MEPEC 2015 Abstract Book 30 09 2015

15-17 September 2015
Bahrain International Exhibition &

Convention Centre
Under the Patronage of His Royal Highness
Prince Khalifa bin Salman Al Khalifa

Prime Minister, Kingdom of Bahrain
The premier
Process Engineering
Conference & Exhibition
for the Middle East
Abstract Book
www.mepec.org
Table of Contents
Technical Program Abstracts
15th September
13:15 14:45
Process Synthesis, Modelling and Optimization ........................................................................................... Pg 3

Process Retrofitting, Debottlenecking and Constraint Management ............................................................ Pg 4
Process and Equipment Design .................................................................................................................. Pg 5
15th September
16:00 17:30
Process Synthesis, Modelling and Optimization ............................................................................................ P

g7
Process Retrofitting, Debottlenecking and Constraint Management ............................................................ Pg 8
Process and Equipment Design ....................................................................................................................... P
g9
16th September
10:45 12:30
Process Synthesis, Modelling and Optimization .......................................................................................... P

g 10
Process Retrofitting, Debottlenecking and Constraint Management .......................................................... P
g 12
Process and Equipment Design .................................................................................................................... Pg 13
16th September
13:15 14:45
Process Synthesis, Modelling and Optimization .......................................................................................... Pg 14

Process Retrofitting, Debottlenecking and Constraint Management ......................................................... Pg 15
Process and Equipment Design ................................................................................................................... Pg 16
17th September
10:45 12:30

Process Retrofitting, Debottlenecking and Constraint Management .......................................................... Pg 18
17th September
13:00 14:30

Digital iPoster Program Abstracts
Acknowledgements ........................................................................................................................................... Pg 37
15th September 13:15 14:45

Process Synthesis, Modelling and Optimization
Dynamic Reactor Modeling of Catofin Fixed-Bed
Iso-Butane Dehydrogenation Reactor using ACM
Author: Dr. Zeeshan Nawaz, SABIC, KSA
Co-authors: Khaled Alshammari, SABIC, KSA

Khalid Karim, SABIC, KSA
Abstract:
A robust multi-tubular fixed bed reactor model
is developed for Syngas to Hydrocarbons production using
ACM (Aspen Custom Modeler). The two-dimensional pseudohomogeneous model is developed to optimize the reactor design
and operating parameters. The model used intrinsic kinetics (activity
based) of cobalt-based catalyst for syngas to hydrocarbons. Both CO
hydrogenation to hydrocarbons and water gas shift (WGS) reactions
were considered in the range of 220-270oC. The intra particle mass
transfer limitations is there, therefore, a suitable diffusion length has
been calculated theoretically and in accordance the relevant bulk
density of catalyst is used in the model. CO hydrogenation products
are linked with chain growth probability factor and further linked
with empirical relationships to distinguish between olefins, paraffins
and oxygenates. Both radial and axial heat transfer within the fixed
bed and to the cooling medium (boiling water and molten salt)
and concentration profiles were determined. The model predicts
the operating variable severity (operating temperature, runaways,
H2/CO ratio, reaction pressure, allowable pressure drop, etc.) for
design and operating optimization. The results of the modeling are
consistent with literature data and promising for commercial design
projections of MT-FBR for syngas to hydrocarbon production.
There are technologies available (commercially and under

development) to lower Nitrous Oxide emissions from Nitric Acid
plants. However operating companies have no economic incentive
to implement any N2O abatement measures in their Nitric Acid
processes, as these would require capital and operating costs, with
negative economics. For this reason, producers continued to release
N2O into the atmosphere where no laws or regulations existed
mandating the complete or partial destruction of this greenhouse
gas from Nitric Acid plants.
The United Nations Framework Convention on Climate Change
(UNFCCC) under the Kyoto Protocol introduced Clean Development
Mechanism (CDM) projects in developing countries which help
these countries meet target emissions reduction.
This paper addresses a case study related to the installation of a
catalytic N2O abatement project in the tail gas of a Nitric Acid plant
aligned to the CDM project, with N2O destruction efficiency of 90%.
In addition, this clean technology has not yet been commercialized in
industrialized cities. The project has been successfully implemented.
The paper goes on to describe various challenges faced during the
project stages as well as during registering the project under the
UNFCCC protocol. It also describes the methodology followed for
monitoring the required parameters aligned with UNFCCC board
requirements. The case study project has been successfully audited
by UNFCCC representatives.
Mathematical Formulation of Saudi Aramcos Short

Range Operating Planning (SROP) Model
Author: Mohammed Alyanbaawi, Saudi Aramco, KSA
Co-author: Aninda Chakraborty, Saudi Aramco, KSA
Abstract: This paper will describe the mathematical modeling
framework of an advanced multi-plant, multi-period Linear Program
(LP) used to generate the Short Range Operating Plan (SROP) for
the supply of refined products in the Kingdom of Saudi Arabia. The
model is coded in Aspen Technologys Process Industry Modeling
System (X-PIMS) software. Therefore, the XPIMS Global LP model
satisfies the Kingdoms refined product demand optimally over a
planning considering the Kingdoms logistics and other resources.
Implementation of Clean Development Mechanism

(CDM) at Nitric Acid Plant
Author: Muhammad Talah Sangi, Sadara Chemical Company, KSA
Co-author: Walter Papadopulos, Sadara Chemical Company, KSA
Abstract: Nitrous oxide (N2O) is an invisible by-product in the
production of Nitric Acid by Ostwald technology. It is formed
during the catalytic oxidation of Ammonia over Platinum / Rhodium
gauzes, the major product being Nitric Oxide (NO). Nitrous Oxide
is a potential greenhouse gas with three hundred and ten times the
effect of Carbon Dioxide, and Nitric Acid plants represent now the
single largest industrial process source of nitrous oxide.
Besides refinery local models, including full Aspen PIMS distributive

recursive (DR) models and short-cut slate models, the XPIMS Global
LP are also inter-connected with pipelines, truck hauling and shipping
routes. The model strives to minimize expensive routing options,
generally truck hauling routes in preference to utilizing the pipelines.
The distribution network is linked via volume-based bulk plants,
each modelled with tankage and inventories for major products.
A challenging aspect is to set up tank target levels for inventorying
various products at different locations. The model may choose
to violate certain targets at the expense of paying penalty cost,
allowing the model to build or draw inventory to satisfy demand. On
the contrary, the model also has the flexibility to purchase volume
from a hypothetical short-infeasible market (at high price) or sell
volumes to a long-infeasible market (at a much discounted price).
In general, this paper will discuss the following advanced modeling
techniques, aided with real case studies from Saudi Aramcos Short
Range Operating Plan:
Balancing the global supply chain system by trading-off between
Inventory optimization and unfeasible (Short or Long) markets
Integrating of weight based refinery models with volume based

bulk plant models
a leveraged automated technology serving the Refinery objective

was applied in both the cooling tower and water treatment plants.
Refinery product optimization, namely, how refinery production

competes with the international import market
The results of this great automation have been captured in many

aspects:
Local versus Global optimization: Case studies highlighting

situations where Global solutions economically out-perform
obvious local optimal solutions.
In terms of Safety and Environment:
Regional demand optimization

Cargo scheduling using In-transit dummy bulk plants
Pipeline batching modeling long pipelines as bulk plant with
inventory
Capacity upgrade/downgrade modeling in a bulk plant
Breakthrough in C4 Alkylation Technology

Author: Maurice Korpelshoek, CB&I, USA
Abstract: Several countries, especially in South East Asia,
are expected to have a significant octane shortage due to the
implementation of new fuel specifications, because tighter sulfur
and benzene specifications will result in loss of high octane
components. In addition, octane is demanding a higher value in
both the U.S. and Europe as it is required by high compression
engines that are used in high performance vehicles as well as for the
purpose of increasing fuel efficiency.
To compensate for this change in octane balance, high octane
blending components like MTBE and alkylate need to be added to
the gasoline pool. For refiners, alkylate is an ideal blending component
to boost the gasoline pool octane. CB&I has commercialized the
CDAlky technology, a breakthrough low-temperature sulfuric acid
alkylation process, which is now in operation at three units in China.
A new world scale unit is under engineering for a project outside of
China, and the basic engineering for another CDAlky unit in China
has just started.

