HIGH-EFFICIENCY DESIGN WITH CUSTOM BACK-END WASTE HEAT RECOVERY HIGH-PERFORMANCE EMISSION CONTROLS – FOR THE LOWEST LEVELS OF CO AND NOX AS LOW AS 2PPM COMPLETE SYSTEMS CUSTOM DESIGNED FOR THE MOST STRINGENT CUSTOMER SPECIFICATIONS RENTECH BOILERS AS TOUGH AS TEXAS PRODUCTS Heat Recovery Steam Generators Waste Heat Boilers Fired Packaged Watertube Boilers Specialty Boilers SOLUTIONS Refining and Petrochemical Power Generation Manufacturing & Institutional Food Processing CHP WWW.RENTECHBOILERS.COM Select 53 at www.HydrocarbonProcessing.com/RS JANUARY 2018 | HydrocarbonProcessing.com ALTERNATIVE FEEDSTOCKS/BIOFUELS Production of renewable fuels in existing refining assets Integrate solar/thermal energy in oil and gas processing Optimize LNG production through contaminant mitigation INDUSTRY LEADERS’ FORECASTS Viewpoints from key industry executives on market and technology developments to watch in 2018 BUSINESS TRENDS The future of LNG ™ INNOVATING CAUSTIC TREATING TECHNOLOGY ® Introducing FFC Plus™, the next generation of FIBER FILM Contactor technology Merichem Company’s advanced FIBER FILM technology with an integrated coalescer and treater pushes the boundaries of extractive technologies With this latest innovation, hydrocarbon treating rates can be increased by up to 150% through increased mercaptan extraction efficiency The integrated coalescing and treating device offers a simple installation, reduced chemical use, and reduced service and maintenance complexity FFC Plus truly is mercaptan treating made better Select 84 at www.HydrocarbonProcessing.com/RS www.merichem.com JANUARY 2018 | Volume 97 Number HydrocarbonProcessing.com C–67 SPECIAL FOCUS: ALTERNATIVE FEEDSTOCKS/BIOFUELS 25 Production of renewable fuels in existing refinery assets: A cost-effective coprocessing strategy P Dhar, L Meesala, P Kumar, G Valavarasu, P V C Rao and G Sriganesh 31 Optimize LNG production through contaminant mitigation—Part T H Wines, S Mokhatab and O Trifilieff 35 Integrate solar/thermal energy in oil and gas processing K Gupta, M Ethakota and S Payyanad PROCESS OPTIMIZATION 43 Maximizing energy efficiency in paraxylene production—Part DEPARTMENTS 87 88 90 Advancing export terminal technology: An optimized process for the refrigeration of cryogenic hydrocarbons L Nichols CATALYST TECHNOLOGY UPDATE—SUPPLEMENT C–68 Raise efficiency of ultra-low SHR production of styrene monomer with a novel catalyst formulation K Shinyama and A Battaiotto C–72 C–75 The optimal catalyst makeup in an FCC unit Events Reliability 17 Management 19 Engineering Case Histories 23 Engineering Practices Dry gas sealing technology replaces segmented carbon rings in small steam turbines Active career management Case 99: Pooling knowledge and experience builds personal and team success CAD for plant layout: Being right by being safe DIGITAL EXCLUSIVES Industry Metrics H Salgado Global Project Data Improve FCC yields from contaminated feeds using boron-based nickel passivation Innovations K Cha C–80 Advertiser Index 15 PROCESS CONTROL AND INSTRUMENTATION 63 Migrating from Fortran to ISA S-88 J Ford, T Kolluri and J Bozeman Marketplace Biofuels—A viable fuel source for the future? M Rosetta and K Patel OUTLOOK: INDUSTRY LEADERS’ VIEWPOINTS 55 2018 Industry Leaders’ Viewpoints Business Trends COLUMNS Editorial Comment C Colling 49 Industry Perspectives A new generation of dewaxing catalysts H W Rasmussen PROJECT MANAGEMENT 83 Incorporate assurance into an operational readiness program—Part G Picheo and W Reed Cover Image: Enerkem Inc is the first waste-to-biofuels producer to launch a world-class, commercial-scale cellulosic ethanol operation, in Edmonton, Alberta, Canada The biofuel is made from non-recyclable, non-compostable, mixed municipal solid waste People www.HydrocarbonProcessing.com Industry Perspectives P O Box 2608 Houston, Texas 77252-2608, USA Phone: +1 (713) 529-4301 Fax: +1 (713) 520-4433 HPEditorial@HydrocarbonProcessing.com PUBLISHER Catherine Watkins Catherine.Watkins@GulfPub.com EDITOR/ASSOCIATE PUBLISHER Lee Nichols Lee.Nichols@GulfPub.com EDITORIAL New gas processing/LNG project announcements increase for the first time in three years According to Hydrocarbon Processing’s Construction Boxscore Database, nearly 800 new projects have been announced since 2015 Over the past few years, new project announcements have decreased each year However, the rate of decline has slowed over the past year New project announcements decreased from 302 in 2015 to 256 in 2016, and to 220 in 2017 This trend represents year-over-year (y-o-y) decreases of 15% and 14%, respectively Conversely, new gas processing/LNG project announcements have increased over the past year New gas processing/ LNG project announcements declined from 127 in 2015 to 68 in 2016, representing a y-o-y decline of 46% However, nearly 75 new gas processing/LNG projects were announced in 2017, representing a y-o-y increase of approximately 7% Over the past yr, nearly 270 projects have been announced in the gas processing/LNG sector The majority of these projects are located in the Asia-Pacific region and the US Combined, the Asia-Pacific region and the US represent more than 62% of the total number of new gas processing/LNG project announcements over the past yr The Asia-Pacific region has announced millions of tpy of LNG import capacity to provide additional natural gas supplies for power generation On the other hand, the US has announced significant new LNG export capacity, primarily along the US Gulf Coast The US is utilizing cheap, readily available shale gas to fuel its LNG export capacity growth By the end of the decade, the US is forecast to begin operations on more than 70 MMtpy of LNG liquefaction capacity Total capital expenditures for these projects will eclipse $50 B This construction would propel the US to become one of the top three LNG exporting nations in the world by 2020 140 100 80 Adrienne Blume Mike Rhodes Bob Andrew Ashley Smith Heinz P Bloch Alissa Leeton ARC Advisory Group Anthony Sofronas MAGAZINE PRODUCTION / +1 (713) 525-4633 Vice President, Production Manager, Advertising Production Assistant Manager, Advertising Production Manager, Editorial Production Assistant Manager, Editorial Production Artist/Illustrator Graphic Designer Sheryl Stone Cheryl Willis Krista Norman Angela Bathe Dietrich Lindsey Craun David Weeks Andreina Keller ADVERTISING SALES See Sales Offices, page 88 CIRCULATION / +1 (713) 520-4498 / Circulation@GulfPub.com Manager, Circulation Suzanne McGehee SUBSCRIPTIONS Subscription price (includes both print and digital versions): One year $399, two years $679, three years $897 Airmail rate outside North America $175 additional a year Single copies $35, prepaid Hydrocarbon Processing’s Full Data Access subscription plan is priced at $1,695 This plan provides full access to all information and data Hydrocarbon Processing has to offer It includes a print or digital version of the magazine, as well as full access to all posted articles (current and archived), process handbooks, the HPI Market Data book, Construction Boxscore