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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 a catalytic reformer. The reformer not only supplied the large quantities hydrogen needed, but also upgraded virgin naphtha to the much more valuable high octane reformate. An NGL refrigeration unit and a steam turbine generator were also proposed to handle the gas produced by the reformer. Enough hydrogen rich fuel was produced to supply all of the hydrogen and fuel requirements of the refinery as well as balance the refinery’s electrical consumption through steam turbine power generation.
  • Process Unit Debottlenecks

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

  • Vac Unit Additions

    Problem With crude feed slates becoming heavier over time, the client’s capabilities of recovering diesel and atmospheric gas oil became limited with the existing Atmospheric Crude Distillation Towers. As a result they were not able to recover a small portion of diesel and large portion of Atmospheric Gas Oil from the Atmospheric Tower Bottoms (ATB). Thus, these products were downgraded to No. 6 Oil. Solution Polaris proposed the design of a Vacuum Distillation Tower that would not only recover the Diesel Cut and Atmospheric Gas Oil, but also increase Gas Oil yields further to meet Low Sulfur Vacuum Gas Oil […]

  • 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 […]