Process Retrofitting, Debottlenecking and
Constraint Management
Saudi Aramco Riyadh Refinery Chemical Treatment
Real-time Optimization in the Cooling Tower and
Water Treatment Plants
Author: Abdulmalik A Turki, Saudi Aramco, KSA
Abstract: Being inland, Saudi Aramco Riyadh Refinery is challenged
with respect to water in terms of both sources and quality. In order
to alleviate and/or resolve the quality issues, very heavy weighted
chemicals programs have been established since the inception of
this Refinery. Most of the work is being done by the operator. Not
to mention the environmental concern that we have with these
chemicals with respect to the chemical spillages. Also, water quality
is managed by daily or sometime monthly sampling such as the
corrosion rate where the effects of off-targets KPI could negatively
affect the entire Refinery coolers before it can be detected.
Evaluating several initiatives that could resolve these matters, an
in-house engineering design has been established. The design
was assessed for applicability through literature reviews, standards
and a detailed study on our unique and dynamic water quality has
been conducted. Through partnership with the chemical provider,
The Refinery managed to avoid regular operator dilution which

has inhalation risks that can have severe effects over years.
The Refinery managed (through the very detailed connections of
PVC piping) to avoid chemical spillage over all areas.
In terms of Performance:
The refinery chemical compliance has increased form 70 percent
range to 100 percent (in the plants that has applied the automation)
and the Refinery supply cooling water corrosion rate has dropped by
60% (from fair to excellent corrosion resistance as per Saudi Aramco
Best Practice Cooling System Corrosion Control [SABP-A-026])
In terms of Return on investment:
The automation has helped the Refinery to manage the chemicals
dosing through the detailed control circuit which in turn reduced the
chemicals spending by almost 10% (in the plants that have applied
the automation). Also, it reduced the cooling water blow down rate
by 28%. In overall return, the Refinery was able to payback the two
projects applied in the Refinery in only one year.
Efficient Reforming Process for New Plants and

for Revamp of Existing Plants provided by
Haldor Topsoe Exchange Reformer
Author: Kristian Lindell, Haldor Topsoe, The Hague, Netherlands
Abstract: Haldor Topsoe has for the past 25 years been designing
convective reformers utilizing excess heat from flue gas as well
as process gas for the steam reforming process. The Haldor
Topsoe Exchange Reformer (HTER) is developed in order to utilize
the excess heat in the process gas coming from the main steam
reformer (e.g. the autothermal reformer in the GTL front-end, the
secondary reformer in ammonia and methanol plants, and the
tubular reformer in hydrogen plants) for converting an additional
amount of hydrocarbon feed stock into process gas. By utilizing the
excess heat for additional process gas generation, the overall feed
and fuel consumption in the plant will be reduced significantly.
The HTER is also an excellent option for revamping the plant,
boosting the process gas generation with up to 30% for a very
competitive investment, and still getting the large advantage of
relative reduction in the feed and fuel consumption.
Since 2003, an HTER has been in industrial operation in a synthesis
gas plant in South Africa with success, where it was introduced
to boost the plant capacity. Subsequently, the technology was
introduced in hydrogen plants in India.
This paper will discuss the design challenges for heat exchange
reformers such as metal dusting, operability, and simulation of
the interaction between catalyst performance and heat transfer.
These design challenges have been overcome, and the operational
evidence from an industrial hydrogen plant, including HTER, will be
described.
Debottlenecking Techniques using

Simulation
Authors: James Brigman, Ingenero, USA
Co-author: Pratap Nair, Ingenero, USA
Abstract: A basic debottleneck study can often be accomplished
by simply reviewing an equipment-by-equipment review of design
capacities and constraints. This provides a solid foundation for
understanding the likely capacity constraints. However for operations
that are already at or exceeding design capacity this methodology is
seemingly no longer valid. The typical approach is then to attempt
to understand on an equipment-by-equipment basis the level of
overdesign and the safe boundary limits of the equipment. However
just doing this ignores the efficiency and safety implications to the
entire process. To be truly effective and safe, debottlenecking must
consider the entire process and the implications of the increased
flows, temperatures and pressures on both the safety and efficiency
of the process. Effective simulation is a key to doing this.
The goal of a debottleneck exercise is to be able to understand the
multiple layers of constraints and process implications in terms of
both capital cost and operational cost in eliminating each progressive
constraint. Approaching this on a step-by-step basis can be costly
since inefficiencies and potentially repeat replacement of the same
systems can occur as successive layers of constraints are addressed.
For example there can be separate winter versus summer operations
constraints. This is nice in the debottleneck study because prior
to beginning the debottleneck study there will already be several
layers of constraint understanding. For example if operations can
see the constraint due to cooling water capacity during the summer
months, a project to justify purchasing additional exchangers and
increasing pumping capacity may seem like a reasonable approach
to solving this issue and thereby allowing the constraint faced in
winter months to be the primary focus. Investing in the exchangers
and pumping capacity to solve the summer time issue is seemingly
a known value proposition since the difference in production
achieved during the winter versus the summer production is the
value by with the additional cooling capacity must be measured.
However if then after adding the cooling water capacity and taking
the next step of addressing the winter constraint, the cooling water
constraint again becomes the bottleneck; payback on the previous
improvements may not have been achieved and repeat replacement
of new equipment may become necessary. A cohesive plan utilizing
simulation is the key to avoiding such situations.
The process Ingenero utilizes in performing debottlenecking
studies utilizes simulation to ensure the most cost efficient and safe
expansions occur. Ingenero utilizes a multiple step process where
simulation is key. The presentation will go through how simulation
is utilized in each of these steps to lay out the most cost effective and
safe expansions possible.
Diesel Hydrotreater Optimization to Maximize

Refinery Profitability
Author: Adel Al-Gayedi, SAMREF, KSA
Co-author: Mukesh Patel, SAMREF, KSA
Abstract: SAMREF produces Automotive Diesel (ADO) to serve
export and domestic markets. As Sulphur specification of ADO is
continuously reducing, SAMREF was required to produce 10 ppm
Sulphur ADO by 2016. This requirement exceeded the existing
Diesel Hydrodesulphurization (CHD) Unit capabilities. SAMREF had
considered revamping of existing CHD unit to increase the unit
capacity from 98 KBD to 125 KBD, and to comply with clean fuel
ADO Sulphur specification of 500 ppm by 2013, and 10 ppm by 2016.
Debottlenecking of existing CHD unit was carried out in two phases
called Interim and Expansion. Interim phase process design was
98 KBD feed with new reactors and catalyst but with existing
hydrogen supply from Naphtha Hydrotreater (NHT). Expansion
phase was designed to process 125 KBD feed with high pressure
pure hydrogen supply from new Hydrogen Recovery Unit (HRU).
Reactor pressure was increased from 37.2 barg to 55.2 barg in
expansion phase with a new recycle gas compressor and a make-up
gas compressor.
Revamp process design was considered to minimize the capital
investment by maximum use of existing equipment. Unit was
designed to accommodate all distillate components produced in
the refinery with three block operations namely ADO 10, ADO 500,
and Fuel Oil Cutters stock. As existing unit was designed for low
pressure operations (37.2 barg), only reactor section was revamped
to increase operating pressure to 55.2 barg, keeping the rest of
the unit at lower pressure to minimize revamp scope. Four
new reactors were installed with two parallel and two in series
configuration to achieve product Sulphur specifications. Two new
charge heaters and charge booster pumps were required to fulfill
new reactor operating conditions. New steam stripped Product
stripper tower was installed instead of fired heater reboiled tower
and new Sand/Salt filters were added to polish ADO product to meet
copper corrosion and moisture specification.
Post revamp, per market requirement, Samref was required to
produce 500 ppm ADO. With thorough evaluation of catalyst
deactivation, unit capability and Hydrogen availability, Samref has
decided to eliminate Cutters stock run and upgraded total LCO make
to ADO 500. Unit was optimized in terms of operating pressure,
LCO content in feed and evaluating the impact on CHD catalyst life
cycle by sophisticated modelling. Unit feed rate was increased to
138 KBD safely and successfully with detailed assessment of process
safety aspects. In addition to considerable margin improvement of
upgrading 3250 m3/d LCO from fuel oil cutters stock to ADO 500
product, about 40% extension in catalyst cycle life was achieved by
optimized operations strategy. Diesel feed components make rate
was increased by further deep cutting to fill the capacity margin in
Diesel Hydrotreater to maximize refinery profitability.