Database project updates and more Because Hydrocarbon Processing is edited specifically to be of greatest value to people working in this specialized business, subscriptions are restricted to those engaged in the hydrocarbon processing industry, or service and supply company personnel connected thereto Hydrocarbon Processing is indexed by Applied Science & Technology Index, by Chemical Abstracts and by Engineering Index Inc Microfilm copies available through University Microfilms, International, Ann Arbor, Mich The full text of Hydrocarbon Processing is also available in electronic versions of the Business Periodicals Index DISTRIBUTION OF ARTICLES Published articles are available for distribution in a PDF format or as professionally printed handouts Contact Foster Printing at Mossberg & Co for a price quote and details about how you can customize with company logo and contact information For more information, contact Jill Kaletha with Foster Printing at Mossberg & Co at +1 (800) 428-3340 x 149 or jkaletha@mossbergco.com Hydrocarbon Processing (ISSN 0018-8190) is published monthly by Gulf Publishing Company, 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 Box 2608, Houston, Texas 77252 Copyright © 2018 by Gulf Publishing Company All rights reserved 2015 2015 gas processing/LNG 2016 2016 gas processing/LNG 2017 2017 gas processing/LNG 120 Executive Editor Managing Editor Technical Editor Digital Editor Reliability/Equipment Editor Contributing Editor Contributing Editor Contributing Editor Permission is granted by the copyright owner to libraries and others registered with the Copyright Clearance Center (CCC) to photocopy any articles herein for the base fee of $3 per copy per page Payment should be sent directly to the CCC, 21 Congress St., Salem, Mass 01970 Copying for other than personal or internal reference use without express permission is prohibited Requests for special permission or bulk orders should be addressed to the Editor ISSN 0018-8190/01 60 40 20 Africa Asia-Pacific Canada Europe Latin America Middle East US FIG Trend analysis on new project announcements vs new gas processing/LNG projects by region, 2015–2017 Source: Hydrocarbon Processing’s Construction Boxscore Database 4 JANUARY 2018 | HydrocarbonProcessing.com President/CEO CFO Vice President Vice President Vice President, Finance and Operations Vice President, Production Publication Agreement Number 40034765 John Royall Alan Millis Andy McDowell Ron Higgins Pamela Harvey Sheryl Stone Printed in USA Other Gulf Publishing Company titles include: Gas ProcessingTM, Petroleum Economist ©, World Oil ®, Pipeline & Gas Journal and Underground Construction We’re looking into your future You face great transformation these days, especially digitalization and ever-changing trends And you want stable, efficient operation of plant and enterprise, assuring creation of value for optimal resource use and profitability This is where co-innovation comes alive We’ll respond with solutions and proposals from a perspective outside the box, and with insights into advanced technologies that support sustainable growth for you and society Yokogawa Your partner in a vital future yokogawa.com/into Co-innovating tomorrow is a registered trademark of Yokogawa Electric Corporation Select 60 at www.HydrocarbonProcessing.com/RS Highest possible return values for spent PGM bearing catalysts— including rhenium On-site kilning eliminates trans-shipping costs, speeds processing In-house settlement and metals management options to meet your liquidity and metals transfer needs World class continuous sampling system helps provide maximum returns SA-BIN® secure containers store spent PGM bearing catalysts for fast and hassle-free shipping directly to our refining facilities Green initiatives help protect our environment— and your financial interests—for peace of mind Sabin's One Stop recovery and refining services Security, accuracy, convenience, and speed Sabin's all inclusive one stop recovery and refining services eliminate the need to send your spent PGM bearing catalysts to multiple sources We handle everything with one stop Stop by our website today and discover the Sabin difference: sabinmetal.com Select 55 at www.HydrocarbonProcessing.com/RS Editorial Comment LEE NICHOLS, EDITOR/ASSOCIATE PUBLISHER Lee.Nichols@HydrocarbonProcessing.com Biofuels—A viable fuel source for the future? This issue of Hydrocarbon Processing focuses on the use of alternative feedstocks and biofuels The goal of utilizing these technologies is to produce fuels and products that lower total carbon output/emissions, which is a major focus in decarbonizing economies around the world But how viable are biofuels as a major fuel source in the future? Although biofuels represent a small percentage of global fuel consumption, the increase in production and consumption—primarily through government mandates—cannot be ignored According to the International Energy Agency’s (IEA’s) 2017 mediumterm market report on renewable energy, world biofuel production is forecast to increase by approximately 16% to more than 2.7 MMbpd by 2023 Asia will be the leader in biofuels consumption growth due to increasing consumption in transportation fuels Biofuels in the global transportation sector is the main driver for biofuels consumption The leaders in biofuels consumption include Brazil, China, Europe and the US, representing approximately 90% of global biofuels consumption, according to the IEA Although Asia will see a spike in biofuels consumption into the early 2020s, a number of countries around the world are taking steps to increase the use of biofuels in their total energy mix In December 2017, Brazil’s Senate approved a bill that would set up a new biofuels program to promote the production and use of biofuels The program, referred to as RenovaBio, would help the country reduce carbon emissions to help comply with the Paris Agreement China and India have made plans to increase the use of biofuels in their transportation sectors, as well As part of its clean fuels program, China is experimenting with alternative fuels for the transportation market, as well as ramping up ethanol blending into the gasoline pool India increased its ethanol blending rate in gasoline to 3.3% in 2016—the highest market penetration by ethanol to date, according to a report by the USDA Foreign Agriculture Service’s Global Agriculture Information Network The increase in biofuels blending is part of the country’s ethanol blending program (EBP) Although the EBP has made significant progress, the tightness in ethanol supplies will limit market penetration in 2018 India plans to increase ethanol imports by approximately 200 MMl to 600 MMl, with nearly 80% of the imports sourced from the US India also plans to blend methanol in petrol to help reduce pollution, especially in major cities like Delhi In 2018, the US EPA has mandated a blending quota of nearly 19.3 Bgal of renewable fuels into the gasoline pool The US EPA mandate on blending, which falls under the Renewables Fuel Standard (RFS), also calls for more