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BOILERS FOR PEOPLE WHO KNOW AND CARE

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www.HydrocarbonProcessing.com

FEBRUARY 2011

HPIMPACT SPECIALREPORT TECHNOLOGYCLEAN FUELSCLEAN FUELSNew methods focus onNew methods focus onbottom-of-the-barrelbottom-of-the-barreland clean fuelsand clean fuels

Energy stocks offerEnergy stocks offerpositive returnspositive returnsAdvances in cellulosicAdvances in cellulosicbiofuel productionbiofuel production

Updates on flareUpdates on flaresystems and designsystems and designConsider new gasConsider new gasanalysis techniquesanalysis techniques

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XX Dewitt petrochemical-conference out look

XX Six strategic businesstechnologies to watch

XX Australia makingcrucial GTL decisions

XX IEA assesses energy poli-cies of U.S.

XX Creating more value incapital projects

HPIMPACT

Cutline for fig.00

cutline for fig00

cutline for fig00


FEBRUARY 2011 VOL. 90 NO. 2

SPECIAL REPORT: CLEAN FUELS

33

HPI Viewpoint: Consumer protection is a key issue for E15

NPRA wants to be sure that adding greater amounts of ethanol to gasolineis safe and will not cause engine damage C. T. Drevna

37Slurry-phase hydrocrackingpossible solutionto refining marginsOpportunity crudes require more hydrogen addition to upgradeorphan product streams into higher-value clean products

M. Motaghi, B. Ulrich and A. Subramanian

45Convert bottom-of-the-barrel into diesel and light olefins

Integrating residue hydrocracking operations with advanced fluid catalytic crackingoptimizes upgrading of heavy crude oils

M. Rama Rao, D. Soni, G. M. Sieli and D. Bhattacharyya

51What are the future fungible transportation fuels?Alternatives hold promises to decrease dependence on crude oil,

but they also uncover other challenges in distribution and engine useM. Stockle

57

How to fabricate reactors for severe service Many critical factors are involved in the design and welding of hydrocracking reactors

D. Quintiliani, G. Fossataro and M. De Colellis

63

Designing atmospheric crude distillation for bitumen service Oil sands add complexity to separation units and require a new approach

M. Grande and M. Gutscher

71

Minimize carbon footprint from Claus tail-gas units Reevaluate emissions efficiencies on sulfur-removal operations

M. P. Heisel and M. Rameshni

Cover Neste Oil started up the worldslargest and most advanced renewablediesel plant in Singapore in November2010. The plant was completedon-schedule and on budget, and it islocated at the industrial area of Tuas,in the southwestern part of Singapore.This facility has a production capacityof 800,000 tons based on the NestesNExBTL renewable diesel process;product is targeted for markets inEurope and North America. Nest Oil isconstructing a similar sized renewableNExBTL unit in Rotterdam with

start-up in the first half of 2011. Photocourtesy of Neste Oil.

HPIMPACT13 Energy stocks

outperformed marketindices in 2010

15 Team overcomesobstacles to cellulosicbiofuel production

COLUMNS

9 HPIN RELIABILITYAlignment choiceshave consequences

11 HPINTEGRATIONSTRATEGIESData historiansprovide effectivedecision support in

near real time

94 HPIN CONTROLInferential controlmodel input selection

GAS PROCESSING DEVELOPMENTS

79

Avoid these risks concerning combustion controlin fired heatersTuneable diode laser analyzers offer diagnostic benefits

R. Jenkins

PLANT SAFETY

85

Circumvent design issues when addingnew hydrotreating unitsFollow these guidelines for substantial capital cost savings with existing flare systems

M. H. Marchetti

DEPARTMENTS

7 HPIN BRIEF 19 HPINNOVATIONS 25 HPIN CONSTRUCTION

31 HPI CONSTRUCTION BOXSCORE UPDATE

90 HPI MARKETPLACE 93 ADVERTISER INDEX

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EDITORIALEditor Stephany RomanowProcess Editor Tricia CrosseyReliability/Equipment Editor Heinz P. BlochNews Editor Billy ThinnesAssociate Editor Helen Meche

European Editor Tim Lloyd WrightContributing Editor Loraine A. HuchlerContributing Editor William M. GobleContributing Editor Y. Zak FriedmanContributing Editor ARC Advisory Group

(various)

MAGAZINE PRODUCTIONDirectorEditorial Production Sheryl StoneManager Editorial Production Angela BatheArtist/Illustrator David WeeksManagerAdvertising ProductionCheryl Willis

ADVERTISING SALES

See Sales Offices page 92.

CIRCULATION +1 (713) 520-4440DirectorCirculation Suzanne McGeheeE-mail: [email protected]

SUBSCRIPTIONSSubscription price (includes both print anddigital versions): United States and Canada,one year $199, two years $359, three years$469. Outside USA and Canada, one year$239, two years $419, three years $539, digi-tal format one year $199. Airmail rate outsideNorth America $175 additional a year. Singlecopies $25, prepaid.

Because Hydrocarbon Processing is edited spe-cifically to be of greatest value to people work-ing in this specialized business, subscriptionsare restricted to those engaged in the hydro-carbon processing industry, or service and sup-ply company personnel connected thereto.

Hydrocarbon Processing is indexed by AppliedScience & Technology Index, by ChemicalAbstracts and by Engineering Index Inc.Microfilm copies available through UniversityMicrofilms, International, Ann Arbor, Mich.The full text of Hydrocarbon Processing is alsoavailable in electronic versions of the BusinessPeriodicals Index.

ARTICLE REPRINTSIf you would like to have a recent article reprint-ed for an upcoming conference or for use as a

marketing tool, contact Foster Printing Companyfor a price quote. Articles are reprinted on qual-ity stock with advertisements removed; optionsare available for covers and turnaround times.Our minimum order is a quantity of 100.

For more information about article reprints,call Rhonda Brown with Foster PrintingCompany at +1 (866) 879-9144 ext 194or e-mail [email protected].

HYDROCARBON PROCESSING (ISSN 0018-8190) is published monthly byGulf Publishing Co., 2 Greenway Plaza, Suite 1020, Houston, Texas 77046.Periodicals postage paid at Houston, Texas, and at additional mailing office.POSTMASTER: Send address changes to Hydrocarbon Processing, P.O. Box2608, Houston, Texas 77252.

Copyright 2011 by Gulf Publishing Co. All rights reserved.

Permission is granted by the copyright owner to libraries and others regis-tered with the Copyright Clearance Center (CCC) to photocopy any articlesherein for the base fee of $3 per copy per page. Payment should be sentdirectly to the CCC, 21 Congress St., Salem, Mass. 01970. Copying for other

than personal or internal reference use without express permission is prohib-ited. Requests for special permission or bulk orders should be addressed tothe Editor. ISSN 0018-8190/01.


GULF PUBLISHING COMPANY

John Royall, President/CEORon Higgins, Vice President

Pamela Harvey, Business Finance ManagerPart of Euromoney Institutional Investor PLC.

Other energy group titles include:World Oil

Petroleum Economist

Publication Agreement Number 40034765

Printed in U.S.A

Houston Office: 2 Greenway Plaza, Suite 1020, Houston, Texas, 77046 USAMailing Address: P. O. Box 2608, Houston, Texas 77252-2608, USAPhone: +1 (713) 529-4301, Fax: +1 (713) 520-4433E-mail: [email protected]

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www.uhde.euUhde

A fruitful partnership.To help secure future food supplies, Uhdes engineers develop large-scale

plants for the fertiliser industry.As a leading EPC contractor, we also have a proprietary portfolio of

technologies. And we network intelligently within the Uhde group based on

our business philosophy Engineering with ideas.


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8/97HYDROCARBON PROCESSING FEBRUARY 2011

I 7

The US does not have the infra-structure to meet the federal man-date for renewable fuel use withethanol but could meet the standardwith significant increases in cellulosicand next-generation biofuels, accord-ing to a Purdue University study.

The reports authors used USDepartment of Energy (DOE) and

Environmental Protection Agency(EPA) data to determine that the USis at the blending wall, the satura-tion point for ethanol use. Withoutnew technology or a significantincrease in infrastructure, the studypredicts that the country will not beable to consume more ethanol than isbeing currently produced.

