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Near Zero Sulfur Diesel Hydrotreater

Location of Project:Southeast

Project Cost :$13 million

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Met new stringent EPA requirements while increasing capacity

EPA regulations were changing from 500 wppm diesel total sulfur content to 15 wppm. The original diesel hydrotreater unit was designed for 12,000 BPD production and 500 wppm diesel total sulfur in the treated diesel. The C&I project design basis was to increase the diesel hydrotreater unit production to 22,000 BPD while simultaneously reducing the diesel total sulfur content to less than 15 wppm.

This ISBL project was a collaborative effort between the refinery and C&I involving the refinery’s most profitable unit. Our preparations were meticulously designed to guide operations from the pre-turnaround stage through early tie-in, turnaround, and post-construction. These included pipe support, demolition, storm water sewer, and steel drawings; raceway plans; equipment layouts;

and instrument datasheets. A senior C&I staff member remained on-site throughout construction to coordinate activities on the hydrotreater and similar projects that were underway at the time.

C&I also functioned as a go-between for the client and the various vendors engaged to supply equipment and instrumentation for the project, curating a list of trusted providers, soliciting quotes, evaluating bids for cost and expertise, and inspecting and accepting deliveries.

Thanks to monthly cost status reports and capital cost estimates developed during the FEED and Detail Design phases, the project required no rework and was completed 4% under budget. The improved hydrotreater met or exceeded all operation and process criteria.

We demonstrated we could do it, then were awarded the design.

Process Technical Solutions

C&I developed a complete process engineering design package for the Near Zero Sulfur Diesel Hydrotreater project. A Pro II model of the existing facility was developed and calibrated to be used for the design.

Engineering Services

The first step was to conduct a test run, evaluate the data and adjust the model for the existing design. The calibrated model was used to develop the expansion case, along with the requirements to meet less than 15 ppm in the treated diesel. This involved finalizing the catalyst selection. Equipment was sized, and the detailed engineering to install the new or modified equipment was finalized.

“In addition to increasing capacity and meeting tougher EPA regulations, we designed an elevated walkway, allowing operations to travel from heaters to valve stations to reactors and air coolers, making a complete circuit without having to climb up and down.”

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To learn about similar work C&I has handled for our client partners, or to find out what we can do for your operation, call us today at (502) 451-4977.
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