than Bgal of biodiesel to be blended into the diesel fuel supply Although blending quotas for 2018 are relatively flat when compared to 2017, the US is the largest producer of biofuels in the world In turn, US ethanol production capacity has increased substantially over the past several years According to the US EIA, domestic ethanol production has increased from nearly 14 Bgpy in 2014 to approximately 15.5 Bgpy in 2017 The EU is the leader in biodiesel production, and is focusing its efforts on greater usage of renewables, biofuels and electric and hybrid-electric vehicles in efforts to decarbonize the region As previously mentioned, a number of countries are instituting regulations and mandates that call for the additional usage in biofuels to help mitigate emissions, primarily in the transportation sector Although the IEA’s forecast increase in global biofuels consumption is relatively moderate—the agency forecast an increase of 1%, reaching 5% of the global transportation sector by 2023—many regions are focusing their efforts to increase the use of biofuels in their total energy mix INSIDE THIS ISSUE Business Trends LNG is forecast to become one of the most valuable commodities in the world However, LNG supply is outpacing demand growth, creating a glut of supplies that could derail LNG developments This two-part series details the global LNG landscape, the future of LNG growth and a look at LNG operations and developments in each region around the world 24 Special Focus This issue’s Special Focus examines advances and challenges in gas processing and biofuel technologies, as well as the changing role of natural gas and alternative feedstocks in the production of refined fuels 43 Process Optimization The manufacture of paraxylene (pX) is an energy-intensive process Part examined the energyefficient process design principles that are widely used in aromatics processing Part details case studies on pX manufacturing by crystallization and selective adsorption to show how to maximize energy efficiency in pX manufacturing 55 Industry Outlook Industry leaders and esteemed colleagues in the downstream hydrocarbon processing industry provided HP with their insight into growing regions of activity, technology advances and how the downstream industry can innovate in 2018 and into the future 67 Catalyst The use of catalyst in plant operations provides many benefits to operators In this special Bonus Report, advances in catalyst technologies are discussed, along with the strategies of several companies that are leading the charge in catalyst technology development Hydrocarbon Processing | JANUARY 2018 7 | Business Trends As natural gas continues to gain favor in the energy mix, primarily as a feedstock for power generation, global LNG trade has surged over the past several years Global LNG trade is forecast to increase into the foreseeable future This surge in the supply and demand of natural gas has led to billions of dollars of new investment in the construction of LNG liquefaction and regasification infrastructure Millions of tons per year of capacity have commenced operations, with dozens of additional LNG projects proposed or under development This two-part series details the present global LNG landscape, the future of LNG growth and a look at LNG operations and developments in each region around the world Photo: LNG tanker Excelsior is shown at the dock at Freeport LNG’s regasification facility during cooldown and commissioning Image courtesy of Freeport LNG Development LEE NICHOLS, EDITOR/ASSOCIATE PUBLISHER Lee.Nichols@HydrocarbonProcessing.com Business Trends The future of LNG—Part Over the past several years, new gas processing/LNG capacity has surged in nearly every region Growth on both the supply and demand sides has resulted in the announcement of billions of dollars of capital investment across the world Millions of tons of new LNG import and export capacity have commenced operations, with hundreds of millions of tons still under development According to the International Group of LNG Importers’ (GIIGNL’s) The LNG Industry: GIIGNL Annual Report 2017, global LNG trade has increased from approximately 239 MMtpy in 2014 to 245 MMtpy in 2015 to nearly 264 MMtpy in 2016 This trend represents a year-over-year (y-o-y) increase of 2.5% and 7.5%, respectively In 2017, Bloomberg New Energy Finance expects total LNG demand to reach 280 MMtpy— a 6% demand increase from the previous year LNG trade is expanding at a substantial rate, and is forecast to grow seven times faster than pipeline gas trade, according to BP’s Energy Outlook 2017 BP forecasts that LNG’s market share of total global gas trade will increase from 32% in 2017 to approximately 50% by 2035 The global LNG export market has been dominated by Qatar, Australia, Malaysia, Algeria and Indonesia for the past 15 yr Over the past several years, Australia has led the growth in new LNG export capacity However, in the next decade, the US will significantly expand its liquefaction capacity and become one of the most prominent LNG exporters in the world (FIG 1) 80 70 60 Other Russia Africa US Australia Qatar LNG supply, Bcfd 50 40 30 20 10 1990 2005 2020 FIG Global growth in LNG supply to 2035 Source: BP 2035 According to the International Gas Union (IGU), global regasification capacity is nearly 800 MMtpy, as of mid-2017 (FIG 2) The Asia-Pacific region remains the main demand center for LNG consumption Soaring natural gas demand for power generation will be instrumental in adding millions of tons of new LNG import capacity through the early 2020s (FIG 3) The additional import capacity will come in the form of conventional onshore import terminals and the use of floating vessels (e.g., FLNG, FSRU, etc.) Even with natural gas demand increasing around the world, LNG supply is outpacing demand growth This imbalance has led to an oversupplied market, which is expected to last into the early 2020s LNG buyers are renegotiating long-term contracts, as well as increasing short-term purchases and spot-market deals The LNG glut has delayed multiple final investment decisions (FIDs), as LNG developers appear to be hesitant to invest in heavily capital-intensive terminal construction Part of this global LNG overview will provide details on the LNG sectors of the Asia-Pacific region, Canada and Latin America Part will focus on Africa, Europe, the Middle East and the US Asia-Pacific The region will not only be the leader in the construction of new refining and petrochemical capacity through the rest of the decade, but it will also witness the startup of millions of tpy of new LNG import and export capacity Japan, 197, 43% US, 129, 1% South Korea, 101, 35% Spain, 49, 21% China, 49, 56% UK, 35, 21% India, 27, 75% France, 25, 36% Mexico, 17, 25% Turkey, 16, 54% Taiwan, 13, 118% Brazil, 12, 11% Italy, 11, 40% Egypt, 10, 75% UAE, 10, 37% Netherlands, 9, 4% Indonesia, 9, 36% Argentina, 8, 47% Canada, 8, 3% Belgium, 7, 15% Singapore, 6, 36% Portugal, 6, 23% Kuwait, 6, 66% Chile, 6, 59% Thailand, 5, 50% Small markets, 30, 46% FIG LNG regasification capacity (MMtpy) by country, 2016 Source: IGU Hydrocarbon Processing | JANUARY 2018 9 CATALYST TECHNOLOGY UPDATE A NEW GENERATION OF DEWAXING CATALYSTS HENRIK W RASMUSSEN, Haldor Topsoe Inc., Houston, Texas The refining industry has been considering incorporating dewaxing in ultra-low sulfur diesel (ULSD) and hydrocracking services to increase the flexibility of hydroprocessing units and to process more barrels by increasing the endpoint of the feed when diesel margins are favorable Processing higher endpoint feed makes it more difficult to meet product specifications for cold flow properties and the T90 Dewaxing is one solution, but because today’s dewaxing catalysts also have a significant cracking functionality, some of the extra diesel barrels will be lost to naphtha and light ends, making dewaxing less attractive in many cases The key is to use a dewaxing catalyst that is very selective towards isomerization and, consequently, will result in a minimal reduction of the die- sel yield Topsoe has recently launched a series of dewaxing catalysts that are true isomerization catalysts and have very little activity toward the cracking of diesel molecules These catalysts are called TK-910 D-wax, TK-920 D-wax, TK-930 D-wax and TK-940 D-wax, and their application areas are shown in TABLE Cold flow properties These catalysts will enable true molecule management In other words, refiners can increase the endpoint of the diesel feed, even during the winter months, to produce extra diesel barrels and still meet cold flow property specs, easily justifying the cost of the dewaxing catalyst ULSD cold flow properties are defined as cold filter plugging (CFPP) and cloud point (CP), or pour point (PP) These properties are negatively affected TABLE The new generation dewaxing catalyst, TK-900 D-wax Sweet mode Sour mode Diesel/renewable TK-920 TK-930 Lube/VGO TK-910 TK-940 Metal type Noble metal Base metal Yield loss Very low Very low H2 consumption Very low Very low Old generation dewaxing by the presence of waxy molecules, such as normal paraffins, in the diesel feed Without the use of a dewaxing catalyst, only a few remedies can get the cold flow properties on spec during the winter months: Feed management: Endpoint reduction and consequently a loss of barrels Kerosine blending: Diluting the wax molecules Use of additives: An increased operating cost to the refinery These options are often not commercially attractive The case study here will show that the use of the TK-930 D-wax catalyst in ULSD service provided the refiner with a substantial increase in profitability during both the winter and summer periods, easily justifying the cost of the dewaxing catalyst The dewaxing catalysts are based on a proprietary zeolite structure promoted with nickel and tungsten, or noble metals, to provide an unmatched selectivity towards isomerization and an exceptional yield structure of the product Another key feature of the TK-930 Dwax and TK-940 D-wax catalysts is that they exhibit good desulfurization (HDS) and denitrification (HDN) activity in TABLE Feedstock properties and operating conditions Diesel yield loss, < 150°C, wt% FF Distillation TK-930 D-wax Distillation curve, IBP 221 Distillation curve, 10 wt% 392 Distillation curve, 30 wt% 466 Distillation curve, 50 wt% 529 Distillation curve, 70 wt% 591 Distillation curve, 90 wt% 663 Distillation curve, FBP Sulfur Nitrogen 10 20 30 Cloud point improvement, °C 40 FIG Yield loss as a function of dewaxing C–80 CATALYST TECHNOLOGY UPDATE | JANUARY 2018 | HydrocarbonProcessing.com 50 60 Aromatics Pressure LHSV 752 1.0 wt% 350 wtppm 41 wt% 1,200 psig 1.2 hr-1 CATALYST TECHNOLOGY UPDATE their sulfided state, which means that they work well in a sour environment Since the catalysts work in a sour environment, they may be installed in the same reactor as the hydrotreating catalyst FIG shows that the new D-wax series catalysts generate only 1/8 of the yield loss per degree of CP improvement, compared to the company’s previous generation dewaxing catalyst Furthermore, 90% of the diesel yield loss experienced with the D-wax series is lost to naphtha— which still provides value for the refiner— and 10% is lost to light ends (C1–C4 ) Case study A US refinery operating a 25-Mbpd ULSD unit selected a load of NiMo catalyst TK-611 HyBRIM on top of a layer of TK-930 D-wax for use in the higher pressure ULSD unit This was based on a detailed pilot plant study confirming the high activity of TK-611 HyBRIM and the selectively of the dewaxing catalyst The feed properties of this unit are listed in TABLE Using the TK-930 D-wax catalyst enables the refinery to increase the feed rate during the five winter months by more than 600 bpd while still meeting cold flow property specifications In addition, the catalyst system reduces the T90 point of the product by 12 degrees–15 degrees, depending on the level of dewaxing Most refineries are limited on the feed endpoint because they are up against the T90 spec in the product The reduction in the T90 enabled the refinery to process an additional 1.5 Mbpd during the summer months and still meet all ULSD specifications The additional profit from the enhanced winter and summer modes of operation correspond to approximately $6 MM/yr–$8 MM/yr, or approximately $30 MM over the catalyst cycle Renewable fuels dewaxing with TK-920 D-wax Renewable diesel generated by the hydrotreating of triglycerides is mainly n-paraffins and will have very poor cold flow properties Unless the renewable diesel is used in a very warm climate or as blendstock, it is necessary to dewax the product significantly Since the renewable feedstocks are typically very sweet, the use of noble metal-based TK-920 D-wax is recommended This catalyst is already installed in several renewable fuels reactors and is providing the required cloud point reduction with a very low diesel yield loss Takeaways The new dewaxing catalysts have been proven to provide 1/8 of the yield loss experienced with a traditional dewaxing catalyst per degree of cloud point improvement The outstanding selectivity allows refiners to maintain high feed endpoint during the winter months and, due to a reduction in the T90 point of the product, it is also possible to process more barrels in the summer months HENRIK RASMUSSEN has worked at Haldor Topsoe for more than 25 yr, and has held a number of technical and management positions for all of Topsoe’s business units Mr Rasmussen is the Vice President of Catalyst and Technology for Haldor Topsoe and is responsible for the catalyst and license technology business for the US, Canada and the Caribbean He graduated from the University of Copenhagen in 1989 with a degree in chemical engineering before relocating to the US in 1991 SAVE THE DATE October 25, 2018 | Houston, Texas GasProcessingConference.com Gas Processing and Hydrocarbon Processing are gathering the gas processing industry’s key players for GasPro 2018 This exclusive, one-day conference offers delegates a unique opportunity to network with their peers, discuss industry challenges and developments, learn about