The US federal renewable fuelstandard requires an increase ofrenewable fuel production to 36 bil-lion gallons per year by 2022. About13 billion gallons of renewable fuel

was required for 2010, the sameamount the report predicts is thethreshold for US consumption.

The study contends that there sim-ply are not enough flex-fuel vehicles,which use an 85% ethanol blend,or E85 stations to distribute morebiofuels. According to EPA estimates,flex-fuel vehicles make up 7.3 millionof the 240 million vehicles on thenations roads. Of those, about 3 mil-lion of flex-fuel vehicle owners arenteven aware they can use E85 fuel.

There are only about 2,000 E85fuel pumps in the US, and it took

more than 20 years to install them.In order for the US infrastructureto match the numbers in the fed-eral mandate, the studys authors say2,000 pumps a year would need tobe installed through the year 2022.They also note that E85 needs to besubstantially cheaper than gasolineto entice consumers to use it, becauseE85 gets lower mileage.

The report says that advances inthe production of thermo-chemicalbiofuels, which are created by usingheat to chemically alter biomass andcreate fuels, would be necessary tomeet the renewable fuel standard. HP

[email protected]

BILLY THINNES, NEWS EDITOR

HPIN BRIEF

Marathon Oil Corp. is moving forward with plans to spinoff Marathons downstream business, creating two independent energy companies.Marathon Petroleum Corp. (MPC), to be headquartered in Findlay, Ohio, is expected tobe the fifth largest US refiner with a downstream portfolio of strategically aligned assetsconcentrated mainly in the Midwest, Gulf Coast and Southeast regions of the US. Thespin-off is expected to be tax-free and to be effective June 30, 2011. Marathon Oil Corp.will be a global upstream company with a portfolio of assets delivering defined growthleveraged to crude oil production and with exploration upside. It will continue to bebased in Houston, Texas.

PetroChina International is forming a partnership with INEOSfornew trading and refining joint ventures related to refining operations in Grangemouth,Scotland, and Lavra, France. All companies will work toward the formation of the pro-

posed joint ventures by the end of June 2011. Underlying the international importanceof PetroChinas and INEOS collaboration, the official signing ceremony for the agree-ments was witnessed by Nick Clegg, the British deputy prime minister, and Li Ke Qiang,the Chinese vice premier. The deal will create a strategic partnership between the twocompanies, and INEOS believes it will improve the long-term sustainability of its refiner-ies, enhance security of supply for customers, and secure jobs in both the UK and France.

Axens North America has signed an agreement with CriterionCatalysts and Technology and Shell that allows for the purchase of Criterions catalyticreforming catalyst business. The specifics of the deal allow Axens to obtain CriterionsWillow Island, West Virginia, manufacturing plant for reforming catalyst and appropri-ate intellectual property rights to pursue such business.

KBR and SK Innovation started up an advanced catalytic olefins(ACO) demo plant in Ulsan, South Korea. Operations to date have met the companiesexpectations for olefins production, particularly propylene, with improved economicsrelative to steam cracking due to the technologys higher total olefins yields and increasedpropylene/ethylene ratios approaching 1.0. The startup marks the first commercial dem-onstration of the ACO process. The demonstration unit achieved a design feed rate asscheduled in late October 2010. The ACO process provides an alternative to naphthasteam crackers, and, according to KBR, not only does it offer higher olefins production,the process also produces a lower emissions footprint than a conventional cracker.

Iraqs South Oil Co. has awarded Emerson Process Managementa contract to provide crude-oil metering systems and related technologies for the newAl-Basra oil terminal now under construction in the Persian Gulf. The new terminal,

which includes both onshore and offshore facilities, will boost Iraqs oil-export capacityby 2.7 million bpd. The added capacity will give Iraq increased access to global marketsas it expands production from its southern oil fields. Emersons metering systems willmeasure the amount of oil as custody is transferred from producers to shippers throughthe Al-Basra terminal. The systems combine ultrasonic measurement technology withdiagnostic software that can detect potential problems before they affect accuracy.

Gushan Environmental Energy, a producer of biodiesel in China,is in the process of assessing the effect of a recently issued notice on consumption taxfrom the Chinese Ministry of Finance and the Chinese State Administration of Taxation.The notice regarding the exemption from consumption tax on pure biodiesel made fromwaste animal fats or vegetable oils was issued on December 24, 2010, and became effec-tive immediately. It clarifies that pure biodiesel made from waste animal fats or vegetable

oils is exempted from consumption tax in China, and that such exemption will be imple-mented retroactive to January 1, 2009. HP

Ethanolinfrastructurelacking

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I have someone retiring after 33 years on the job.I have someone taking 33 years of experience with him.And now someone with just

3 years has to do that job.

The Emerson logo is a trademark and a service mark of Emerson Electric Co. 2011 Emerson Electric Co.

With new Human Centered Design technologies from Emerson, its like the experiencenever left. Using our deep insights into how your people perform their roles and tasks, Emerson

is designing all of our new products based on the science of Human Centered Design. This lets us

embed the same experience and understanding thats walking through your plant into our control

and monitoring technologies making them the easiest and most intuitive to use. Tasks are

accomplished in fewer steps, and with greater confidence, even when relying on less expertise

and specialization. Its the certainty that jobs are done right, no matter whos doing them. Find the

experience youve been missing at EmersonProcess.com/Experience

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HEINZ P. BLOCH, RELIABILITY/EQUIPMENT EDITOR

HPIN RELIABILITY

[email protected]

HYDROCARBON PROCESSING FEBRUARY 2011 I

9

Optimists tell us about steady industry trends toward reli-ability-imparting procedures and work processes, while realistscontinually make us aware of pressures to reduce expenditures.As outside observers, we affirm that striving to reduce monetaryoutlay is quite commendable, but only as long as these aims dontrun counter to the professed longer-term reliability improvementobjectives. Conflicting issues are often alluded to in queries thatwe receive from readers. For instance, we were asked if we knewof literature that quantifies the merits of precision alignment for

pumps, and if its really appropriate to shun old-style methods.

Modern vs. old school. With modern alignment methodstaking no more time than tinkering with old-style methods, com-mon sense should point toward using precise methods. Inad-equate alignment still causes major calamities (Fig. 1); whereas,the results of sound alignment approaches typically show up asimproved mean time between repairs (MTBR) and a reductionin maintenance outlay. The November 2006 HPIn Reliabilitycolumn shed additional light on this topic.

A likely consensus among reasonable people holds that preci-sion alignment typically lowers vibration to half of the value ofconventional alignment. Fig. 2 represents an estimate of bear-

ing operating life extension due to reduced vibration velocity fortypical process pumps. Fig. 3 gives an indication of how a majorbearing manufacturer rates the effects of misaligned bearings.Most rolling element bearings fit somewhere between the twocurve boundaries and at tangents below 0.001; bearing life isthought to exceed a relative rating of 1.2

On average, there is then reason to believe that precision align-ment alonewould result in a pump MTBR multiplier of somewherebetween 1.4 and 1.7. The problem is that best-of-class performersinevitably implement additional upgrades and they will seldom con-fine their work to just better alignment. That is why Ref. 1 puts the

pump MTBR of a very marginal performer at 1.6 years, while bestperformers often get 9 years or more between pump failures. HP

LITERATURE CITED

1 Bloch, H. P. and A. Budris, Pump Users Handbook: Life Extension, ThirdEdition, 2010, Fairmont Press, Lilburn, GA 30047; (ISBN 0-88173-627-9).

2 Leibensperger, R. L.; Look beyond catalog ratings, Machine Design,April 3, 1975.

Alignment choices have consequences

The author is Hydrocarbon Processings Reliability/Equipment Editor. A

practicing consulting engineer with almost 50 years of applicable experience, headvises process plants worldwide on failure analysis, reliability improvement and

maintenance. He has authored or co-authored 18 textbooks and close to 500

papers or articles dealing with related subjects.

Process pump failure that started with misalignment, high

vibration and bearing distress. Source: Murray & Garig ToolWorks, Baytown, Texas.