Process and Equipment Design
Inferential Measurement and Overall
Plant Optimization using Aspenplus
Equation Oriented Models
Author: Subbarao Kommuri, SABIC Research and Technology
Center, KSA
Co-author, Anapat Samir, SABIC Research and Technology Center,
KSA
Abstract: Many process parameters are measured in a typical
process plant, but some cannot be measured from a technical
and economic standpoint. These unmeasured parameters could
provide useful information to run the plant more efficiently and
safely. Many a time, its been observed that column top and bottom
streams are over-purified as the there are no real-time composition
measurements. If a tool can be developed, which can predict the
useful information from the available information in the DCS/IP21,
columns can be operated more efficiently by reducing the energy
usage requirement.
In this work, a framework (EProcess tool) has been developed
to read the available information from DCS, and predict the useful
information, after improving quality of data obtained from plant
measurements using AspenPlusTM Equation Oriented models.
This EProcess tool has been tested in a reactive distillation column

in one of the SABIC plants to predict the compositions and column
hydraulic loads so that operators can take informed decisions.
Optimization of process conditions for individual process equipments
many times lead to suboptimal conditions as those parameters affect
downstream and upstream equipments which may not be global
optimium. AspenPlusTM Equation oriented models can be utilized
to come up with global optimum process conditions without violating
imposed constraints for very large and interconnected plants.
In this work, plant optimization studies were performed using
AspenPlusTM Equation Oriented methodology for one of SABIC's
plants to come up with best operating parameters, which minimize
the specific steam consumption while maintaining the same
production rates. This study shows that 1.1Million$/year savings can
be realized by steam savings.
Optimizing FCC-PT Performance with Albemarle

Stax Technology
Author: Alessandro Riva, Albemarle, UAE
Abstract: As refiners deal with challenges requiring production
of ultra-low sulfur gasoline and increasing diesel fuel output, FCC
Pre-Treat (FCC-PT) units are becoming even more important
assets in helping them meet these challenges. There is no single
typical unit that is characteristic of FCC-PT operations as a whole.
FCC-PT units process many types of heavy, dirty feeds across a
very wide range of operating conditions. In addition, primary
operating objectives may be to produce constant product sulfur,
maximize HDN and aromatics saturation, and/or to increase
conversion to produce more diesel product.
Albemarle has determined that VGO STAX-FCCPT is generally the
preferred technology solution to enable customers to successfully
meet the increasingly difficult FCC-PT challenges in their refineries.
This technology allows us to leverage the activity and stability
benefits of new catalysts that have been recently commercialized
and further optimized the performance of customer units. In addition
to our revamped catalyst portfolio, Albemarle has been conducting
research across the broad spectrum of customer operations and how
best to help customers successfully meet their needs. Albemarle has
a proprietary process model that gives highly reliable performance
estimates and is used to generate and assess catalyst loading design
recommendations for customer units.
Unlike processes that directly produce clean fuel products, however,
the economic value of FCC-PT is largely determined by how well
it improves FCCU product yields, product qualities and operations.
Depending on the refinery, the key objectives for FCC-PT operations
may be: 1) to maintain low product sulfur level with high HDS in
order to meet environmental regulations on gasoline sulfur content
as well as FCCU SOX emissions, 2) to maximize HDN and aromatics
hydrogenation (HDA) to improve FCCU product yields/ selectivity
and improve operations, and/or 3) to increase conversion of VGO
to diesel-range product from the FCC-PT unit. Controlling FCC-PT
catalyst fill cost and achieving target cycle lengths are generally high
priorities for most refiners.
Albermarles FCC-PT technology portfolio is able to address targets
set by each individual unit and a catalyst system can be tailored
based on Albemarles STAX concept. This technology solution has
had numerous successful applications in FCC-PT units around the
world and some of them are illustrated in this paper.
Right On Schedule: AspenTech On Managing Crude

through Refined Products with One Integrated
Scheduling Platform to Achieve Multiple Business
Benefits
Author: Satyadev Susarla, AspenTech, Bahrain
Abstract: Refinery scheduling bridges the gap between the monthly
plan and daily operations. Where planning determines what is
to be done (i.e. what crude to buy and what products to make),
scheduling determines how and when products must be produced.
As new feedstock becomes available and petroleum supply chain
complexity increases, having a comprehensive overview of the
process is vital in todays marketplace.
Aspen Petroleum Scheduler, the leading scheduling simulation and
optimization tool for refineries, supports industry best practices by
bringing the refinery, dock, and pipeline operations into one platform.
In this session, learn how the capability to track inbound and
outbound crude movements and product shipments simultaneously
within the refinery schedule can help you to achieve multiple
business benefits. Clients leveraging these powerful capabilities
report benefits such as the ability to better align of the schedule
with the plan; streamline production, anticipate and respond to
disruptions, and improve inventory and transportation assets. Hear
real world examples of how AspenTech clients are benefiting from
their use of Aspen Petroleum Scheduler.
The Role of Scheduling and Rigorous Process

Models in Improving Plant Performance
Author: Christian Petsch, KBR, USA
Abstract: Process unit models are characterized by two types
of data, static data and dynamic data. Static data can be further
distinguished into two categories (a) truly static data, defined during
physical design of the dimensions of the process unit, which only
change when there is a significant change in the structure of the
process units and (b) process data, which essentially define the
yields and qualities of the product streams and depend on the feed
quality and the operating conditions of the unit.
Rigorous process models generate process data, which are then
used by both the planning and scheduling applications. The rigorous
process models are traditionally tuned based on test runs, in order
to enhance their accuracy.
A more advanced and effective approach is to use integrated
planning and scheduling to improve the quality of the process
data in a continuous manner, increasing in turn the quality of
production planning and scheduling, which has direct impact on
plant performance and profitability. The accuracy of the process
models is evaluated by comparing the calculated yields to actual
production output on a frequent basis. This comparison can be
done on a daily basis, based on the predicted yields calculated by
the scheduling model, because scheduling is a continuous activity.
The results are passed back to the rigorous process models, in order
to further tune it.
This forms essentially a closed improvement loop between the
actual and predicted production yields. This technique can also be
applied to the process unit stream quality predictions, however this
is much more difficult and time consuming than for yields.
The advantages of this approach vs. the traditional test runs is
significant reduction in cost, as test runs are quite expensive and
subject to random disturbances. This approach is more controllable
and offers a continuous improvement, provided that the associated
business processes are appropriately designed and widely adopted
to support it. Technology can also play a significant role in enabling
and facilitating it.
The purpose of this paper is to discuss the technological and

business process aspects which enable this approach.