the current economic outlook, share best practices, and explore solutions to improve production and efficiency GasPro Americas now includes the popular GTL Technology Forum Sponsorship opportunities are available! For more information on sponsorship opportunities, please contact: Hortensia “Tish” Barroso, Business Development Manager, at Hortensia.Barroso@GulfPub.com ORGANIZED BY: HYDROCARBON PROCESSING | JANUARY 2018 | CATALYST TECHNOLOGY UPDATE C–81 EVOLVING NEEDS SOLVING WHEN THE INDUSTRY PRESENTS BIGGER PROBLEMS, CRI PRESENTS BIGGER SOLVERS M O RE S O L U TIO N S M O R E R & D M O RE E FFIC IE N CY MORE C O ST S AV IN G S AND NO BIG ADVANCEMENT EVER HAPPENED WITHOUT CHANGE CHANGE IS COMING W W W C R I C A T A LY S T C O M Select 74 at www.HydrocarbonProcessing.com/RS Project Management G PICHEO, Jacobs Consultancy, The Hague, Netherlands and W REED, Jacobs Consultancy, Manchester, UK Incorporate assurance into an operational readiness program—Part Investors have a critical need for assurance that the asset they are invested in will achieve continuous operation at the designed rates, as well as meet—and hopefully surpass—reliability, availability and maintenance targets safely To achieve required production rates, leading companies routinely implement a structured operational readiness process in their capital project transitions The key factor that differentiates leading companies from the rest of the industry is the shift from a static culture of conventional, classic project delivery, to a more dynamic, holistic and pragmatic approach that targets, in early project phases, the future operations and production phases This enlightened approach goes beyond the commissioning and startup phases These companies devote significant resources to leverage the benefits of their operations experts and apply the lessons learned from their previous experiences In Part 1, the theory of an operational readiness assurance (ORA) program was introduced Part of this article moves from theory to practice, and illustrates how a client dealt with their operational readiness needs The conclusions drawn from this case study demonstrate the benefits of implementing an ORA program, as well as the steps that companies must take moving forward Looking beyond a vertical startup The projects the authors have been involved in look forward through mechanical completion certificate (MCC), ready for startup (RFSU), pre-startup safety review (PSSR), etc., to the startup of the project and up to 90 d beyond startup Beyond the 90-d window, there can be worrying signs of carelessness to ensure ongoing safety, preservation of integrity and readiness to operate and optimally maintain the asset Operators have focused on what must be done to satisfy external and internal stage gates, and, in some cases, have shifted attention and resources from “should do” items to deliver upon the “must do” items Typically, clients respond that they will catch up on these matters once in operation In the authors’ experience, this is a rarity, and it can take up to yr into production to fully deal with what should have been done earlier This methodology is sub-optimal and can be avoided Where practically possible, the owner of the facility must deal with the “musts” and “shoulds” concurrently On a recent project, a key concern was the lack of understanding and use of reliability, availability and maintainability (RAM) techniques early in the design, construction, commissioning and handover phases This lack of understanding led to an unacceptable situation, whereby the operation and maintenance (O&M) strategy was contrived without proper reference to the levels of RAM that should be achieved If RAM targets are not defined, then the O&M strategy has no basis for achieving the RAM targets This situation is unacceptable for two major reasons: It cannot show the value and/or impact of the strategy on the RAM targets It cannot calculate what the O&M budget must be vs what is possible Why use a third party for independent assurance? An independent assur- ance will provide an unbiased, outside-in view of the project status and readiness level The potential issues, as well as the project risks, will be highlighted and intensely challenged Ultimately, the assessment will be beneficial to all stakeholders, which helps assess the governance mechanisms and mitigate value losses with real-time feedback on the identified issues Finally, a third party will be able to benchmark and provide insights on the functionalities (and dysfunctionalities) it has witnessed vs previous experiences Is assurance a “nice to have?” The short answer is no, it is not Assurance is part of corporate governance, in which management provides accurate and up-to-date information to stakeholders about the efficiency and effectiveness of their policies and operations, and the status of compliance with statutory obligations Assurance is an integral part of overall project governance It is not a choice or an “add-on service,” but is rather a requirement of each project A 2009 technical paper explained major deficits in project governance.3 The article stated, “Capital project owners typically appoint contractors to deliver their projects, and they often then become remote from delivery activity Syndicates of lenders are likely to be even more remote It is all too easily assumed that, once the Hydrocarbon Processing | JANUARY 2018 83 Project Management contract is in place, the project will run itself and no active control is needed As a result, the project turns into a ‘black box,’ with little visibility over what is going on until the very end Project sponsors then find that they face significant time and cost overruns, and possibly even litigation Toward the end of the project, options reduce and there is an increased tendency to spend more money to resolve the problem.” ORA BUSINESS CASE Background A refiner was building a $5-B, 200-Mbpd greenfield crude oil refinery The refinery was to produce naphtha, mixed xylenes, ultra-low sulfur diesel, jet fuel and LPG, among other petroleum products The project is highly complex, with approximately 10,000 people onsite during the construction phase and several primary engineering/licensing companies providing project services and technologies This type of project required the refiner’s organization to define a systematic approach to provide assurance on its operational readiness The refiner acknowledged the need for a fully integrated ORA process, based on industry best practices, for safer and efficient startup, as well as a timely transition to normal operations The ORA program in practice Ideally, the ORA program begins during proj- ect feasibility and ends when the plant achieves continuous operation at the design production rate and meets reliability and availability targets at an optimal cost Typical project phases are shown in FIG The refiner wanted to install a fully integrated ORA program One of the project aims was to introduce a structured and consistent process to assess critical issues and to achieve a smooth (vertical) startup