FIG. 1

0.0

0.0 0.1 0.2 0.3

Vibration, ips0.4 0.5 0.6 0.7

0.2

0.4

0.6

Life,

ofL10a%0.8

1.0

1.2

Bearing housing vibration velocity vs. bearing life forprocess pumps.1

FIG. 2

0.000

0.00

0.50

0.00

0.75

1.00

1.25

1.50

0.001 0.002 0.003

Tangent of misalignment angle

Relativebearinglife

0.004 0.005 0.006

How tangent of misalignment angle affects bearing life.FIG. 3

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of tomorrowtoday

Growingthe green fuelsOur partnership is designed to help refiners realize

the potential of processing biomass into green fuels.

Our green is growing.

Visit us on the web at www.fwc.com/green and www.petroalgae.com


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ALLEN AVERY, CONTRIBUTING EDITOR

HPINTEGRATION STRATEGIES

[email protected]


11

Plant data historians are moving beyond their traditional roleas a tool for collecting and archiving data to better understandpast plant performance, to becoming a powerful tool that canbe used to improve real-time operations. With increased datathroughput and higher data resolutions, historians have alsobecome a foundation for plant asset management initiatives,thanks to new visibility and trending tools that can also be usedto support energy management programs. Todays historians alsosupport techniques, such as complex event processing, which can

analyze multiple streams of plant data in real time to identify anddiagnose emerging problems before they disrupt the productionprocess in the plant, or negatively affect smart grids or otherdistributed assets.

Plant historians get enhanced functionality. Recentproduct advances increase historian data throughput, solutionscalability, compatibility and connectivity with plant systemsand third-party solutions. They provide powerful visualizationand analytical tools. These allow users to access and leveragehuge volumes of plant data in near real time. Historians cancollect and display real-time data and events, giving users amore comprehensive view of what is happening in a plant or

distributed assets. Powerful processing capabilities, coupled withadvanced software algorithms, have changed how historians areused. Historians are transitioning from their traditional role, asplant record-keepers and planners, to tools that can have a posi-tive impact on plant operations in real time.

With recent advances in computing technology, includ-ing 64-bit processing architectures, historians can collect andstore large amounts of plant and process information. Manycan archive up to several exabytes of data. Many can simul-taneously store and retrieve plant data, giving users an up-to-the-minute view of plant performance. Todays historians canhandle hundreds of thousands of discrete events per second, soreal-time plant data is available almost immediately for analysis.

Modern computing power has enhanced historians to such adegree that, rather than just being used to look back on plantperformance, they can be used to predict and positively impactfuture performance.

The use ofde facto standards and environments, such as OPCand Microsoft .NET, allows easier interfacing between systemsand different historians. This helps users leverage existing his-torian data, even if they choose a new solution from a differentvendor. OPC compatibility also enables easy access to, and useof, data from HMI, DCS, CMMS and other plant-level appli-cations. Since suppliers are also beginning to offer OPC-UAcompliant products, historian data is now also readily available toapplications running on non-Microsoft platforms. In addition to

plant-level equipment, historians also interface well with EAM,ERP and advanced optimization applications.

Historian suppliers have worked to offer improved dataaccess and visibility tools with their solutions. Many offer web-based, thin-client access to historians, and most offer access tohistorian data via mobile devices. Powerful trending and graph-ics tools allow users to generate custom reports and charts tovisualize plant data. Suppliers have also emphasized ease of useand configuration in their product development. Users can easilycreate custom interfaces and role-based dashboards to view andmanipulate historian data.

Due to their high data capture rates, todays historians canact as a foundation for plant asset management programs.The ability to store, access and analyze plant data in near realtime can help users identify any anomalies or troubling perfor-mance trends that could indicate a problem with productionequipment. Historical data can be used to develop models orprofiles that help users determine how a given asset shouldbehave under normal conditions, and to set alarms or formulatemaintenance strategies to balance production needs with assetviability, remotely and in real time. We expect historians toplay a role in energy-management initiatives as well, by help-ing to develop energy-consumption models that can be usedto identify under-performing and inefficient plant equipment,

or to make real-time adjustments to production to minimizeenergy costs.

Coming soon: Complex event processing. Though inits infancy, complex-event processing is another technology thatcan harness the capabilities of plant historians. Historians can beused to complement and augment complex event processing, atechnology that can analyze multiple incoming streams of datain near real time. When viewed individually, these streams mightmean little. But when viewed simultaneously and in context,they could help identify process or plant equipment problemsusing advanced data filtering and algorithms.

ARC analysts are following recent trends in data historians

closely. These include the evolution of many plant historiansfrom large-capacity historical data repositories, to real-timedecision-support and business intelligence platforms, andulti-matelyto platforms that enable real-time operations centersfunctionality for a single plant or even a set of plants. HP read-ers should stay tuned to this column, or visit www.arcweb.comfor details on future reports on this important topic. HP

Allen Avery is an analyst at ARC Advisory Group. His focus areas include fieldsystems (flow, level, pressure, temperature and gas detection) and wireless networks.

In addition, he covers plant asset management, energy management issues, and

SCADA systems. He recently completed an extensive end-user study on energy

management practices, and is the author of the report SCADA Systems Oil & GasIndustry Worldwide Outlook.

Data historians provide effective decision supportin near real time

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SD-CHEMIEpatricia.hesse@sud-chemie.comwww.defining-the-future.com

Industry executives, technical experts and analysts will be discussing the latest innovations and breakthroughs in catalysis, processengineering, battery materials and water treatment technologies applied in these fields at the Defining the Future V Conference.Through open exchange and in-depth discussion, it is our goal to offer valuable insight into opportunities and challenges the industriesare facing, and to support the formulation of strategies that can be developed to address them. This conference will be comprised ofparallel sessions on:

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Please mark your calendar and join us in Beijing!

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I13

HPIMPACT

Energy stocksoutperformed marketindices in 2010

Despite a poor start, 2010 finished asa wonderful year for energy investors,with more than 65% of oil and gas stocksdelivering positive returns last year, accord-ing to a report from IHS Herold. Driven byeconomic growth, crude prices, which hitbottom in late May 2010 at around $65per barrel, rose steadily and consistentlythrough the second half of the year, and

took oil company shares with them.The median gain for the 503 stocks cov-

ered in the report was 21%, which, whileit did not match the record-setting 59%gain posted in the 2009 IHS report, didoutperform the market indices of nearlyall Organization for Economic Coopera-tion and Development (OECD) countries.Total capitalization jumped by more than$300 billion, further reducing the severelosses the sector incurred in 2008 the reportsaid, but did not extinguish them.

Sometime in the first quarter of 2009,

equity markets began to move upward inresponse to the economic growth that wasbecoming apparent in OECD countries,said Robert Gillon, senior vice presidentand co-director of energy equity researchat IHS. It seemed as though every statisticthat confirmed expansion was under waywas reflected in a rise in the price of crude,which boded well for oil stocks. That pat-tern continued throughout the year, withoil prices and oil shares at a recovery highat the closing bell of 2010. In particular,North American oil stocks delivered the

most returns to their investors.

Group returns. After finishing second-to-last as a peer group in 2009, US royaltytrusts earned redemption by taking tophonors in 2010 as the best-performingpeer group reviewed, posting a gain of morethan 44%. MV Oil Trust led the group byposting a return of 111%.

Companies in the E&P limited incomepartnerships group followed closely withgains of nearly 43%. According to the IHSreport, these survey-leading returns were

in response to monetary stimuli by numer-ous central banks, where open-market

interest rates fell to the lowest levels seenin decades, which forced yield-consciousinvestors to take on more risk in order tomaintain their desired level of income.

The vast amount of liquidity beinginjected into the economic system, par-ticularly in the US, has resulted in a strongcorrelation between equity prices and oilprices, Mr. Gillon said. By contrast,for many years prior to 2009, there wasa reverse relationship, with higher crudeprices perceived to cause a reduction in dis-posable income, lower consumer spending,

and declining domestic product and stockprices. To our mind, this is the normal stateof affairs, but to predict we will be back tonormal in short order would be unwise.