Online Process Optimization in an Aromatics Facility
Oman LLC (AOL) and Oman Polypropylene Company (OPP). Orpic

is the brand name of the company. It is one of Oman`s largest
companies and is one of the most rapidly growing businesses in
the Middle East's oil industry. Orpic provides fuels, chemicals and
feedstock to the Oman local market and to the worlds international
markets as well.
The four plants and depot of Orpic are located in three primary
locations:
Mina Al Fahal Refinery in Muscat (MR)
Three Plants within the Sohar Industrial Port Complex located at
north of Oman in Sohar.
Author: Tariq Khan, Schneider Electric, KSA
Sohar Refinery - Conversion Refinery (SR)
Abstract: Todays global economy and volatile economic climate

requires Aromatic plant operators to operate their facilities in the
most profitable possible manner. Stringent quality constraints on
refinery formulations limiting the amount of aromatics in Pyrolysis
Gasoline will impact the economics of operations.
Polypropylene Plant - Petrochemical Plant (PP)
Controlling the unit processes for conversion and transformation of

feed to be efficiently separated through the unit operation are keys
to improved (optimized) operations. ROMeo Aromatic Optimizer is
an exciting non-linear online optimization system that enables more
accurate and credible economical optimization. Important Real Time
Optimization applications in the Aromatic Facility are listed below:
Feedstock selection
Minimize operating cost
Refinery gross margin
Operations Optimization
Proper feedstock selection is important since the cost of feedstock
for most plants is often in the range of 70-80% of variable operating
costs. A small percentage improvement in feedstock selection
can dramatically increase profitability. The catalyst activity is
another important parameter that dictates the operating cost.
This is achieved through establishing minimum redundancy of
data that can reconcile the operating parameter and thus adapting
the online model to actual catalyst activity. Thus improved plant
operations can be realized by better Reforming (or Hydro Treating),
improved separation process and controlled recycle stream from
isomerisation and alkylation to the separation loop.
The requirements for a modern aromatic plant optimization system
are:
Ease-of-use
Accurate optimized set-points
Off line Case studies
ROMeo allows development of open-equation based, non-linear
optimization models. Romeo Aromatic Optimizer can include not
only non-linear fractionation and compression representations, but
also the capability of Reformer (CCR) Reactor models, Hydrotreating
Model and Isomerization models. The system can rigorously perform
chemical and thermodynamic calculations to accurately determine
plant yields and utility requirements. Building models is facilitated
through the use of an easy-to-use graphical user interface.
Aromatics Plant - Petrochemical Plant (AP)

Raysut Depot: Located at the south of Oman in Salalah
The two refineries, MAF and Sohar, locations are joined by a 266
kilometer pipeline, delivering mixed crude oil feedstock from Mina
Al Fahal Refinery to Sohar Refinery. The Refineries' raw material is
mainly Oman export blend of crude oil and processed to produce
fuels and petrochemicals.
Orpic Model is X-PIMS model.
It is a Multi-Plants/Multi-Periods system, contains the following
production plants:
Local Plants:
Mina Al Faha Refinery (MAF)
Sohar Refinery (SOH)
Aromatics Plant (ARO)
Polypropylene(PP)
Global:
Local Plants + Raysut Depo
The optimization considers all the technical, logistical and market
constraints and among these boundaries it provides the highest
possible margins for Orpic.
Why Orpic started to use X-PIMS?
Orpics integrated supply chain is reflected in the transfers between
the plants and depot. MR participates in providing feed to SR and
SR provides feeds to AP and PP, there are also other important
integration aspects. SR is considered as the main MOGAS pool
where component streams flow from MR and AP to SR MOGAS
blending pool. MR is the main fuel provider for Oman. SR mainly
supply the fuels to the northern regions or government of Oman,
and also supplies fuel shortfall of MR. With maintaining one MOGAS
grade production in MR which is M95, SR transfers M95 demand
shortfall and all M90 demand to MR. MR Gas Oil and Aviation
Fuel demand shortfalls are also supplied by SR. SR also supplies
Raysut Depot with all its fuels (M90, M95, GO and AF) demand at
the south of Oman.
X-PIMS is used to maximize the integration for Orpic. Orpic continues
to expand, with new investment, new projects and new operations
which also can be optimize the Multi-Plants/Multi-Periods by using
X-PIMS.
Orpic on Leveraging XPIMS for Multiplant

Multiperiod Optimization
Author: Naeema Al Hamdani, Orpic, Oman
Abstract: Introduction: Oman Oil Refineries and Petroleum Industries
Company (Orpic) created from the integration of three companies:
Oman Refineries and Petrochemicals Company (ORPC), Aromatics
New Approach for Anticoking Technologies

Qualification for Ethylene Furnaces
Author: Dr. Abduljelil Iliyas, SABIC, KSA
Co-authors: Munawar Saudagar, SABIC, KSA
Hatem Belfadel, SABIC, KSA
Abstract: There are over 20 Anti-Coking Technologies (ACT)
commercially available in the market today and each technology
provider claims to have the best technology. However, plant
experience has shown that there is no one-size-fits all technology.
What works in one furnace may fail in others, depending on coil
design, operating conditions, feed type, etc.
The above consideration serves as motivation for SABIC T&I
to develop a structured approach for qualifying and translating
best-in-class anti-coking technology to all SABIC ethylene furnaces.
The developed approach considers the peculiarity of each of SABICs
furnaces, in terms of coil design and operating philosophy and
recommend best-suited ACT. In this work, we report the conceptual
framework of the developed anti-coking qualification approach with
application examples.
APPROACH: The developed anti-coking qualification approach
involves four major steps;
1. Establish furnace performance before anti-coking (Baseline)
2. Estimate furnace performance after anti-coking deployment
3. Predict furnace performance if anti-coking is deployed on a
new furnace
4. Quantify potential economic benefits/risks from anti-coking
deployment
We have used this approach to qualify best-in-class anti-coking
technologies for over 100 furnaces across SABIC affiliates.
As shown in Table 3, the applied anti-coking technology was very
effective in lowering both the pyrolytic and catalytic coking rates
by 90 % and 81% respectively. Table 3 further shows that catalytic
coke formation is the dominant mechanism of coke formation i.e.,
~10 times higher than pyrolytic coking for the ethane cracking in
this example.
The extracted coking parameter are utilized to predict expected
performance if the technology is deployed on another furnace at a
different site shown in Figure 3.
Based on above technical benefits, we estimate the economic benefit
the plant will gain if the recommended technology is deployed
assuming furnace availability constitutes the main plant constraints.
CONCLUSIONS
SABIC T&I has recently developed a novel approach for qualifying
anti-coking technologies for deployment on ethylene furnaces.
This approach relies on in-house developed furnace simulation
tool using superior mechanistic coking kinetics model coupled with
SABIC cracking kinetics. The four-step approach was demonstrated
via application examples to be effective in a-priori translation of
anti-coking technical benefits from one ethylene furnace to another
while considering the peculiar characteristics of each furnace
such feed type, furnace design and operating conditions. The
approach has been successfully used to transform a multi-year
anti-coking qualification process into few weeks while ensuring
higher chance of success.

Designing and Troubleshooting Distillation Column
Internals
Author: Petar Pribic, Sadara Chemical Company, KSA
Abstract: Mass transfer equipment is estimated to consume 3% of
the worlds energy and across the CPI (Chemical & Petrochemical
Industry) separations account for 40 to 70% of both capital and
operating costs of the facilities. Since internals installed in mass
transfer equipment cannot be easily accessed after startup, tower
related problems can be difficult, time consuming and expensive to
diagnose and fix. Because of this, it is crucial to choose the right
internals for the right operating service.
Besides the fact that the mass transfer equipment designer must first
understand the nature of the desired separation task, the final and
most important step is to choose the right internals. The wide variety
of trays, structured and random packing, and distributors makes the
selection of the most appropriate internals, difficult and challenging.
Trays and packing each offer unique advantages depending on its
application. The following general factors are indicators of whether
trays or packing should be favored.
Pressure drop per theoretical stage
Liquid holdup
Foaming systems
Corrosion
Solids or slurry present
Cost
There is no general rule, as in many applications; the separation
could be performed using either trays or packing. However, one
application always offers some advantage over the other. Each
mass transfer column is a unique piece of equipment that has to be
analyzed based on the process, energy and capital requirements.
When designing a new column, the engineer has a certain freedom
to choose column diameter. However, debottlenecking a distillation
column is a major undertaking, as it would typically cause a major
interruption to production and major capital cost impact: changes to
it can be very costly, especially if replacing a column or installing a
second one in parallel is not practical.
Replacing existing internals or building a new tower with the latest
high capacity packing and trays is a common practice to reduce
capital and operating costs. However, replacing them with mass
transfer equipment only, without paying attention to design details
like feed inlets, draw-offs, collectors, etc., can diminish all the
benefits that high capacity devices can bring to the process.
The latest distillation technology applications, like Dividing Wall
Columns, have proved themselves over the last several years, and
substantial energy and capital savings can be achieved by choosing
the right mass transfer internals.
Monetize Off-Gases to produce low cost Ammonia