and continuous operations An ORA program is designed to promote the implementation of best practices to ensure that the desired operational performance is achieved during commissioning, startup and initial operations Typically, these are proven practices—the results of recurring lessons learned in previous projects The project’s size, complexity and schedule are taken into consideration to determine the optimum timing to perform the sequence of ORA assessments These factors allow the project team to implement any modifications to identified gaps in a timely manner The evaluation of the readiness status was based on the assessment of key operational planning practices on 18 areas/domains of the project (FIG 6) The assessment evaluated the level of involvement of the different operational interfaces (i.e., operations, maintenance, project teams, contractors, etc.) The operational readiness index (ORI) measurement allowed a quanti- FIG Operational readiness throughout all phases of the project FIG Operational readiness assessment tool 84 JANUARY 2018 | HydrocarbonProcessing.com tative benchmark of the use and effectiveness of operational practices against industry best practices The benchmark is based on: • Project phase and size • Types of deliverables • Diagnostic control systems • Processes and procedures • Organizational capability and utilization In addition, the operational readiness assessment included facilitated group exercises designed to trigger the identification of operational and startup risks and ongoing issues (i.e., operational bugs), and to identify and describe mitigating actions aimed at a smooth transition to startup and operations Ready-to-operate (RTO) plan An RTO plan includes setting milestones and critical activities for the asset owner to achieve prior to beginning operations.a Different from an integrated project plan, the RTO plan aims to identify and track the status of mission-critical activities, assigning ownership and guiding the focus of the organization’s leadership In collaboration with the owner’s team, key project management and contractors’ team members, the RTO plan was developed and initiated at the end of the construction phase To ensure a successful implementation, it is critical to align the operational readiness milestones with the existing EPC project This alignment ensures that key operational deliverables are completed in a timely manner, with the desired level of quality The assurance that these deliverables are demonstrably in use and working as intended is equally as important Along with the RTO plan, an active scorecard (FIG 7) acts as an attentionfocusing device for the project leadership Now Available! HPI MARKET DATA 2018 Make Smarter Decisions and Plan Ahead Dive into the latest market trends, forecast spending and activity in the global petrochemical, refining and natural gas/LNG industries Produced annually by the editors of Hydrocarbon Processing and the Construction Boxscore Database, and featuring data provided by governments and private organizations, HPI Market Data 2018 is the hydrocarbon processing industry’s most trusted forecast of capital, maintenance and operating expenditures HPI Market Data 2018 features: • Global spending in the refining, petrochemical and gas processing sectors • Forecast on global capital, maintenance and operating spending in the HPI • Short-term and long-term implications of today’s low crude oil prices • An exploration of changing markets and demand within the global HPI, with discussion of emerging markets • More than 35 tables and 70 figures, including information and data collected from governments and private organizations • Editorial analysis of worldwide economic, social and political trends driving HPI activity across all sectors Highlights include: • The HPI’s capital, maintenance and operating budget for 2018 and a year-over-year comparison against 2017 • 2018 capital spending forecast broken out by region and sector • Expanded section on global construction and investment • How crude oil supply and demand is affecting the downstream HPI, as well as global and regional trade • How refineries will be designed to handle unconventional feedstocks, such as NGLs, bitumen, heavy oil, and shale • Detailed overview on new sulfur and clean-fuels regulations around the world • Detailed overview the IMO 2020 Global Sulfur cap on marine fuels ORDER TODAY! HydrocarbonProcessing.com Call +1 (713) 520-4426 or visit GulfPub.com/MDB2018 Project Management Readiness is a necessary constant While this article focused on the early life of an endeavor, an argument can be made that the state of readiness must be maintained throughout the complete lifecycle of any endeavor Each time that substantive changes are made to facilities during the O&M life cycle phase at key times, such as a turnaround (TAR), an ORA program should be deployed as a necessary activity before the TAR Therefore, when the operation is back online, the owner can update the events post-TAR The point is that readiness is a constant need during operations, and must be considered an integral part of operational excellence It is not something that is a focus only during the transition to normal operations FIG An example of an active ORA scorecard This data is used to monitor organizational and project outcomes, take actions and allocate resources to correct deviations Assurance reviews In parallel with the implementation of the RTO plan, the asset owner’s management and project management team should plan a series of operational and startup reviews aimed at identifying any operational gaps, as well as review the completion status and effectiveness of the execution of the RTO plan Looking ahead Value leaking from capital projects as they fail to achieve operability targets is unacceptable This loss of value can be completely avoided or mitigated A consistent, structured operational readiness program, based on industry best practices, will have a major impact on cost savings The key to achieving readiness is the focus on future operations, which limits the impact of short-term efforts that may increase the risks onsite Staffing, interface management and information handovers are the main con86 JANUARY 2018 | HydrocarbonProcessing.com tributors to disruption and poor performance during transition The operational readiness work process should provide measurable assurance and prove that all deliverables are demonstrably in use, with measurable impacts An independent assurance will provide an unbiased, outside-in view of the project’s status and its readiness level Crucial for the success of an operational readiness assessment is the necessity to craft the operational readiness approach to the specifics of each unique client and capital project A 2016 technical paper on the importance of implementing an ORA program mentioned, “Research has shown that most of the projects without operational readiness experience problems in startup and capital cost increases Inadequate operational readiness introduces defects and reduces equipment life, which significantly delays the realization of expected business results (typically, 60%–70% benefits after yr of operation).”4 These results show that a project’s economics can be negatively affected long past startup and initial operations when an ORA program is not implemented Professional operational readiness Enough information is available in the public domain to illustrate that a compelling need exists to address this operational readiness topic more thoroughly It is time to apply the lessons we say that we have learned, which suggests that effort should be applied to documenting, in a standardized way, what operational readiness must encompass It is time to level the playing field and craft an international standard on operational readiness for the oil and gas community—a standard that should be augmented with professional qualifications and certifications as operational readiness professionals NOTES aRefers to Jacobs’ Operational Readiness Plan LITERATURE CITED PricewaterhouseCoopers, What’s wrong with Project Governance? 