As a group, master limited partnerships(mostly pipeline and storage companies)enjoyed a hearty gain of nearly 35%, whilethe peer group of integrated oil stocks with

US downstream returned 22%, which wasmarginally above the survey average. Cana-dian integrated oil stocks and integrated oilstocks without US downstream operationsgained less than half that amount, at 10%and 9%, respectively. Returns from the lat-

ter group, the report said, were draggeddown by the generally poor performanceof European markets. On the other hand,shares in the refining and marketing cat-egory offered a healthy median gain of 38%and did well globally as demand for distil-lates rose with increasing economic activity.

Among the largest integrated and diver-sified oils group, top-ranked Ecopetrols84% gain reflected rapidly growing oil pro-duction, and it also got an updraft fromthe soaring Bogot market. Sunoco Inc.and Valero Energy, last years bottom two

performers in this grouping, moved intothe top 10 due to a dramatic turnaround in

refining margins. BHP Billiton is the onlymember of the 2009 crop to repeat in thetop 10 this year.

Natural gas.While oil stocks carried thesector in 2010, continued weakness in theNorth American natural gas market did notprevent the large producers from generatingsolid shareholder returns, with the medianperformance of the group nearly matchingthat of the entire survey. However, a highconcentration of North American naturalgas in the production mix detracted from

returns, since US natural gas spot prices,which began the year at what now seemslike the lofty price of $6/MMBtu, ended theyear at a nine-year low for the date, whichwas about 30% below where they began.

Natural gas inventories were wellabove average, and US domestic produc-tion showed no signs of topping out, Mr.

Gillon said. Fortunately for everyone butthe Europeans, it has been ferociously coldin Europe, so gas is being shipped to thehigher-priced markets. The world is wellsupplied with gas, and the modest upwardslope to the current futures curve is testi-

mony to the glut in supply.

Alternative energy. Stocks in the alter-native energy group held the basementposition as worst in class, posting losses ofmore than 24% after gaining 26% in 2009.

Were not sure what to say about alter-native energy, except perhaps a requiem. Inthe five years we have shown this segment inthe survey, it has been the worst performinggroup twice, second worst twice, and soaredto fourth from the bottom on one happyoccasion, Mr. Gillon said. They suffer

when natural gas prices go down, when gov-ernment subsidies are cut, when the wind

BILLY THINNES, NEWS EDITOR

[email protected]

The vast amount of liquidity being injected into the

economic system, particularly in the US, has resulted in a

strong correlation between equity prices and oil prices,

Mr. Gillon said. By contrast, for many years prior to 2009,

there was a reverse relationship, with higher crude prices

perceived to cause a reduction in disposable income

and lower consumer spending.

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HPIMPACT

15

doesnt blow, when it blows too much, andwhen the sun doesnt shine. There may beother problems, as well, which we will prob-ably find out about in 2011.

Team overcomesobstacles to cellulosicbiofuel production

A newly engineered yeast strain cansimultaneously consume two types of sugarfrom plants to produce ethanol, researchersreport. The sugars are glucose, a six-carbonsugar that is relatively easy to ferment; andxylose, a five-carbon sugar that has beenmuch more difficult to utilize in ethanolproduction. The new strain, made by com-bining, optimizing and adding to earlieradvances, reduces or eliminates several

major inefficiencies associated with cur-rent biofuel production methods.

The findings, from a collaborative ledby researchers at the University of Illinois,the Lawrence Berkeley National Labora-tory, the University of California and BP,are described in the Proceedings of theNational Academy of Sciences. The EnergyBiosciences Institute, a BP-funded initia-tive, supported the research.

Yeast strains. Yeasts feed on sugar andproduce various waste products, some of

which are useful to humans. One type ofyeast, Saccharomyces cerevisiae, has beenused for centuries in baking and brewingbecause it efficiently ferments sugars and,in the process, produces ethanol and carbondioxide. The biofuel industry uses this yeastto convert plant sugars to bioethanol. Andwhile S. cerevisiae is very good at utilizingglucose, a building block of cellulose andthe primary sugar in plants, it cannot usexylose, a secondarybut significantcom-ponent of the lignocellulose that makes upplant stems and leaves. Most yeast strains

that are engineered to metabolize xylose doso very slowly.

Xylose is a wood sugar, a five-carbonsugar that is very abundant in lignocellu-losic biomass but not in our food, saidYong-Su Jin, a professor of food science andhuman nutrition at Illinois and a principalinvestigator on the study. Most yeast can-

not ferment xylose.A big part of the problem with yeasts

altered to take up xylose is that they willsuck up all the glucose in a mixture beforethey will touch the xylose, Dr. Jin said. A

glucose transporter on the surface of theyeast prefers to bind to glucose.

Its like giving meat and broccoli to mykids, he said. They usually eat the meatfirst and the broccoli later.

The yeasts extremely slow metabolism

of xylose also adds significantly to the costof biofuels production.

Dr. Jin and his colleagues wanted toinduce the yeast to quickly and efficientlyconsume both types of sugar at once, a pro-

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Illinois University food scienceand human nutrition professorYong-Su Jin, center, and hiscolleagues engineered a yeast

that outperforms the industrystandard.

FIG. 1

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HPIMPACT

16

cess called co-fermentation. The researcheffort involved researchers from Illinois, theLawrence Berkeley National Laboratory,the University of California at Berkeley,Seoul National University and BP.

Adjustments. In a painstaking processof adjustments to the original yeast, Dr. Jinand his colleagues converted it to one thatwill consume both types of sugar faster andmore efficiently than any strain currently in

use in the biofuel industry. In fact, the newyeast strain simultaneously converts cel-lobiose (a precursor of glucose) and xyloseto ethanol just as quickly as it can fermenteither sugar alone.

If you do the fermentation by using

only cellobiose or xylose, it takes 48hours, said post-doctoral researcher andlead author Suk-Jin Ha. But if you do theco-fermentation with the cellobiose andxylose, double the amount of sugar is con-

sumed in the same amount of time andproduces more than double the amountof ethanol. Its a huge synergistic effect ofco-fermentation.

The new yeast strain is at least 20%more efficient at converting xylose to etha-

nol than other strains, making it the bestxylose-fermenting strain reported in anystudy, Dr. Jin said.

Critical changes. The team achievedthese outcomes by making several criticalchanges to the organism. First, they gavethe yeast a cellobiose transporter. Cellobi-ose, a part of plant cell walls, consists of twoglucose sugars linked together. Cellobiose istraditionally converted to glucose outsidethe yeast cell before entering the cell throughglucose transporters for conversion to etha-

nol. Having a cellobiose transporter meansthat the engineered yeast can bring cellobiosedirectly into the cell. Only after the cellobi-ose is inside the cell is it converted to glucose.

This approach eliminates the costly stepof adding a cellobiose-degrading enzyme tothe lignocellulose mixture before the yeastconsumes it.

It has the added advantage of circum-venting the yeasts own preference for glu-cose. Because the glucose can now sneakinto the yeast in the form of cellobiose, theglucose transporters can focus on drawing

xylose into the cell instead.

Bottleneck solutions. The team thentackled the problems associated with xylosemetabolism. The researchers inserted threegenes into S. cerevisiae from a xylose-con-suming yeast, Picchia stipitis. The teamidentified the bottleneck in this metabolicpathway. By adjusting the relative produc-tion of these enzymes, the researchers elimi-nated the bottleneck and boosted the speedof xylose metabolism in the new strain.

They also engineered an artificial iso-

enzyme that balanced the proportion oftwo important co-factors so that the accu-mulation of xylitol, a byproduct in thexylose assimilitary pathway, could be mini-mized. Finally, the team used evolutionaryengineering to optimize the new strainsability to utilize xylose. The cost benefitsof this advance in co-fermentation are verysignificant, Dr. Jin said.

We dont have to do two separate fer-mentations, he said. We can do it all inone pot. And the yield is even higher thanthe industry standard. We are pretty sure

that this research can be commercializedvery soon. HP

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Background

The EPAs New Source Performance Standards (40 C.F.R.60.100-1-0, subpart Ja) regulates refinery particulate emissions,including the discharge of catalyst fines from the FCCU flue gasscrubber stack.