Author: V.K. Arora, KPI, USA
Abstract: Ammonia production from hydrogen rich off-gases has
been well known for a long time but practiced only in a handful of
plants. The dynamics of new feedstock trend in the Petrochemicals
industry coupled with new process options provide opportunities
to source large volumes of hydrogen rich gas streams to produce
low cost Ammonia. The new sources of hydrogen rich streams
are large enough to integrate and support a typical world scale
Ammonia plant and also provide economy of scale even in smaller
sizes with an added environmental benefit. However, sourcing those
streams does pose its own challenges and will be further discussed
in the paper.
The paper will present various process schemes including the new
ones including their relative merits, capacity potential, efficiency
and economics using different sources- like Steam crackers, Propane
Dehydro units, Methanol/CO plants. Various process schemes will
include PSA, Nitrogen wash, Secondary reforming with Oxygen
enrichment and gas heated reforming. Impact on the source plant
will also be discussed.
Such projects are now being implemented in US and Middle East
locations.
This paper will also include a comprehensive case study with
economics for USGC & Middle East locations for different sourcing
& process options for different feedstock for steam crackers. The
sensitivity analysis demonstrates attractive returns for most cases.
Heat Exchangers Network Retrofit With Retrofit in

Mind in Crude Oil Refining
Author: Akram Kamel, Saudi Aramco, KSA
Abstract: World-wide industrial facilities energy efficiency
optimization practices are underway by most of the major energy,
chemical & petrochemical companies, where well-structured energy
efficiency programs are making a difference in such industrial
facilities. Energy efficiency in most of the big industrial companies
has been established and organized through engineering procedures
for conducting energy assessment studies for existing facilities or
grassroots ones to realize significant reductions in energy resources
and energy-based GHG emissions. Heat exchanger network (HEN)
retrofit plays an important role in energy saving in process industry.
Many design methods for the retrofit of heat exchanger networks
have been proposed during the last three decades. Such methods
are essentially Pinch design and method and its modifications;
network pinch and mathematical programming-based methods.
Conventional retrofit methods rely heavily on topology modifications
which often result in long projects execution times and high initial
costs. Moreover, the addition of new heat exchangers/new matches
are most of the time difficult due to topology, safety and downtime
constraints. Some of these problems can be mitigated through the
use of heat transfer enhancement in heat exchanger network retrofit,
for instance and via our Saudi Aramcos novel patented method of
retrofit which is the subject of this paper. Crude distillation units
(CDUs) in crude oil refineries are major consumers of energy
because of the high energy consumption of the crude furnace in the
crude preheat train.
This paper uses the new Heat exchangers network Retrofitability
concept, HEN retrofit-with-future-retrofit-in-mind to illustrate
the essence of the method through an actual project recently
implemented in integrated atmospheric and vacuum distillation
units (ADU/VDU). Heat transfer enhancement is used aside
with increased heat exchanger network surface area to reduce
retrofit capital investment cost and hence modification duration
and payback period are reduced. Simulation models has been
developed to find the appropriate heat exchangers to be enhanced
with minimal additional surface areas required to optimize the heat

integration trains and minimize the fuel required in crude furnace.
The case study identifies the most cost effective initiatives to enable
the reduction in the ADU/VDU furnace duties by 56.8 MM Btu/h and
energy-based GHG emissions by about 40,000 ton/y.
Utilize LC-Fining Platform to Retrofit an Existing

Refinery
Author: Arun Arora, CB&I, USA
Abstract: Driven by the need to upgrade low-value, high-sulfur
residual fuel oil, refiners are looking for economically attractive
ways to improve product slate. Many refiners who already have
a delayed coker as the primary residue upgrader are interested in
cost-effective and reliable technology solutions to increase liquid
yield and/or to make anode coke to improve gross margins. Inspite
of the recent upheaval in crude prices, the global product slate
continues to shift towards middle distillates. Hydrogen addition
technologies prudently coupled with delayed coking and/or FCC,
even during depressed refinery margins periods, can prove to be
attractive to stay competitive for the long term.
Chevron Lummus Global (CLG) is currently engaged in multiple
major residue upgrading programs, all dealing with reducing or
eliminating residual oil and maximizing middle distillates and/or
naphtha and propylene. The paper presents how CLGs LC-FINING
technology, with recent enhancements, if installed upstream of an
existing coker, can significantly improve a refinerys liquid yields
while debottlenecking the coker and offering an option to produce
anode-grade coke. For the refiners without a coker the attractiveness
of using standalone LC-MAX or LC-SLURRY, built on the robust
LC-FINING process platform and developed to eliminate the
conversion restrictions of residue hydrocracking, is presented.
Innovations commercialized in the recent years to handle particularly
difficult feeds are discussed.

High Integrity Pressure High Integrity Pressure
Protection System (HIPPS) Application: For Relief
Load Evaluation & Optimization of Flare Sizing
Author: Zahid Mahmood , Worley Parsons Arabia
Co-author: Yasir Nadeem, Worley Parsons Arabia
Abstract: Process safety and risk mitigation during plant operations
upsets, traditional methods and new techniques/best practices,
not only guide us towards a risk-free working environment, but
also bring new thoughts to mitigate catastrophic incidents. These
incidents can occur in case of upset plant conditions and leading to
an overpressure scenario.
For pressurized systems, relief devices are used to ensure safety
of equipment and personnel. These systems relieve all additional
loads to the flares. Proper Flare Sizing was and is still a big challege
to optimize the operational/environmental cost by avoiding fluids to
go to flare. For optimize relief system, following are the key items:
Relief Load Calculations
Design of Relief Valve
Proper Flare Load Calculation
Relief load calculations must be performed very carefully in order

to protect the process system and at the same time optimizing the
relief system avoiding oversize of the relief headers & flare stacks.
Similarly, proper Flare Load Calculations is the key factor for the
optimized performance in order to operation as well as environment.
HIPPS (High Integrity Pressure Protection System) is a tool to ensure
alternate solution to protect equipment in cases where:
High-pressures and/or flow rates are processed.
The environment is to be protected.
The economic viability of a development needs improvement.
The risk profile of the plant must be reduced.
The HIPPS will shut off the source of high pressure before the
design pressure of the system is exceeded, thus preventing
loss of containment through rupture (explosion) of a line or
vessel. Therefore, a HIPPS is considered as a barrier between a
high-pressure and a low-pressure section of an installation.
However, in some cases, to enhance process safety times, some
alternate/parallel options to be considered as well i.e. relief system
along with HIPPS, or HIPPS along with relief system.
Online Dynamic Plant Simulator

Author: Dr. Mushtak Mogal, Yokogawa, Bahrain
Abstract: Online dynamic process simulator is an innovative
technology wherein a dynamic simulator is connected online to
the actual control and safety systems concurrently performing
simulations using real-time plant data.
It is used to improve plant productivity and safety. This technology
identifies current plant conditions and runs simulations that will
precisely visualize internal conditions and predicts future plant
behaviors. It helps plant operators run plants more efficiently and
assists technical staff in improving plant operations.
It employs three kinds of simulation models: a virtual model (tracks
real plant conditions thereby reproducing plant behavior), an
identification model (performs data reconciliation, adjusts various
parameters) and analytical model/s (perform/s predictive and
analytical calculations).
Its applications are:
How to Avoid Pitfalls in Design Basis

