WORLDWIDE REFINERY PROCESSING REVIEW. First Quarter 2010

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1 WORLDWIDE REFINERY PROCESSING REVIEW Monitoring Technology Development and Competition in One Single Source First Quarter 2010 HYDROCARBON PUBLISHING COMPANY Translating Knowledge into Profitability SM P.O. Box 661 Southeastern, PA (U.S.A.) Phone: (610) / Fax: (610)

2 Review 1. Introduction 1 MARKET/TECHNOLOGY TRENDS & OPPORTUNITIES 1.1 Market Conditions and Outlook Transportation Fuels Supply and Demand Crude Capacity Feed Diversification and Variability Impact on Downstream Processes and Plant Profitability Capacity 1.2 Technology Competition, Direction, and Future Prospects Crude Blending Trends Crude Desalting Trends Chemical Treatment Trends 1.3 Conclusions 2 STATE-OF-THE-ART TECHNOLOGY 2.1 Introduction 2.2 Crude Blending Software ABB Automation Aspen Technology GE Infrastructure Water & Process Technologies Haverly Systems and PetroTech Intel Honeywell Invensys M3 Technology Nexidea Spiral Software Topnir 2.3 Crude Blending Systems Jiskoot/Cameron Veolia Environmental Services 2.4 Stability Tests and Analyzers Baker Petrolite ExxonMobil Finnish Measurement Systems Formulaction Kittiwake Development Lawler Manufacturing LT Industries, Inc Nalco Energy Services Petrobras Process NMR Qualion Ltd Shell Soluble Solutions i

3 2.5 Electrostatic Desalting Hardware Allied Technology Cameron Dual Frequency Dual Polarity Desalter Electro-Dynamic Desalter Bilectric Desalter Silectric Desalter TriVolt Low Velocity GasTech Mackenzie Hydrocarbons 2.6 Static Mixers ProPure Komax Sulzer Chemtech 2.7 Desalter Brine Effluent Treating New Logic Research Veolia Water Solutions & Technologies UniPureEnergy 2.8 Chemical Additives Baker Petrolite Emulsion Breakers Contaminant Removal Corrosion Prevention and Control BJ Chemical Services CECA Champion Technologies Clariant Oil Services Dorf Ketal Eonchemicals GE Infrastructure Water & Process Technologies Emulsion Breakers Contaminant Removal Corrosion Prevention Nalco Energy Services Sinopec 2.9 Desalter Interface Monitors and Control Devices Agar Tank Control/Safety Monitoring Desalter Interface Control Emerson Process Management Kam Controls Tracerco Transducer USA 2.10 Summary of Commercial Technology and Products ii

4 3 PLANT OPERATIONS AND PRACTICES 3.1 Crude Blending Operations Compatibility Issues Self-incompatible Crudes Incompatible Crudes Nearly Incompatible Crudes Practices to Avoid Crude Incompatibility Practices to Mitigate the Effect of Crude Incompatibility Conductivity Issues Logistical Issues Homogeneous Blending Crude Blending Systems Crude Blending as a Corrosion Control Method 3.2 Desalter Operational Guidelines Feed Concerns Water Content Crude Conductivity Feed Rate Interfacial Tension Solids Content Preheat Viscosity Crude Contaminants: Impact on Refinery Processes and Catalysts Mixing Mixing Energy Globe Valves vs. Static Mixers Chemical Treatment Processing Opportunity Crudes Adding Demulsifier in Tankage Adding Surfactants to Stabilize Asphaltenes Dispersion Polymers Washwater System Volume and Injection Point Quality and Sourcing Issues with Using Spent Caustic to Control Desalter Washwater ph Process Monitoring and Control Measuring Desalter Performance Portable Desalter Simulation Measuring Water in Crude Sampling Desalted Crude Oil/Water Interface Level Transmitters Desalter Maintenance: Mud washing 3.3 Troubleshooting Guidelines 3.4 Desalter Effluent Reduction and Treatment: Alleviating the Strain on the Waste Water Treatment Plant Effluent Water/Oil Separation Problems with Hydrocyclones Methods to Reduce Benzene in Desalter Water Preventative Methods Corrective Methods Reducing Chemical Oxygen Demand Reducing Waste Water iii

5 3.5 Unit Revamp Conducting Desalter Revamps on a Field-installed Basis 4 REFINING R&D ALERT! 4.1 Introduction 4.2 Crude Oil Scheduling Patents Research 4.3 Predicting Crude Blend Properties Patents Research 4.4 Miscellaneous Blending Topics Patents Research 4.5 Electrostatic Desalting Processes Patent Research 4.6 Mixing Technology Patents Research 4.7 Chemical Additives Demulsifier Patents Research Metals Removal Patents Fouling, Corrosion, and Scaling Inhibitors Patents Neutralizer Patents Viscosity Reduction Patents 4.8 Emulsion Characterization and Desalter Simulation Patents Research 4.9 Process Monitoring and Control Patents Research 4.10 Miscellaneous (Alternative Processes) Research 4.11 Effluent Water Treatment Patents Research 5 WORLDWIDE INSTALLED CAPACITY 6 CONSTRUCTION 6.1 Recent Construction Activity 6.2 Completed Construction Projects 7 REFERENCES iv