Because refiners have traditionally correlated particulate matter(PM) emissions with FCCU cokeburn, high flue gas stack PM canresult in reducing severity or throughput in the FCCU at a potentiallyhuge economic cost. The proper selection of mass transfer internalsin the scrubber can contribute to its performance in controlling PMemissions, and can improve the refinerys bottom line.

A unit turnaround is a prime opportunity for the refiner to addresssuch issues as de-entrainment section fouling, chimney tray plug-ging, and overall poor performance contributing to stack PM.

Removing Solids with a Flue Gas Scrubber

Flue gas scrubbing is one method to control particulate and SO2

inFCCU flue gas vents. In scrubbers with external venturis, the flue

gas is mixed with water and caustic to neutralize SOX. The com-bined stream enters a disengaging drum through large venturis,where centrifugal force is used to separate the liquid from the fluegas. The flue gas then travels upward toward the stack. A bed ofstructured grid packing is used to eliminate entrained droplets thatcontain particles of catalyst or salt. The condensate is collectedin a chimney tray and drained to the bottom of the disengagingdrum. The scrubbed and de-entrained vapor is allowed to exit thescrubber stack.

Design of the Chimney Tray

A Sulzer chimney tray design for flue gas scrubbing service fea-tures a sloping floor to prevent solids accumulation and multiplesmall chimneys. The open area is sized to minimize pressure drop,

while the riser arrangement allows for the best distribution into thepacked bed.

Selection of Packing

Grid-type structured packing is used in direct-contact heat trans-fer, scrubbing, and de-entraining services such as the FCC flue gasscrubber. Due to its high open area, grid has a very low pressuredrop and high capacity. Grids have low wetting rates compared withstructured packing, and can therefore achieve low turndowns.

An excellent option for de-entrainment in the flue gas stack is SulzerMellagridTM, which has a smooth surface to provide the maximum

Sulzer Chemtech

Tower Technical BulletinProper Design of Mass Transfer Internals in the FCC Flue Gas Scrubber Can HelpReduce PM Emissions

fouling resistance and is designed to be self-draining to avoid anysolids trap-out problem. The Mellagrid smooth angles and transi-tions minimize shearing of liquid droplets, aiding in droplet settling.

The Sulzer F-GridTM or Nutter GridTM can be utilized as drop-inreplacements for an existing flue gas scrubber de-entrainment bedduring a turnaround, or Sulzer can customize the grid design foroptimum capacity, pressure drop, efficiency, and fouling resistancewith a combination bed.

Design of the Grid Wash Sprays

Scrubber packing is subject to plugging from the residual salts andcatalyst fines that are removed from the flue gas. A set of wash spraysis positioned above the bed for a periodic solids removal water wash.

High stack velocities can entrain the spraying wash water overhead,not allowing adequate washing of the grid. Sulzer takes this intoconsideration in our design of the spray header, with the selectionof nozzle type and nozzle pressure drop keeping the droplet sizeslarge and preventing re-entrainment. The sprays would be designedto fully cover the cross sectional grid area with sufficient overlap toaccount for some droplet carry-up.

Sulzer F-Grid

TM

and Sulzer Mellagrid

TM

Grid Packing

The Sulzer Refinery Applications Group

Sulzer Chemtech has over 50 years of operating and design experi-ence in refinery applications. We understand your process and youreconomic drivers. Sulzer has the know-how and the technology toprovide a scrubber internals design with reliable, high performance.

Sulzer Chemtech, USA, Inc.8505 E. North Belt Drive | Humble, TX 77396Phone: (281) 604-4100 | Fax: (281) [email protected]

Legal Notice: The information contained in this publication is believed to be accurate and reliable, but is not to be construed as implying any warranty or guarantee of performance. Sulzer Chemtechwaives any liability and indemnity for effects resulting from its application.


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HPINNOVATIONS


19

SELECTED BY HYDROCARBON PROCESSING EDITORS

[email protected]

Siemens expands anaerobic-digestion product offeringSiemens Water Technologies has

acquired the JetMix hydraulic mixing sys-tem from Liquid Dynamics Corp. Thisproprietary system agitates sludge withinthe anaerobic digestion process, optimizingdigestion and methane production. Thelatter can be captured and used as energywithin a wastewater treatment facil ity.Compared to similar mixing systems, theJetMix system allows operators to schedulemixing timesreducing power usage by

60%80% without decreasing gas produc-tion or negatively affecting volatile solidsreduction. Suitable for use in new instal-lations, as well as for retrofits or upgradesfor a variety of municipal and industrialapplications, the JetMix system comple-ments Siemens existing line of equipmentand solutions for anaerobic digestion.

The JetMix system creates an effectivemixing volume rating of 95% or more,even with internal piping and roof supportcolumns. The system uses powerful jetsto maintain or resuspend solids. Nozzles

mounted inside the tank can be rotated360 to create a flow pattern that virtuallyeliminates solids settling, reduces energyrequirements, and makes dead spots obso-lete. A top nozzle effectively controls scumand grease as well as foam and other floata-bles. The modular design of the JetMix sys-tem allows for various pumps and nozzlesto be used in combination to meet a widerange of application requirements and loadfluctuations. Viscosity, particle size, density,settling rate and tank geometry are all con-sidered when designing the mixing system.

The mixing system can be paired withthermophilic and mesophilic digesters, andcan be coupled with heat exchangers. Thesystem can be used in channels as well asin circular, square and rectangular tanks.Suitable applications include tanks withgas holders, or fixed and membrane roofs,with the tanks located either above orbelow ground.Select 1 at www.HydrocarbonProcessing.com/RS

Accurate field calibratormeasures differential pressure

Crystal Engineering is releasing a sig-nificant addition to their nVision Refer-

ence Recorder. This most recent (and free)quarterly update enables the intrinsicallysafe, hand-held field calibrator to graph andrecord average and differential pressure data.

Now, the nVision (Fig. 1) can display,record and graph differential pressure to aremarkable accuracy of 0.025% of the dif-ferential reading up to 300 psi static, 0.05%up to 3,000 psi static, and 0.1% up to10,000 psi static pressure. The nVision canalso record 500,000 data points from eachof its two modular sensors, simultaneously.It takes these measurements as frequently as

every 0.1 sec, without any change in accu-racy between 20C and 50C.

The nVision delivers this accuracy whilemaintaining excellent field capability, andwithout risking sensor damage. Other dif-ferential calibrators sustain damage easily,when an improper connection or opera-tion of valves exposes their single sensorto full static pressure. Because the nVisionReference Recorderuses two independentpressure modules, operators cannot damageeither sensorproviding they have selectedthe appropriate pressure modules for the

anticipated static pressure.Our customers needed a reliable,

safe, and portable device for differentialmeasurements at high static pressure. ThenVision was already recording from twosensors with extraordinary accuracy acrossa broad range of temperatures and pres-sures. Measuring the difference betweenthe two was a logical step for us. However,accurate differential pressure measurementwith two sensors was only possible becauseof the arrow-straight linearity inherent inour technology. At no additional cost, this

new capability puts tremendous value inthe hands of our users. said Tom Halacz-kiewicz, president of Crystal Engineering.Select 2 at www.HydrocarbonProcessing.com/RS

Next-generation technologyremoves high acidic impurities

Merichem Company, introduced NAP-FINING HiTAN, a next-generation tech-nology that removes high levels of naph-thenic acid compounds in kerosine, jetfuel and diesel. NAPFINING HiTAN isbased on Merichems popular, cost-effective

NAPFINING platform, and it employsMerichems highly reliable and efficient

proprietary FIBER FILM technology andcaustic to remove acidic impurities duringrefining. Reducing high TAN (> 0.1 mgKOH/g) feed levels allows production ofhigher-quality and more-profitable prod-ucts from lower-grade and less-expensivecrudes. Other advantages of the NAPFIN-ING HiTAN and FIBER FILM technolo-gies are lower capital costs and a smallerplant footprint.