Author: Rajasekhar Polapragada, SNC Lavalin
Abstract: Process Engineering Design success hinges precariously,
on two pillars: Design Basis and Design tools. While tools are
continuously sharpened and even made simpler, thanks to
Simulations, super-fast computers and user friendly software,
Design basis is still a prerogative of owners, management and
has not come down from Ivory towers. This paper sites pitfalls in
design basis and assumptions in Narrative Specification. One of
the classic examples is the design case of Sour water and Sulfur
recovery units, all over the world. The pitfalls backed up by real case
studies and possible solutions are outlined in the paper based on
the authors three decades of Refinery, Petrochemical and Oil & Gas
Design experience in Asia and the Middle East. This paper covers
the designers pitfalls, either due to lack of general guidelines or
lack of understanding. The focus is on different design guidelines
followed by designers, lack of agreed empirical values and less
understood or less measured properties, to name a few.
Case studies covered are on the following topics:
1. Sour Water systems Process Safety issues
2. Sulfur recovery units
3. General project Design Basis assumptions in major projects
Visualization of Plant Conditions

Transient/Steady State Conditions Prediction
Searching Optimal Operation Conditions
Preventive Diagnosis (of Abnormal Conditions)
Improvement of Controllability
Operator Training
Users reported the following benefits:
Provides operational information closely resembling a soft sensor
system, finds optimum operating conditions based on current plant
state and by predicting/displaying future conditions, operators can
know beforehand the future plant behavior.
Provides alarms for non-DCS state variables and predictive alarms
for state variables thereby helps stabilize the plant, since irregularities
can be detected earlier. The preventive diagnosis function is useful
for equipment and sensor maintenance, as it provides direct
guidance for detecting failures and false indications.
Operations can be investigated by using case study functions.
This is a powerful tool for performing operation design for plant
operations.
10

Hydrogen Production for Fuel Cell Applications
Author: Shigeki Hirano, Osaka Gas Co. Ltd, Japan
Abstract: There is no doubt that human beings will have to depend
more and more on carbon-free energy. Along with electricity,
hydrogen is an ideal media for transportation and distribution
of carbon-free energy, particularly when it is produced from
fossil energies combined with carbon capture and storage,
or from renewables such as biogas, wind or photovoltaics.
Hydrogen economy, in the strict sense of the word, means a
society where genuinely carbon-free hydrogen will be supplied in
sufficient quantity at affordable prices. It is expected to become a
reality within the next few decades. Transition to and creation of
hydrogen economy has four major objectives; energy conservation,
enhancement of energy security, reduction of greenhouse gas
emission and stimulus to national and local economies.

In accordance with the Japanese government initiative to establish
a nationwide hydrogen supply infrastructure, the efforts are in
progress to construct hydrogen refueling stations across Japan.
Osaka Gas has recently inaugurated the first commercial hydrogen
refueling stations within its supply territory. The primary component
of the station is an on-site hydrogen generator called HYSERVE,
which converts natural gas reticulated by our pipeline network to
ultra-high purity hydrogen. Chemical reactions take place in four
steps; firstly, desulfurization for removal of the odorant contained
in reticulated natural gas, secondly, steam reforming of methane
to produce hydrogen, thirdly, water gas shift reaction to increase
hydrogen content, and finally purification of the product gas using
pressure swing adsorption. HYSERVE is designed to realize its
unique characteristics such as ultra-high product purity, high thermal
efficiency, low installation cost and small installation area.
In 2009, Osaka Gas released the worlds first residential fuel cell
under the brand name of ENEFARM. There are two types of
technologies for ENEFARM depending upon the electrolytes used.
One is PEFC that stands for polymer electrolyte fuel cell, and the
other is SOFC meaning solid oxide fuel cell. In the case of PEFC,
polymer electrolyte operates at temperature lower than 100 degrees
Celsius. Carbon monoxide can deteriorate the platinum catalysts
on the electrolyte. Therefore, natural gas needs to be preprocessed
to pure hydrogen by selective oxidation of carbon monoxide. In
the case of SOFC, carbon monoxide is permissible in hydrogen
supplied to zirconia-made electrolytes because the high operating
temperature of about 700 degrees prohibits carbon monoxide from
poisoning the catalyst.
Smart Energy House utilizes rooftop solar cell and electric battery
along with ENEFARM. It is designed to optimize home energy
use through total management of the system, without sacrificing
convenience and amenities for users. Our field experiments such
as inter-accommodation of power among households or demand
response program will be introduced with results discussed.
Optimization of Paraxylene Recovery via Double

Reslurry Crystallization
Authors: Homok Lee, CB&I and Craig Coiling, BP
Abstract: Paraxylene Is a basic building block In the polyester value
chain. Because the belling points of the three xylene Isomers and
ethylbenzene are so close to each other, the recovery of para xylene
from a wide range of feed streams cannot be accomplished through
traditional distillation. Today, two recovery methods, crystallization
and selective adsorption, are commercially practiced. This paper
will describe a progression of Improvements that led to an energy
Integrated, flexible crystallization process. The resu It Is a pa
raxylene recovery configuration offering flexibility for a wider range
of feedstocks, lower energy consumption and lower emissions than
other competing technology. The presentation will also discuss the
ability to take advantage of inherent process f lex ibility in double
reslurry crystallization to debottleneck any existing facility with
minimal capital expenditure.
Utility Optimization through Combined Heat and

Power Balance Modeling
Author: Sreenivas Yelneedi, SAFCO-SABIC, KSA
Co-author: Mufeed Al-Ghumgham, SAFCO-SABIC, KSA
Abstract: The Utilities plant at an industrial manufacturing facility is
also popularly called the Combined Heat and Power, or CHP, system.
CHP is fast becoming the internationally accepted terminology for
describing the energy utilities generation and distribution systems
in the industrial plants. The CHP system includes all the elements
involved in the generation and distribution of energy to drive the
process and supporting infrastructure like boilers, fired heaters,
steam turbines, gas turbines, expanders, refrigeration systems, etc.
A simulation model of the CHP system is an extremely useful tool
to understand the interactions between the various components.
Applications include: Identifying opportunities for cost reduction
through efficiency improvement, accurate energy cost accounting,
evaluating the energy cost impact of proposed process changes on
the demand side, identifying load shaping strategies (e.g., switching
between motors and turbine drives).
At SAFCO, for one of the operating plants, CHP modeling was
conducted and it achieved significant benefits. This work describes
how CHP models can be developed at low cost using electronic
spreadsheets, and illustrates their application at SAFCO. Also, other
benefit of CHP modeling is its use for on-line real time optimization
and with this feature utility processes can be monitored on-line
continuously. If there any deviations from the simulations, it means
that the equipment in that zone has efficiency loss. As this tool
is integrated with web interface, process and production
engineers can see the process deviation trends from their desktops
and can debug any performance issues. In turn this practice
improved the reliability of the corresponding process or equipment.
It is recommended that this tool be adopted by other SABIC
affiliates for energy cost accounting and to improve energy
efficiency,with attendant reduction in operating cost and emissions
of greenhouse gases.
Utilization of CO2 to Chemicals Activation of

Methane with CO2 to Produce Acetic Acid
Author: Dr. Emad Shafei, Saudi Aramco, KSA
Co-authors: Ki-Hyouk Choi, Saudi Aramco, KSA
Sai Katikaneni, Saudi Aramco, KSA
Abstract: Utilization of methane and CO2 gases to chemicals
through direct reaction route would reduce several complicity
reaction steps. The study investigated the concept level of methane
coupling on heterogeneous catalyst and executed by reaction with
CO2 to produce acetic acid. Mesoporous catalysts of binary and
ternary oxides based on TiO2 were synthesized. At atmospheric
pressure, methane coupling was tested through fixed bed reactor
at temperature of 300 to 750C. The result showed formation of
ethane synthesized from methyl radicals dimerization. On the other
hand, by introducing CO2, methyl radical was consumed mostly
to direct reaction with CO2 and formulate acetic acid molecule
instead of methyl dimerization. The promoted catalysts showed
different catalytic temperature activation of methane to generate
methyl radicals of methane and reacted with CO2. The gas ratio of
methane and CO2 was optimized and the study showed an increase
of chemical yield of direct reaction route between methyl coupling
of methane with CO2. The presentation will discuss on the details
of this potential reaction on utilization of CO2 with activation of
methane to produce chemicals.
11

Modular Refiner Solutions
Author: Mike Trivunovic, UOP A Honeywell Company, USA
identify suitable modification in the system including the pump.