2009 Pesenti, W., “Capital projects right the first time = Operational readiness assurance,” LinkedIn, February 2016 GABRIELE PICHEO is Senior Consultant at Jacobs Consultancy He is based in The Hague, The Netherlands His expertise includes operational readiness, maintenance and reliability, due diligence and asset management Mr Picheo earned an MS degree in aeronautical engineering and a BCh degree in aerospace engineering WAYNE REED has worked in the manufacturing and process industries for his entire career He has more than 40 yr of hands-on and practical global experience in more than 60 countries For the last 20 yr, Mr Reed has consulted on change initiatives globally, across all industries BOB ANDREW, TECHNICAL EDITOR Bob.Andrew@HydrocarbonProcessing.com Innovations Producing monoethylene glycol from sugar Braskem and Haldor Topsoe have signed a technological cooperation agreement to develop a pioneering route to produce monoethylene glycol (MEG) from sugar The agreement calls for the construction of a demonstration plant in Denmark, with operations slated to begin in 2019 The demonstration plant will conduct tests to validate the technology and confirm its technical and economic feasibility, which is a critical step before launching production on an industrial scale and commercial operations The unit will be flexible to validate the technology in different raw materials, such as sucrose, dextrose and second-generation sugars MEG is a key component of PET resin, the main raw material used by the textile and packaging industries The project is based on a two-step process developed at Topsoe’s labs and focuses on the conversion of sugar into MEG at a single industrial unit, which will reduce the initial investment in production and boost the competitiveness of the process With this agreement, Braskem seeks to expand its portfolio of renewable products to offer new solutions that complement its bio-based polyethylene business This new partnership strengthens Braskem’s position in the development of innovative solutions that will leverage the competitiveness of different biomasses and complements the traditional solutions offered by the petrochemical industry For Haldor Topsoe, catalysis will play an important role in developing sustainable solutions that produce important chemicals from renewable sources, such as sugars Select at www.HydrocarbonProcessing.com/RS Measure two process variables with a single wireless transmitter Emerson Automation Solutions introduces the Rosemount 3051S MultiVariable wireless pressure transmitter (FIG 1), which is designed to directly measure two process variables in one installation so users can gain greater insight into their process without increasing installation costs The more devices there are in a facility, the greater are the required cost and time investments for installation, scheduled maintenance and downtime Users can simplify installation and maintenance routines with the 3051S Since the transmitter measures differential and static pressure, users can reduce pipe penetrations and impulse piping, along with their associated costs The static pressure sensor is available as either true gage or absolute, for reduced maintenance and calibration costs Backed by Emerson’s proven experience in smart wireless field instrumentation, users have instant visibility to their measurements through a non-intrusive, WirelessHART monitoring system With Rosemount 3051S wireless transmitters, users can monitor more assets throughout their facilities with greater than 99% reliability and at 40%–60% cost savings over wired installations The Rosemount 3051S MultiVariable wireless pressure transmitter delivers a decade of maintenance-free performance with a 10-yr stability specification, making it a cost-effective and reliable way to monitor assets, while reducing installation costs Select at www.HydrocarbonProcessing.com/RS Reliable shielded solid insulation MV switchgear Combining Schneider Electric’s expertise in both air-insulated switchgear and gas-insulated switchgear, Schneider is breaking new ground with the increased reliability of Shielded Solid Insulation System (2SIS) This technological breakthrough opens the path to improved efficiency and customer experience, and provides the following benefits: • Reduced opportunity of arc flash or contact with live parts Insulation and screening of all FIG Two process variables wireless HART pressure transmitter live parts with 2SIS reduces the likelihood of exposure to electrical hazards • Longer time between maintenance intervals 2SIS offers improved performance in harsh and demanding environments compared to traditional switchgear • Flexible, simple, modular and functional The product is simple to install and use, with operator-friendly switchgear and minimum servicing of main units • Smart grid-ready, distributed intelligence The product includes advanced protection, control and monitoring, and is fully integrated for higher dependability and energy efficiency With its 3-in-1 switchgear design, the system’s operational interface is simple, intuitive and user friendly The circuit breaker is in series with the isolating grounding switch, which, combined with interlocks, provides integrally designed protection for the operator Select at www.HydrocarbonProcessing.com/RS An expanded version of Innovations can be found online at HydrocarbonProcessing.com Hydrocarbon Processing | JANUARY 2018 86–A MIKE RHODES, TECHNICAL EDITOR Mike.Rhodes@HydrocarbonProcessing.com People SIMMONS EDECO has appointed Niels Versfeld as Chief Executive Officer Before joining SIMMONS EDECO, he served as General Manager of Gibson Energy’s environmental services division Previously, he worked as Chief Operations Officer (COO) for Palko Environmental until it was acquired by Gibson Energy in 2011 Throughout his career, Mr Versfeld has worked in a variety of roles, initially as an environmental consultant serving the energy sector, and as an Environment and Regulatory Manager for CCS Corp LyondellBasell has named Darleen