February 2008

Special Report: Clean Fuels

Avoid catalyst replacement pitfalls

Lessons learned on a gasoil hydrotreater revamp show how to mitigate problems

Eskaros, M. G., WorleyParsons

T?his case history discusses the difficulties encountered during a gasoil (GO) hydrotreater catalyst replacement upgrade project. A heavy gasoil (HGO) hydrotreating unit, built in the Gulf area in the 1980s, produced GO at 0.25% (2,500 ppm) sulfur from a feedstock with 1.1%–1.2% (11,000–12,000 ppm) sulfur levels. To meet current clean fuel trends, the hydrotreater unit operation was re-evaluated. From the study, several changes were required to produce GO at much lower sulfur levels. Retrofit actions included: Upgrading catalyst selection Retrofitting reactor Modifying unit operating conditions to produce hydrotreated product at 0.05% (500 ppm) sulfur. Blending the GO

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