The Software tools perform piping hydraulic & heat exchanger
calculation through steady state simulation model.
Following are work steps in order to conduct revamping study for
existing CW Network:
To perform the detailed study of the prevailing condition of
existing CW network, it is of utmost importance to consider
the actual process condition (i.e. flow rate & pressure) and field
condition of all equipment, unit connected to the network.
An extensive field survey is required to collect following
operation data to support this study:
Abstract: Todays rapidly changing energy industry presents many

opportunities and challenges for developing oil & gas projects.
In recent years, abundant supplies of cost-advantaged feedstock
sparked a dramatic increase in construction activity and created a
premium for fast-track project execution. As a result, owners find
themselves faced with rapid swings in project cost and delivery
schedule. Innovative technology, delivered in modular form,
provides owners with an alternative end-to-end technology delivery
solution that reduces project cycle time and cost. With more
than 1,400 fully engineered and fabricated modular process units
delivered to customers around the world, UOP has successfully
managed a broad range of project execution situations and enabled
owners to manage and monetize their resources effectively.
CW Flow rate to various equipment and units by means of

installed or portable flow meter (Clamp-on type Ultra-Sonic
flow meter).
This presentation will provide brief case studies of recent successful

applications of modular delivery of technology to customers. Project
considerations that guide investors toward modular execution
techniques will be discussed.
Check healthiness of the model with comparing the calculated

pressure balance and operation data. Adjust the model as per the
operation data.
Troubleshooting Fouling in Heat Exchangers of

Aromatics Plant A Case Study
Identify bottlenecking part of the system and make modification

idea.
Author: Dr. Prasanna Pathath, SABIC, KSA

Abstract: Fouling of heat exchangers is the major chronic operating
problem especially in process industries. This has led to over
design of heat exchangers, additional energy consumption, and
maintenance problems which may eventually lead to production loss.
There are several different mechanisms the fouling may occur and
it depends on several variables. One such mechanism is the
chemical reaction related where on the process stream side, a solid
phase occurs on or near the heat exchanger surface. The current
paper discusses diagnosis, prevention and mitigation of one
such problem encountered at the SABIC Pyrtol preheating unit of
aromatics plant, wherein the carbonaceous material i.e. the coke is
being formed on the cold shell side of one of the heat exchangers.
The deposits are so tenacious that the plant has to be shut down
every six months for cleaning the heat exchanger resulting in
considerable production loss.
In this paper, the root cause analysis of the coke formation and
suggested process improvements are discussed to decrease heat
exchanger maintenance.
Pressure measurement at user Inlet /Outlet and unit battery limits.

Status of various users either in use or not, as well as status of
manual valve i.e its % opening.
Prepare the hydraulic model including pump, heat exchanger
and main distribution pipe up to each unit based on Process Flow
Diagram. Plot Plan, Piping & Instrumentation Diagram, Isometric
drawing, Heat Exchanger datasheet and Pump performance
curve would be used as input for the model.
Study debottlenecking case with the model and estimate

available pressure drop for the units.
Screen all units if there are critical users which need detailed
hydraulic study inside the unit. Potentially critical units/ users will
be the one which CW consumption will be increased or the one
located further from the supply pump.
Modification idea derived from overall system study would be
overviewed and shall be optimized considering the operational
and cost point of view.
Based on analysis of different operating scenarios a comprehensive
report should be prepared. Report should contain comparison of
existing operating condition with future operation and identification
of modification requirement to fulfill future CW demand.
Rapid Online Analysis of Acetylene in Hydrogenation

Reactor to Minimize Flaring Incidences in Ethylene
Plant
Author: Rohit Gupta, Yokogawa, Bahrain
Co-author: Sriram Anantha Narayanan, Yokogawa, Bahrain
Abstract:
Revamping of Existing CW Network
Purpose
Author: Majed M. Mulla, Sadara Chemical Company, KSA
Flaring incidents are very common in Ethylene plants. Every time

the Ethylene product becomes off spec with a contamination of
5 ppm or more Acetylene it isnt stored or reprocessed. There is
no other option but to flare Ethylene. Each flaring incident creates a
high business cost and adversely affects the environment.

Abstract: Revamping of cooling water (CW) network for future
additional demand in existing refinery and petrochemical plants
requires extensive study prior to propose any modification. Hydraulic
simulation is the best option to model existing system as well as
to estimate modification for future requirement. The basic approach
in hydraulic simulation study is to determine the CW system pressure
drop at the future flow rate and then confirm whether the future
operating point is within the existing pump performance curve or
12
Problem Statement
Plant operators manage to minimize the flaring incidents by adding
excess Hydrogen. But this results in converting not only Acetylene to
Ethylene, but Acetylene can get hydrogenated to Ethane. Moreover,
Ethylene also can get converted to Ethane. Both of these reactions
undo all the cracking that was done in the front end and hence drain
capital spent.
Approach
Analysis of Acetylene in crack gas in faster and in near real time
would allow tighter acetylene hydrogenation process control.
Existing technologies of Gas Chromatography (slow response) and
Filter Photometers (which has interference) inhibits the requirement.
Development of Off-Axis Integrated Cavity Output Spectroscopy
(ICOS) enables a real time analysis of Acetylene in <1 ppm levels.
This laser based technology provides the desired speed, reliability
and accuracy of Acetylene which is very critical to process control
optimization, safety and product quality drivers. ICOS is an
optical absorption spectroscopic technique which is based on the
principle that when a molecule interacts with a light beam at a
specific wavelength it will cause the molecule to vibrate/rotate, and
thereby absorb the energy (the light source). This is determined
from Beers Law.
Results
Conventional laser sensors cannot provide analysis of process gas
samples with spectroscopic interference backgrounds. Utilizing
chemometrics as an analytical enables the same laser-based
technology to analyze and monitor analyte concentrations in the
presence of spectral interferences. Chemometrics model spectral
data allows the Off-Axis ICOS analyzer to accomplish the following:
Ability to monitor real-time component(s) in process streams
Ability to predict multi-components
Ability to provide concentration estimates
CHEMOMETRIC MODEL VALIDATION
Seven gas mixtures with various concentration ranges for Acetylene,
Methyl Acetylene, Ethylene, Methane and Ethane were obtained to
perform model validation. It was observed that the accuracy and
precision of the ICOS prototype for C2H2 application are better over
GC specifications. Due to GC slow response-time for the existing
Methyl Acetylene analysis, this parameter has not been previously
used in the acetylene hydrogenation process optimization control.
Thus, the Methyl Acetylene measurement required specifications
are not available for comparison.
In this paper we shall speak about the conventional methods for

calculating relief load for a distillation column in an expansion
project and compare it with results obtain using dynamic simulation
also indicating potential savings.
Alkylation and its Vital Role in Clean Fuels