NAPFINING HiTAN is anotherpractical example of the innovation thatis driving a transformed Merichem in ser-

vice to an evolving refining industry, said

As HPeditors, we hear about

new products, patents, software,

processes, services, etc., that are true

industry innovationsa cut above

the typical product offerings. This

section enables us to highlight these

significant developments. For more

information from these companies,

please go to our website at

www.HydrocarbonProcessing.com/rs

and select the reader service number.

nVisiondifferential pressurerecorder.

FIG. 1

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IFEBRUARY 2011 HydrocarbonProcessing.com

HPINNOVATIONS

Kenneth F. Currie, Merichem chairmanand CEO.

NAPFINING HiTAN and NAPFIN-ING technologies employ the FIBER FILMcontactor as a mass-transfer device andcaustic as the treating reagent to remove

naphthenic acid compounds mainly fromjet fuel, kerosine and diesel, condensate andcrude oil streams.

NAPFINING HiTAN and FIBERFILM are non-dispersive and extremelyreliable when compared with commerciallyavailable treating alternatives. The smallerfootprint and smaller capital expenditureare attractive as well, said Tom Varadi, vicepresident and general manager of Meri-chem Process Technologies. The onstreamfactor between routine turnarounds is100%, whereas electrostatic precipitators

are much less reliable and incapable of pro-cessing high TAN feeds.Select 3 at www.HydrocarbonProcessing.com/RS

Additives reduceflare SOx emissions

Baker Hughes has developed additivesspecially designed to reduce sulfur oxide(SOx) emissions from refinery flaring oper-

ations. Baker Petrolite SULFIX additivesreduce SOx air pollution that is createdwhen hazardous hydrogen sulfide (H2S)is burned; helping US refiners meet theEnvironmental Protection Agencys NewSource Performance Standards (NSPS) for

petroleum refineries.Refineries produce SOxemissions when

H2S-laden gases are flared. This combus-tion process converts H2S to SOx. Nowrefineries can quickly reduce SOxemissionsby treating the flare gas with Baker PetroliteSULFIX additives to reduce the amount ofH2S it contains and avoid noncomplianceissues without major capital investment.Baker Hughes provides comprehensiveservices for effective control of flare gasH2S levels to help refiners select suitableadditives, use the correct injection system

equipment and design, and implement anappropriate monitoring program.

Baker Hughes has successfully appliedSULFIX additives and helped refinery cus-tomers reduce SOx emissions to complywith environmental regulations, notes JerryBasconi, vice president and general man-ager of industrial services of Baker Hughes.SULFIX products for flare gas reduce air

pollution from SOx and H2S, improvingair quality and environmental compliance.Select 4 at www.HydrocarbonProcessing.com/RS

Automation moduleimproves tank farm logistics

Building on years of experience andtechnology in terminal and tank farm logis-tics operations, Emerson has added a move-ment logistics management module to itsSyncade Smart Operation ManagementSuite. The new application complementsEmersons established base of instrumenta-tion, control and custody transfer systemsfor tank farm and terminal product move-ments. Initial installations include termi-nals and tank farms in North America,Europe and Asia.

Combining the power of the DeltaV

automation system with the Syncadesuites operations management capabili-ties, the new movement logistics managerapplication supports marine, rail, truckand pipeline site operations. Key compo-nents include order management, logis-tics planning and scheduling, inventorymanagement, and production accounting.It connects and interacts with every level


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Catalyst valveproblems?We Have Solutions!The Hemiwedge Valve was designed to take on the severe conditionsof catalyst handling. If you thought there was no alternative to

traditional valve designs, we have great news!

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The STATIONARY CORE in the Hemiwedge Valve protects theseating surfaces from the solids flow, resulting in greatly increased

service life over conventional metal seated ball valves.

In some instances, where traditional metal seated ball valves werelasting 2-3 months, the Hemiwedge Valve has tripled or quadrupledthe service life of the valve . . . and is still going strong!


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HPINNOVATIONS

23

of the operation, from enterprise resourceplanning (ERP) systems to the devices thatload the ships and trucks and open the gateat the terminal. The system manages taskssuch as custody transfer of products, print-ing shipping documents and reporting

final accounting results back to the ERPfor invoicing.

Todays pressures on safety, security,cash flow and cost reduction require termi-nal operations and tank farms in produc-tion facilities to be more reliable, repeat-able, secure and safe, said Jim Nyquist,president of Emersons PlantWeb solutionsgroup. These needs expand beyond phys-ically controlling material movement tomanaging the business information associ-ated with them. Thats why Im proud thatEmerson can now offer our customers this

powerful, comprehensive solution.Automation can dramatically improve

tank farm and terminal efficiency, withfewer people handling more activities anddoing it more reliably in less time. Addingintegrated order management and sched-uling can help to increase the number oftrucks and ships handled by the facility.Embedding the knowledge behind a paper-driven process into an electronic systemalso means the operation can do more withless-experienced employees.Select 5 at www.HydrocarbonProcessing.com/RS

Flue gas compressorsuccessfully commissioned

On December 10, 2010 BurckhardtCompression successfully completed themechanical test run of the Laby-GI com-pressor. DNV certified the test run andissued the survey report. The Laby-GI wascommissioned by Golar LNG Limited andBurckhardt Compression on the floatingstorage and regasification unit (FSRU)Golar Freeze, which is now permanentlymoored at the Jebel Ali port in Dubai. The

Laby-GI Compressor is used as a boil-offgas (BOG)/minimum send-out compres-sor and has been successfully in operationat full capacity.

The Laby-GI compressor is fully bal-anced, eliminating unbalanced forces andmoments guaranteeing a smooth operationfor all offshore applications. The uniquedesign combines two well established seal-ing technologies in a single crankgear forlubricated or non-lubricated compression.Therefore, the Laby-GI compressor easilymanages the compression of LNG BOG at

suction temperatures to -250F (-170C)without pre-heating the gas or pre-cooling

the compressor. The gastight compressorhousing eliminates gas emission and lossesto the environment.

The Golar Freeze was convertedfrom an LNG carrier to an FSRU and iscapable of storing ~125,000 m3 of LNG

and delivering up to 480 million cubicfeet per day (MMf3/d) of regasified LNGto Dubai Supply Authority (DUSUP) forfurther distribution into the Dubai naturalgas network. Shell, as DUSUPs appointed

adviser for the project has worked closelywith Golar LNG Limited on the develop-ment of this project.

Laby-GI compressors are used for liquidgas carriers, LNG/LPG FPSOs, FSRUs,LNG RVs and production platforms. They

are extremely reliable with unexcelledavailability, combining best performancewith unmatched operational flexibility andlong lifetime.Select 6 at www.HydrocarbonProcessing.com/RS

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7/22/2019 H P 2011 02.pdf


I25

HPIN CONSTRUCTION

HELEN MECHE, ASSOCIATE EDITOR

[email protected]

North AmericaThe Dow Chemical Co. plans to

increase ethane-cracking capabilities on theUS Gulf Coast over the next two to threeyears, and improve these capabilities by20%30% in this timeframe. In addition,Dow is also reviewing joint-venture optionsfor building a natural gas liquids (NGL)fractionator to secure this ethane supply.

Both actions are intended to capitalizeon the favorable supply dynamics in NorthAmerica, and further bolster the competi-tive advantage of Dows plastics franchise,

as well as its high-margin, downstream per-formance businesses.

Alfa Laval has received an order for itsPackinox heat exchangers to be used inwhat is said to be the worlds first full-scaleintegrated-gasification combined-cycle(IGCC) process for power generation withcarbon capture, which will be placed in theUS. The order value is about SEK 80 mil-lion and delivery is scheduled for 2012.

The heat exchangers will be used in agas-treatment process of an IGCC power-

generation plant. The project has receivedfunding from the US Department ofEnergy and will, when finalized, includea state-of-the-art gasification facility witha capacity of more than 500 MW and anintegrated carbon-capture facility.

Medicine Bow Fuel & Power LLChas awarded Aker Solutions the front-end engineering and design (FEED) pack-age for its industrial gasification and liq-uefaction plant located near the town ofMedicine Bow, Wyoming. Aker Solutions

successfully completed a pre-FEED studyfor the project in July 2010. Since then,Aker Solutions has worked under a letter ofintent to provide services relating to designreview and licensor support, as well as addi-tional pre-EPC engineering and design.

