retrofitting existing reactors - a novel approach to

Retrofitting Existing

Reactors - A Novel

Approach to

Modernization

MR. HUSSAIN MOHAMMAD HUSSAIN AL-MUTAIRI - KNPC

MR. RAJAN JAWALE – CHEVRON LUMMUS GLOBAL

Retrofitting

reactors –

Outline

- NOVEL APPROACH

- BACKGROUND

- OPPORTUNITIES

- ADVANTAGES

- EXAMPLES

- KNPC SUCCESS STORY

- EXECUTION

- SUMMARY

@ 2018 Chevron Lummus Global, All Rights Reserved. Company Confidential.

Retrofitting reactors – Novel approach

In today’s economy, refiners have to think creatively for projects

to be funded with limited access to capital.

Existing hydroprocessing assets can be creatively repurposed /

upgraded to improve refinery gross margin.

The reactors, their internals and the catalyst are core to the

performance of any hydroprocessing or dewaxing unit.

There are many reactors that are old, under performing, causing

refiners to lose margins and limit their processing capacities.


Retrofitting reactors – Novel approach

Many refiners have opted to upgrade their existing reactor by

retrofitting them with new internals.

Upgrading the existing reactors with latest design of internals in

conjunction with use of high performing catalyst is a novel and

winning opportunity for clients all around the world.


Retrofitting reactors – Background

Hydroprocessing reactors

Fixed bed, High Pressure

High Temperature vessels.

Cr-Mo or Cr-Mo-V material.

Stainless Steel internals.

Typical Life span 30 years.

Needs specialized

fabrication.



Catalyst Support System

Quench and Mixing Section

Distribution Trays

Main components of reactor internals



Improved Reactor Performance is a combination of Catalyst

and Internals performance.

Better Internals make Catalyst perform better and vice-versa.

Leveraging with a catalyst supplier’s presence and contacts

with the refiners, Licensors can offer tangible improvements

with better catalysts and latest internals.



CLG looks for opportunities that bring perceptible value to

client by retrofitting reactors with CLG internals.

CLG offers the latest generation of internals for retrofitting that

are commercially proven since 2003.

CLG offers range of reactor retrofits

❑ Full retrofit from inlet basket to bottom catalyst support.

❑ Process internals only or catalyst support system only.

❑ Wedge Pin mods only to reduce turnaround times.


Retrofitting reactors – Opportunities

There are over 400 hydroprocessing reactors of various

vintage in operation which need upgrading.

Considerable improvement in internals technology has

been to improve performance and offer time savings.

Reactor retrofits can address the following pain points:

❑ Poor Run lengths/Under-util ization of catalyst.

❑ Poor temperature spreads.

❑ High pressure drops/deformation of internals.

❑ Hot Spots/coke formations.

❑ Aging internals (replacement of old / outdated internals).

❑ Need higher turnaround ratios.

❑ Need for saving in turnaround durations.


Retrofitting reactors – Advantages

Retrofitting underperforming reactors with high performing

internals bring the following advantages.

❑ Facilitate better utilization of catalyst

➢ Uniform process distribution prov ides an activ ity advantage.

❑ Promote Safe Operations by allowing Good Temperature

Management

➢ Uniform radial temperature profiles

❑ Provide Operating Flexibility (including turndown)

➢ Adapt to minor feed changes and changes to throughput

❑ Allow faster installation and maintenance times.

➢ Prov ides additional time on-stream thereby increases profits.


Retrofitting reactors – Examples

Retrofit Example 1 - Installation of ISOMIX® Internals.

❑ Before and After performance



Retrofit Example 2 - Installation of ISOMIX® Internals.




Retrofit Example 3 – Installation of ISOMIX® Internals.



KNPC Success

Story

MAA AND MAB

REACTOR RETROFIT PROJECTS


KNPC Reactor Retrofit projects

Project Background

❑ In 2010, CLG retrofitted two Chevron designed Hydroprocessing reactors in MAB refinery and one Hydroprocessing reactor in MAA

refinery with the new internals.

❑ In 2014, CLG retrofitted another Hydroprocessing reactor in MAA refinery.

❑ These reactors were fabricated and installed in 1983 and had the early generation of internals.

❑ All 4 reactors had performance issues (high radial dT, hot spots).

Both refineries were designed for 38,000 SBPD. The units were revamped to 43,000 BPD for MAA and 42,500 BPD MAB before the

retrofit project.



Project

❑ These reactors were bottle type reactors.

❑ Existing process Internals were fully welded to

the internal shell.

❑ Retrofit involved demolishing the existing

process internals (hot work).

❑ CLG designed a internal skirt to mount the new process internals.

❑ Catalyst support grids and Bottom Catalyst

support were not replaced.



Performance Benefits

Performance Before installation of ISOMIX® internals

❑ Severe quench gas maldistribution and gas/liquid channeling.

❑ Severe hot and cold spots.

❑ Hot spots in lower beds was controlled by controlling quench flow in

upper beds.

❑ Low H2 consumption – low volume expansion.

Performance After installation of ISOMIX® internals

❑ Direct Temperature/ quench control at each bed.

❑ Uniform Temperature distribution (within 2°C at SOR)

❑ High catalyst util ization.

➢ 6% Liquid Volume improvement.

➢ 12 months increased cycle for MAA (prev ious cycle 3 years, now 4 years).




Performance After installation of ISOMIX® internals (contd.)

❑ Increased ability to operate at higher severity.

❑ Improved mixing, heat transfer, distribution and liquid dispersion

results in the following operational and economic benefits.

❑ Lower bed inlet and outlet temperatures.

❑ Flexibility to util ize more active catalyst systems.

❑ Improved turndown performance.

❑ The units have since been revamped to 43,000 BPD for MAA and 42,500 BPD MAB.





Typical Radial dT improvements

Post-ISOMIX®Post-ISOIX®

Post-

ISOMIX®Post-ISOMIX®



Quench Control and Temperature Profile Improvement


Retrofitting reactors – Execution

Identify

Opportunity

Understand

pain points

Collect

Op. Data &

drawings

Evaluate

feasibility

Prepare

and submit

proposal

Execute Follow-up



Few Considerations:

❑ Requirement of no hot work inside the reactor is common.

❑ Each application is unique and needs evaluation.

❑ Performance guarantees are difficult to offer for retrofits if catalyst

sale is not by ART.

❑ Catalyst Volume Gain depends on existing support locations.

❑ Installation timing and duration (turnarounds) restrictions.

❑ Usually 4 to 6 weeks required to evaluate/bid a retrofit job.

❑ Usually 40 to 60 weeks required for delivery.



How CLG supports internals retrofitting business:

CLG has signed agreement with McDermott to manage the supply chain for the reactor internals.

CLG/McDermott supplies internals for new licenses as well as

retrofit projects (ISOMIX®, ISOMIX-e® and earlier generation).

McDermott will manage the complete supply chain - proposal

to delivery for the reactor internals.

McDermott can also offer site installations services.


Todays environment is ideal for cost effective upgrading the reactor with internals retrofits.

There are many commercial successes e.g. CLG has commercial experience with retrofits of over 32 reactors so far.

We offer the synergy between ART, CLG and McDermott.

Please contact your ART Technical Services Engineer for any opportunity you wish to discuss.

Retrofitting reactors – Summary


QUESTIONS?

Hussain Mohammad Hussain Al-Mutairi [email protected]

[email protected]


mailto:[email protected]

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