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A large Gulf Coast refinery wanted to expand Crude Unit, Vacuum Unit, Naphtha Hydrotreating, Reforming, and Kerosene Hydrotreating capacity


Polaris Engineering provided test runs, operational recommendations, and complete designs to deliver desired unit capacities. The work was field-intensive, not simply computer designs performed from the Home Office. More than 50% of the claimed benefits from the work were from implemented operational changes, as opposed to benefits from increased throughput that were gained.
  • ULSD Compliance Project

    Problem To comply with the EPA mandated low sulfur standard for highway diesel, refiners are now required to meet a 15 ppmw sulfur specification on diesel sold into this market. To produce ultra low sulfur diesel (ULSD), high severity diesel hydrotreating technologies are required. These processes require a significant supply of hydrogen. In order to enter into the ULSD market, the client would need not only a process unit capable of producing ULSD specifications, but also an economical hydrogen source to supply the unit. Solution Polaris proposed a plant expansion design that would give the refiner ULSD production capability and […]

  • Refinery Refurbishment

    Problem A small Gulf Coast refinery had been dormant for over 4 years. The infrastructure, as well as the main processing units, had fallen into disrepair. The new ownership desired to run a different feedstock as well as different product slate than ever had been produced from the refinery. Solution Polaris Engineering provided designs for refurbishing the refinery as well as modifying the processing equipment to produce the new product slate. Polaris Construction provided fabrication, field services, and general contracting to perform the complete refurbishment of the plant. In seven months, the plant went from being dormant to producing on-spec […]

  • Refinery Emergency Design

    Problem A large Midwest refinery suffered a severe fire in the single crude unit that would render the crude unit out of service for nine months. The refinery called in Polaris Engineering to figure out how to run the plant without the crude unit. Solution Polaris Engineering evaluated the plant and provided a design to utilize existing equipment within the plant in completely new services to process crude. The design was completed in less than one week and passed through HAZOP and Corporate review without any modifications. The revamp cost $10MM and allowed the plant to operate at the designed […]