mix zone design?

110. How often do you tune your FCCsimulation model (“tuning” is under-stood to include a complete heatand mass balance)? How often doyou use reactor mix sampling totune the model? How often do youtune your FCCU linear program(LP)? (Please poll the audience tosupplement the panel’s answers.)

111. When designing or revamping aFCC, under what operating condi-tions would you consider adding acatalyst cooler? In a retrofit case,what needs to be checked whenadding a catalyst cooler?

112. For units that operate in partial burn,what are typical compliance prac-tices to meet the MACT II 500 ppmCO standard when the CO boiler isshut down? What are the typicaloperating handles used in transition-ing from partial burn to full burn ifthis option is used for compliance?What are some ways to optimize theunit in this mode of operation?

113. For resid FCC units converted tooperation with lighter feeds, whatoptions are available to preventregenerator temperature from drop-ping below acceptable levels? Whatare the operating and economicconsiderations for each option?

24

Affiliate Directory

CB&IPaul W. Fisher9800 Centre ParkwaySuite 700Houston, TX 77036-8271Phone: [email protected]

Champion Technologies, Inc.Rhonda Puyau3200 S.W. FreewaySuite 2700Houston, TX 77027Phone: [email protected]

Chevron Lummus GlobalLori De Amaral100 Chevron WayBuilding 10, Suite 3318Richmond, CA 94801Phone: [email protected]

ConocoPhillipsWendy Olson600 North Dairy Ashford RoadHouston, TX 77079-1175Phone: [email protected]

Criterion Catalysts & Technologies L.P.Joyce HurstTwo Greenspoint PlazaSuite 100016825 Northchase DriveHouston, TX 77060Phone: [email protected]

Emerson Process ManagementSarah Danaher7070 Winchester CircleBoulder, CO 80301Phone: [email protected]

ExxonMobil Research & Engineering Co.Charlene Kegerreis3225 Gallows RoadRoom 3A2321Fairfax, VA 22037-0001Phone: [email protected]

GE Water & Process TechnologiesMichael Gibson9669 Grogan’s Mill RoadThe Woodlands, TX 77380Phone: [email protected]

Grace DavisonBetsy Mettee7500 Grace DriveBuilding 25, 2nd FloorColumbia, MD 21044Phone: [email protected]

Gulf Chemical & Metallurgical Corp.Nancy C. WollamP. O. Box 2290Freeport, TX 77542-2290Phone: [email protected]

Haldor Topsoe, Inc.Theresa Deisch10010 Bayport RoadPasadena, TX 77507Phone: [email protected]

Honeywell Process SolutionsStephen Clark7710 BroadviewHouston, TX 77061Phone: [email protected]

Air Products / Technip Hydrogen AllianceShirley Miller7201 Hamilton BoulevardAllentown, PA 18195-1501Phone: [email protected]

Albemarle CatalystsLinda Lopez2625 Bay Area Blvd.Houston, TX [email protected]

Axens North America, Inc.Mike Schmidt1800 St. James PlaceSuite 500Houston, TX 77056Phone: [email protected]

Baker Petrolite CorporationJerry Basconi12645 West Airport BoulevardSugar Land, TX 77478Phone: [email protected]

BASF Catalysts LLCTeresa Garcia1800 St. James PlaceSuite 400Houston, TX 77056Phone: [email protected]

BJ Chemical ServicesLee Ann MaxwellP.O. Box 1499Hobbs, NM 88240Phone: [email protected]

INTERCAT Inc.Jennifer RennickP. O. Box 412Sea Girt, NJ 08750Phone: [email protected]

Intertek PARCMichelle Kozlowski100 William Pitt WayPittsburgh, PA 15238Phone: 412-423-1120 [email protected]

Invensys SimSci-EsscorKathy Beckman26561 Rancho Parkway, SouthLake Forest, CA 92630Phone: [email protected]

Johnson Matthey PTCTina MossTwo TransAm Plaza Dr.Suite 230Oakbrook Terrace, IL 60181Phone: [email protected]

KBC Advanced Technologies, Inc.Tamra M. Daniels14701 St. Mary’s LaneSuite 300Houston, TX [email protected]

Koch Heat Transfer Company, LPRick Covey12602 FM 529Houston, TX 77041Phone: [email protected]

MatrikonRick Kaun10405 Jasper AvenueSuite 1800Edmonton, Alberta T5J 3N4 CanadaPhone: [email protected]

Nalco CompanySam Lordo7705 Highway 90ASugar Land, TX 77478Phone: [email protected]

OSIsoftCraig R. Harclerode738 Highway 6 SouthSuite 260Houston, TX 77079Phone: [email protected]

Pall CorporationDavid Fisher2118 Greenspring DriveTimonium, MD 21093Phone: [email protected]

Praxair Inc.John Olesen222 Pennbright DriveSuite 300Houston, TX [email protected]

Process Dynamics, Inc.Jon Skeds2434 Deane Solomon RoadFayetteville, AR 72704Phone: [email protected]

Prosys, Inc.Alan Thomas11814 Corsey Blvd.Suite 408Baton Rouge, LA [email protected]

Shaw Stone & WebsterGary Jackson1430 Enclave ParkwayHouston, TX 77077-2023Phone: [email protected]

Soteica LLCKevin Bishop16010 Barker’s Point LaneSuite 260Houston, TX 77079Phone: [email protected]

STRATCO, DuPont Refinery SolutionsPam Pryor11350 Tomahawk Creek ParkwaySuite 150Leawood, KS 66211Phone: [email protected]

Süd-Chemie Inc.Jill ParmanP.O. Box 32370Louisville, KY 40232Phone: [email protected]

UOP LLCMargaret Oak25 East Algonquin RoadDes Plaines, IL 60017-5017Phone: [email protected]

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Phoenix, Arizona 2006 NPRA Q&A and Technology Forum