Caron as Executive VP and Chief Human Resources (HR) Officer Most recently, Ms Caron was Executive VP of global HR for SNCLavalin Inc Previously, she led HR functions for the Dow Chemical Co and ABB, and both HR and environment, safety and health for Alcan The National Association of Manufacturers (NAM) named Dr Kirsten LundJurgensen, Executive VP and President at Pfizer Global Supply, to its board of directors Jim Fitterling, President and COO of The Dow Chemical Co and COO of the materials science division at DowDuPont, has been named to the executive committee of the NAM board of directors 86–B Dr Christine EhligEconomides has joined The Letton Hall Group as Principal Advisor in petroleum reservoir and production engineering Dr Ehlig-Economides is widely known for her developments in oil and gas well testing and pressure transient analysis, integrated reservoir characterization, complex well design and production enhancement Following a 20-yr career at Schlumberger, she has been a leading researcher and professor of petroleum engineering at Texas A&M University and the University of Houston, has published more than 100 technical papers and has co-authored two textbooks Tommy Hillock has been named as Regional Manager for the Middle East and Caspian regions for Fulkrum Technical Services He brings 35 yr of international industry experience to his new role, including the last 15 yr as Managing Director of Global Energy SCS, where he supported more than 100 customers worldwide and led the firm’s expansion with new offices in Perth, Australia and Houston, Texas, before establishing operations for SCS in the Middle East As Regional Manager, Mr Hillock will be based in Abu Dhabi and is responsible for all company operations across the Middle East and Caspian regions JANUARY 2018 | HydrocarbonProcessing.com Crestchic has appointed Carmen Nosic as Sales Manager for its US operation As part of Crestchic’s plans to further develop its business in the US, she will be responsible for sale and rental markets Ms Nosic has 19 yr of experience in the power industry and previously worked for Hawthorne Power Systems (HPS) Exxon Mobil Corp.’s board of directors has elected Neil Chapman as Senior VP and member of the corporation’s management committee The board also appointed John Verity, presently the Senior VP of polymers, as President of ExxonMobil Chemical Co Mr Chapman became VP for the global polyethylene business unit of ExxonMobil Chemical Co in 2005, and became President of ExxonMobil Global Services Co Mr Verity joined Exxon Chemical in 1980 and held sales, marketing and strategic planning roles in its polyethylene business in Europe In 2000, he became the Americas Marketing Manager for the ExxonMobil Chemical’s polyethylene business He was appointed President of Univation Technologies LLC in 2001 He returned to ExxonMobil Chemical in 2005 as VP of R&D, and later served as VP of the polyethylene business, VP of the polyolefins business and VP of plastics and resins Tony Evans joins LUX Assure as the newest member of the global business development team for its corrosion inhibitor monitoring product With 18 yr of experience in sales, marketing and business management, Mr Evans has held positions at Synergi Solutions, Bibby Offshore and Nautronix Most recently, he served as sales and marketing Director at Deep C Group LUX’s technical team has also been bolstered with the appointment of scientist Harry Grover, who brings yr of technical and research experience to LUX, most recently working as senior assistant scientist at Charles River Laboratories Peggy Heeg has joined Reed Smith as a partner in its global energy and natural resources group Ms Heeg’s practice focuses on pipeline development, regulatory compliance and corporate governance She joins Reed Smith from the Houston office of Norton Rose Fulbright LLP, where she was a partner and former member of the firm’s executive committee Prior to joining Fulbright in 2003, Ms Heeg was Executive VP and General Counsel for El Paso Corp., which, at the time, owned the largest natural gas pipeline system in the US, and was the nation’s largest provider of natural gas Ms Heeg’s focus includes crude oil pipeline infrastructure The CITGO Board of Directors has appointed Asdrúbal Chávez as the new Acting President and CEO of CITGO Petroleum Corp He began his career at the El Palito refinery in Venezuela, working in the areas of industrial services, distillation and specialties, conversion and treatment, crude and products movement, programming and economics, and process engineering, as well as managing several expansion and organization projects throughout the 1990s Since 2009, he has also served as Vice Minister of petrochemicals, President of PDV Marina, and Director of CITGO Petroleum Corp In September 2014, Mr Chávez was appointed Minister of the Popular Power of Petroleum and Mining, the entity responsible for all oil activity in Venezuela Jim Williams, VP of corporate purchasing and supplier relations for Motion Industries Inc.—a wholly owned subsidiary of Genuine Parts Co.—has been elected as the 2018 President of the Power Transmission Distributors Association (PTDA) Mr Williams has been a PTDA volunteer since 2005, when he joined the motion control task force A past chair of the programs and products committee, he has served on the board of directors since 2015 MARKETPLACE / L.Kane@GulfPub.com / +1 (713) 412-2389 ADHESIVE WITHSTANDS HARSH CHEMICALS EP21TPLV Epoxy Polysulfide EXCELLENT CHEMICAL RESISTANCE TOUGH, FLEXIBLE BONDS LOW VISCOSITY SYSTEM Why should you filter your water? 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Mediterranean Gas Conference (EMGC) back to Nicosia, Cyprus Now in its fifth year, EMGC is the region’s premier conference for companies operating in this rapidly rapidly-evolving energy hub The two-day conference will center around a high-level technical program featuring speakers from leading operating and service companies Eni’s Chief Exploration Officer, Luca Bertelli, will open EMGC 2018 with a high-profile keynote address on Day Join the conversation and network with your peers at EMGC! Sponsorship opportunities are available! For more information on sponsorship opportunities, please contact: Hortensia “Tish” Barroso, Business Development Manager at Hortensia.Barroso@GulfPub.com ORGANIZED BY: Confirmed Keynote Speaker Luca Bertelli Chief Exploration Officer Eni Select 51 at www.HydrocarbonProcessing.com/RS ... to Hydrocarbon Processing, P.O Box 2608, Houston, Texas 77252 Copyright © 2018 by Gulf Publishing Company All rights reserved 2015 2015 gas processing/ LNG 2016 2016 gas processing/ LNG 2017 2017 ... 832.452.2800 WWW.CUDD.COM 14 JANUARY 2018  | HydrocarbonProcessing.com Select 153 at www.HydrocarbonProcessing.com/RS MIKE RHODES, MANAGING EDITOR Mike.Rhodes@HydrocarbonProcessing.com Industry Metrics... copyright 2017 ; all rights reserved; OPEC Monthly Oil Market Report, December 2017 Hydrocarbon Processing | JANUARY 2018  14–A LEE NICHOLS, EDITOR/ASSOCIATE PUBLISHER Lee.Nichols@HydrocarbonProcessing.com