The facility will produce liquid transportfuels and is due to come online in 2015.When complete, the plant will convert coalinto up to 21,000 bpd of gasoline and liq-uefied petroleum gas (LPG) liquid fuels.

The Dow Chemical Co. has announced

that Dow and Mitsui & Co., Ltd., ofTokyo, Japan, have completed the forma-

tion of a previously announced 50/50 man-ufacturing joint venture to construct, ownand operate a new membrane chlor-alkalifacility located at Dows Freeport, Texas,integrated manufacturing complex.

The new chlor-alkali facility is expectedto begin operations in mid-2013, and willhave a capacity of approximately 800 kilo-tons/yr. The new plant will create approxi-mately 50 long-term jobs at the Freeportlocation, along with approximately 500construction jobs.

South AmericaFoster Wheeler AGs Global Engineer-

ing and Construction Group has beenawarded a basic engineering design andfront-end engineering design (FEED) con-tract for two grassroots refineries in Brazilfor Petrobras. The Premium I Refinerywill be a dual-train, 600,000-bpsd facil-ity in Maranhao State, and the PremiumII Refinery will be a single-train 300,000-bpsd facility in Ceara State. Foster Wheelerwill be the prime subcontractor to Honey-wells UOP, the managing process-technol-

ogy licensor. The value of the contract wasnot disclosed.

The contract includes basic design andFEED for the main process units and aux-iliary units.

Petrobras has selected Emerson Pro-cess Managementto provide process auto-mation technologies and services for thePetrochemical Complex of Rio de Janeiro(Comperj) in Brazil. As the main automa-tion contractor for Comperj, Emerson willdeliver engineering services and technolo-

gies for integration of the refining units pro-cess automation and systems, and selectedproject utilities and offsite operations.

Built on an area of 45 million m2, theComperj complex will be able to process165,000 bpd of heavy crude when its firstrefining unit begins operations in 2013,and the same amount in a second unit isexpected five years later. In addition to sys-tems for process control, safety, fire andgas detection, machinery monitoring, andmanagement of process and maintenanceinformation, Emerson will also supply

measurement instruments, control valves,pressure regulators, and other related prod-

ucts and services. Engineering work hasalready begun, with hardware delivery tobegin in 2011.

EuropeTechnip has been awarded an engi-

neering, procurement services and con-struction-management contract byTotalto increase hydrocracker capacity at theNormandy refinery located in Gonfreville,France. This project, which is part of alarger investment plan for the refinery, isvalued at more than 100 million (of which

Technips share is 20%).Technips scope includes debottle-

necking of the hydrocracking plant anddebottlenecking of the hydrogen unitneeded to operate the hydrocracker. Thisextension will increase hydroconversioncapacity to 10,000 tpd from the current8,000 tons, thereby enabling production ofmore diesel fuel and kerosine.

BASF plans to expand its existing super-absorbent polymer-production capaci-ties at its sites in Antwerp and Belgium,

and at its Freeport, Texas, site. Gradualdebottlenecking and technical expansionmeasures are to raise annual capacity by70,000 tons to a total of 470,000 tons by2012, with each site contributing an addi-tional 35,000 tons

A subsidiary ofFoster Wheeler AGsGlobal Engineering and Construction

Trend analysis forecastingHydrocarbon Processing maintains an

extensive database of historical HPI proj-

ect information. The Boxscore Database is a35-year compilation of projects by type, oper-

ating company, licensor, engineering/construc-

tor, location, etc. Many companies use the his-

torical data for trending or sales forecasting.

The historical information is available in

comma-delimited or Excel and can be custom

sorted to suit your needs. The cost depends on

the size and complexity of the sort requested.

You can focus on a narrow request, such as

the history of a particular type of project, or

you can obtain the entire 35-year Boxscore

database or portions thereof. Simply send

a clear description of the data needed and

receive a prompt cost quotation.

Contact: Drew Combs

P.O. Box 2608, Houston, Texas, 77252-2608713-520-4409 [email protected]

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HPIN CONSTRUCTION

26

Group has been awarded a contract byKuwait Petroleum International Lubri-cants to provide detailed engineering ser-vices for a brown-field lube-oil blendingplant to be built at Kuwait Petroleumsfacility in Antwerp, Belgium.

The lube-oil blending plant will sub-stantially enhance the Antwerp facilitysability to operate at European scale byincreasing production capacity from 125million lpy to 250 million lpy. The detailed

engineering activities will be completed bymid-2011.

The State Oil Co. of the AzerbaijanRepublic (SOCAR) and TURCAS Rafi-neri A.S. (STRAS), the joint venture

of SOCAR and TURCAS Petrol A.S.(TRCAS), have awarded Fluor Corp. aproject-management consultant (PMC)contract for a new refinery to be built inAliaga, Turkey. The new planned refin-

ery will be integrated at the Petkim pet-rochemicals site on the Aegean coast.As PMC for the SOCAR and TURCASAegean Refinery (STAR) project, Fluor willassist STRAS in selecting and managing theengineering, procurement and construction

(EPC) contractor(s) and provide overallproject and construction management.

Project work is underway, with thestart of site preparation. EPC work is esti-mated to be in mid-2011, and constructionstartup is scheduled to begin in the firstquarter of 2012.

Africa

Technip has been awarded a contractbySonatrach, the Algerian national oilcompany, for refurbishment and revamp-ing of the Algiers refinery. This lump-sum

turnkey contract, worth approximately$908 million, will last 38 months andcover the execution of the complete scopeof works, including the design, supply ofequipment and bulk material, constructionand startup.

The revamp of the existing installationswill enable refining capacity to be increasedfrom 2.7 million tpy to 3.6 million tpy.The new units will allow the refinery toproduce gasoline at specifications similar tothose in force in Europe. This project willbe carried out by Technips operating center

in Paris, France.

Middle East

Petroleum Development Oman(PDO) has awarded a seven-year engi-neering and maintenance services contract(EMC) to Wood GroupCCC , a jointventure set up to provide operations andmaintenance services for the oil and gasand petrochemical industries in Oman,Bahrain, Kuwait, Qatar, Saudi Arabia,UAE and Yemen. The contract, whichhas a three-year extension option, will

include integrated engineering, construc-tion, maintenance and support services forexisting PDO facilities onshore in South-ern Oman.

Shell Global Solutions InternationalB.V. has signed three license agreementswith the state-owned North RefineriesCo. of Iraq, in Kirkuk, Northern Iraq.Shell Global Solutions will provide a pro-cess license and basic-engineering pack-age for a kerosine hydrotreater, a dieselhydrotreater and a vacuum gasoil (VGO)

hydrocracker unit as part of the agree-ment. Each agreement includes the grant

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HPIN CONSTRUCTION

28

of a license to Shell proprietary technologyand the provision of engineering services.

Agreements for the supply of catalystsand reactor internals are expected to besigned in the future as part of the deal.Based on Shells experience as both an

owner and an operator, these licensedtechnologies are likely to provide NorthRefineries Co. with an integrated solutionthat will help optimize the new refinerysoperations.

Asia-Pacific

CB&I has announced that LummusTechnologyhas been awarded a contractbyLiaoning Tongyi Petrochemical Co.,Ltd., for the license and engineering designof grassroots olefins-conversion technology

(OCT) units and CATOFIN dehydroge-nation units at several of its sites in thePeoples Republic of China. The units willproduce 684,000 metric tpy of isobutyleneand 950,000 metric tpy of propylene.

Jacobs Engineering Group Inc. hasreceived a contract from CPC Corp.,Taiwan, to design and license Jacobs pro-prietary EUROCLAUS technology for adesulfurization unit as part of the Ta-Lin

refinery expansion project in Kaoshiung,Taiwan.

This project is said to be the first tocombine Jacobs EUROCLAUS technol-ogy with DynaWave technology, whichis engineered and licensed by US-basedMECS, Inc. The combination of thesetwo unique technologies reportedlymakes it possible to achieve very-low-sulfur emissions at low-investment costcompared to existing technologies. Thenew desulfurization unit will be inte-gral to CPCs refinery operations. CPC

will design and build the Ta-Lin refineryexpansion. The new facility, scheduledto be operational in 2013, will produceclean-fuel products for the local Taiwan-ese market.

The Shaw Group Inc. has beenselected byGAIL (India) Ltd. to provideits proprietary technology and basic engi-neering for a new 450,000-tpy ethyleneplant. Shaw will also provide support dur-ing detailed engineering, procurementand construction, and commissioning and

startup of the plant, which will be part ofGAILs petrochemica l complex in Pata,Uttar Pradesh, India.

The undisclosed value of the contractwas included in Shaws Energy & Chemi-cals segments backlog of unfilled orders inthe first quarter of fiscal year 2011.

Stamicarbon, the licensing and intel-lectual property center ofMaire Tecni-mont S.p.A., has signed a license agree-ment with Inner Mongolia BodashidiCo., Ltd., in the Peoples Republic of

China (PRC) for a urea plant with a capac-ity of 2,860 metric tpd. The plant will bebuilt in the Industrial Zone of Nalinriver,Wushen, Inner Mongolia, PRC. The ureaplant will use the Stamicarbon Urea2000P-lus pool condenser technology.

Stamicarbon will deliver the processdesign package (PDP) and associated ser-vices. The plant will be built byWuhuanEngineering Corp. of China as the sub-contractor of China Chemical Engi-neering Second Construction Group.Wuhuan has been chosen by the customer

as the designated EPC contractor. Startupis planned in 2013. HP

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KNOW-HOWDELIVEREDWe put tested refining technologies

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I31

HPI CONSTRUCTION BOXSCORE UPDATE

Company City Plant Site Project Capacity Unit Cost Status Yr Cmpl Licensor Engineering Constructor

AFRICA

Algeria Naftec Spa Skikda Skikda BTX RE None U 2012 GTC, Inc GTC, IncLibya Harouge Oil Operation Ras Lanuf Ras Lanuf Storage, Oil None 63 U 2012 Punj Lloyd Ltd Punj Lloyd Ltd Punj Lloyd LtdMorocco OCP Jorf Lasfar Jorf Lasfar DAP (4) EX None P 2013 Jacobs Engineering SA Jacobs Engineering SA Jacobs Engineering SA

ASIA/PACIFIC

China CNOOC Dongfang Dongfang Refinery None 12 U 2013ndia Rashtriya Chemicals Thal Vaishet Thal Vaishet Ammonia RE bbl U 2011 Haldor Topse PDIL

South Korea Hyundai Petrochem Co Ltd Daesan Daesan Aromatics Extraction Mtpy E 2011 HRI KBR|HEC HEC

Taiwan Chinese Petroleum Corp Kaohsiung Kaohsiung Diesel, HDS (2) 50 Mbpd 34.6 A 2010 Axens Fu-Tai Engr Fu-Tai EngrThailand Map Ta Phut Olefins Map Ta Phut Map Ta Phut Aromatics Complex TO 600 Mtpy C 2010 GTC, Inc

EUROPE

Greece Hellenic Petroleum SA Thessaloniki Thessaloniki Naphta 2600 bpsd 184 U 2011taly Montedipe SpA Porto Marghera Porto Marghera Aromatics Extraction 400 Mtpy U 2012 Montedipe Tecnimont Tecnimont

Kazakhstan AGIP KCO Kashagan Kashagan Field FPSO 150 kbpd 30000 E 2012 KBRRomania Petrochemical Holding AG Onesti Onesti Paraxylene 400 Mm-tpy P 2012 GTC, IncRussianFederation Lukoil Perm Perm Aromatics Complex RE 320 Mtpy E 2011 GTC, Inc

LATIN AMERICA

Colombia Ecopetrol Barrancabermeja Barrancabermeja FCC Gasoline RE bbl 30 P UOP AltairStricklandCuba PDVSA Matanzas Matanzas Refinery, Heavy Ends 150 bpd 4300 P 2015Ecuador Refineria del Pacifico-CEM El Aromo El Aromo Refinery 300 bpd 12500 P 2013 PGNMexico Petroleos Mexicanos Cangrejera Cangrejera Styrene EX 100 Mtpy H

MIDDLE EAST

ran Esfahan Oil Refinery Co Esfahan Esfahan Isomerization 27 Mbpsd 187 E 2011 UOP Namvaran|HEC DorrizQatar Qatar Shell GTL Ltd Ras Laffan Ras Laffan MEG 1.5 m-tpy PSaudi Arabia SAMREF Yanbu Yanbu Clean Fuels None 200 F 2013

UNITED STATESCalifornia Valero Refining Co Benicia Benicia FCC Gasoline RE bbl 5 U 2011 AltairStricklandGeorgia CARBO Toomsboro Toomsboro Proppant resin None PMontana ExxonMobil Billings Billings FCC Gasoline RE bbl 8 P AltairStricklandOhio Marathon Oil Canton Canton FCC Gasoline RE bbl P AltairStricklandOklahoma ConocoPhillips Ardmore Billings Coker, Delayed RE bbl 8 P AltairStricklandTexas LyondellBasell Industries Houston Houston Coker, Delayed RE bbl 12 P 2013 FW FW AltairStricklandUtah Holly Corp Woods Cross Woods Cross Benzene Reduction None E 2011 GTC, IncWyoming Medicine Bow Fuel Medicine Bow Medicine Bow Gasification and Liquefaction 21000 bpd F 2015 Aker Solutions

See http://www.HydrocarbonProcessing.com/bxsymbols for licensor, engineering and construction companies abbreviations,along with the complete update of the HPI Construction Boxscore.

THEGLOBALSOURCEFORTRACKINGHPICONSTRUCTIONACTIVITY

BOXSCOREDATABASE ONLINE

For more than 50 years, Hydrocarbon Processingmagazine remains the only source that collects andmaintains data specifically for the HPI community,publishing up-to-the-minute construction projectsfrom around the globe with our online product,Boxscore Database. Updated weekly, our databasehelps engineers, contractors and marketing personnel

identify active HPI construction projects around theworld to: Generate leads Market research Track trend analysis And, decide future budget planning.

Now, weve made our best product even better!Enhancements include: Exporting your search results to Excel so you can

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HPI VIEWPOINT

HYDROCARBON PROCESSING FEBRUARY 2011 I33

Consumer protection is a key issue for E15

Americans have long counted on our nations petroleum refin-eries to provide them with safe, affordable, efficient and reliablegasoline and diesel fuel for their vehicles and outdoor powerequipment.

Unfortunately, a decision last October by the US Environ-mental Protection Agency (EPA) to authorize the sale of gasolinecontaining 15% ethanol (E15) for late-model vehiclesup fromthe current limit of 10% ethanol (E10)could reduce the safetyof the gasoline Americans rely on.

Concern about the potential safety threat of a 50% increase inthe amount of ethanol in gasoline motivated many refiners andthe National Petrochemical & Refiners Association (NPRA), tocall on the EPA to conduct thorough and objective scientific testson the impact of E15 on gasoline engines before authorizing useof the fuel.

Unfortunately, the EPA rejected our call and decided to rush tojudgment, under pressure from the ethanol industry. As a result,

we believe the EPA decision approving E15 for limited use was adisservice to the American consumer.

NPRA is not anti-ethanolour members blend it with gasolineevery day to manufacture the E10 fuel that safely powers most USvehicles. We simply want to be sure that adding greater amountsof ethanol to gasoline is safe and will not cause engine damage.

Following the old proverb to look before you leap, we believethat learning more about E15 before approving its use is justcommon sense.

Because of our concern with consumer protection, NPRA has

filed a lawsuit asking a US appeals court to overturn what we believewas the EPAs premature and unwise decision to approve the useof E15 in cars and light trucks for the 2007 and later model years.

Misfueling. Based on experience with leaded and unleadedgasoline years ago, we know that millions of consumers would nodoubt use the wrong fuel for the wrong vehiclea problem calledmisfuelingif E15 becomes widely available.

No matter what warning signs the EPA requires gasoline retail-ers to post at their pumps, many consumers would undoubtedlypump E15 into older cars and trucks and use it in outdoor powerequipment, motorcycles, boats and snowmobiles.

Some of this misfueling would be unintentionalcon

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