Author: Matthew Clingerman, DuPont Products, UAE
Abstract: As the fuel quality standards around the world continue
to become more stringent, the importance of alkylate as a blending
component for motor fuel is once again being emphasized.
MTBE phase out in the USA and adoption of clean fuels
specifications worldwide are major drivers for refiners requiring
a greater quantity of high octane gasoline blending components
that do not contain aromatics, benzene, olefins or sulfur. Beyond
regulatory requirements, many economic drivers also encourage
the implementation of olefin upgrading technologies. Declining
markets for low octane gasoline or the low relative value of certain
feedstock may lead refiners to consider upgrades that would
improve gross margins.
Alkylate has long been considered the most desired component of
the gasoline pool with its clean fuel properties, and it is uniquely
positioned to give refiners an option to overcome this unique
combination of challenges. The STRATCO Alkylation Technology,
part of DuPont Clean Technologies, is the leading supplier for
alkylation technology in the oil refining industry. The technology
uses sulfuric acid as the catalyst for the reaction of light olefins
(C3-C5) and isobutane. This presentation will include a review of the
alkylation process, how it can be modified to process different to
olefin feeds and the latest technical developments for expansions.
A high level economic review will be also provided to demonstrate
how the STRATCO Alkylation Technology can give significant
economic advantages as well.
Process Intensification in Enrichment of C9+

Compounds from Pygas using Divided Wall
Distillation Columns
Conclusion
Author: Mahesh Kumar Srinivas, SABIC, KSA
Under a variety of process conditions, the ICOS analyzer proved

to be much more accurate, precise and durable than current gas
chromatography methods. The speed and reliability of analysis
provided insight into process run conditions that were previously
unavailable and unexpected. Powerful diagnostic tools designed
into the ICOS capabilities allowed for validation of reported results.
Abstract: The shift towards lighter feedstocks for ethylene and

propylene production, due to lower feedstock price and higher
profit margin, has resulted in lower production of heavier aromatic
fractions and in particular the C9+ fractions. As a result, over
the last 5 years the supply of C9+ fractions has not caught up
with increase in demand. Further, intense competition between
petrochemical complexes has forced companies to retrofit plants
for comprehensive utilization of all streams in the complexes for
better operating margin. Among other things that are considered
for upgradation, enrichment of heavier hydrocarbons from the
Pygas stream has been pursued intensely. In this work, the process
intensification of C9+ stream enrichment from Pygas using
non-conventional divided wall column structures is examined.
The study compares the conventional separation scheme with a
divided wall distillation design.

Dynamic Simulation and Efficient Way of Flare
Network Analysis
Author: Saher Jasvi, Schneider Electric, KSA
Abstract: Conventional relief load calculation methods lead to an
oversize design of the flare header and associated piping network.
Though it is appropriate to keep margins on piping network for
grassroots projects it can lead to expensive flare header replacement
for a brown field expansion project. Dynamic simulation provides
an API approved alternate to the conventional calculation methods
which potentially leads to considerable cost savings.
The study finds that by replacing conventional column sequence

with the divided wall column structure, for a given product quality,
a saving in the separation stages by 31%, energy reduction by around
40% can be realized. This study also demonstrated that the designed
column is robust and tolerable to variations in feed compositions
and location of feed and side draw tray. Finally mechanical analysis
of the column revealed that the complete DWDC can be designed
with single diameter dimension. These findings, together with other
studies, suggest that dividing wall column structures as a promising
candidate for new plants and also an attracting retrofitting options
for intensification of the existing columns.
13

A Multi-tier Approach for Olefin Plant Optimization
Author: Akash Mittal, SABIC Technology Centre, KSA
Co-authors: Abduljelil Iliyas, SABIC Technology Centre, KSA
Deepak Pal, SABIC Technology Centre, KSA
Abstract: Optimization models to maximize profits in steam
crackers have been implemented widely in the industry. A complete
plant simulation including all furnaces, hydrogenation reactors and
recovery section results in a highly non-linear problem. Traditional
optimization approaches utilize either simplified linear programming
models or a steady state plant model in order to reduce the
computational costs.
Typically, the optimal process conditions valid for the start of
run do not remain optimal for the end of run, owing to the coke
deposition, which impact fuel requirements and ultimate plant yield.
In order to achieve a real-optimization, it is hence imperative to
not only consider the energy costs incurred in the furnace and the
compressors, but also to estimate the impact of the dynamic nature
of the coke deposition.
This paper describes a novel multi-tier approach [Figure1] to
decompose the dynamic nature of the non-linear problem. The
furnaces are simulated rigorously using SABIC in-house cracking
kinetics model. At each time-step, the coke-thickness deposited on
the cracking tubes is estimated utilizing the rate of coking reaction
computed at the previous time-step.
A pseudo-steady state optimization problem is then formulated
which is solved in two-tiers.
Making Plant Crew Training Possible Through

Advanced Technology
Author: Ataurrehman Qureshi, Schneider Electric
Abstract: With an ever increasing demand to improve profit margins
and reduce operational costs, there is tremendous pressure on plant
operators to maximize the uptime by reducing the unexpected
slowdowns and shutdowns. For years, industries have been facing
the challenge of training their workforce to ensure the smooth, safe
and profitable operation of their plants. To address the training
needs, various methods have been adopted ranging from providing
the training material to classroom training to having peer discussion
to providing hands on training using the operator training simulator
(OTS), the last one being most effective. However, even with the
OTS the training needs of field operator and maintenance operators
are not fully addressed.
With the advent of Virtual Reality gaming technology, it is now
possible to train the field operators and the maintenance operators
with an Immersive Training Simulator (ITS) that involves an
immersive virtual 3D walkthrough environment of their plant
together with OTS for the control room operator, thereby allowing
for complete Plant Crew training.
This paper provides more information on the ITS technology
including technology drivers, important applications, prominent
features, and new developments.
14
In the inner loop, process conditions are generated by optimizing

the yield of a simplified recovery section model integrated with the
furnace model (Yield Optimizer).
In the outer loop, the profit is computed using a rigorous recovery
section model integrated with the furnace model. Based on the profit
difference between two consequent iterations, constraints on the
process conditions are relaxed in order to run the yield optimizer
recursively.
In this study, our two-tier and dynamic optimization approach is
demonstrated via practical example to improve the computational
efficiency and to achieve realistic profit-based optimization of olefins
plant.
Anti-corrosion Study of a Water Wash Spray

Injection System
simulation of oil production and petroleum refining operations. Hear

client case studies and benefits achieved with these new features.
Author: Kathleen Brown, Spraying Systems, USA

Co-authors: Rudolf Schick, Spraying Systems, USA
Wojciech Kalata, Spraying Systems, USA
Abstract: Throughout the petro-chemical refining process, crude
oil is required to be transported across great distances. Crude oil
contains various salts which can lead to corrosion or plugging at
various stages in transporting equipment. Spray supported water
wash systems are often implemented to scrub the salts from the
process streams to mitigate corrosion risks.
Distribution of water wash spray injection which interacts with
a dynamic environment is an important determinant of the
effectiveness of a water-wash system. The level of liquid and
gas mixing and absorption effectiveness heavily depends on the
interaction of a spray plume within a confined dynamic crossflow environment. For water wash spray injectors and quills,
characterization and computational modeling of the water drop size
distribution, droplet velocity distributions, and spray plume shapes
were conducted within a controlled wind tunnel environment. The
primary focus of this study is to define the distribution of injected
water wash downstream of the injection point.
While the spray characteristics immediately downstream of the
nozzle will govern the significance of the effect of the cross-flow,
this study aims to provide an insight into spray dynamic interaction
in typical to water-wash environment. Water injections from various
hydraulic spray nozzles and injection quills were investigated with
nominally uniform cross-flow air speeds of 20 m/s and 30 m/s.
The results demonstrated the trajectory changes as well as the
changes in spray plume characteristics over a range of spray types
and operating conditions.
The experimental results were acquired with a LaVision Laser Sheet
Imaging (LSI) and an Artium Phase Doppler Interferometer (PDI),
to quantify the spray shape, size, distribution characteristics as
well as droplet size and velocity. The two-phase flow simulations
were conducted using ANSYS FLUENT, a computational fluid
dynamics (CFD) package in conjunction with custom spray injections,
defined based on experimentally obtained spray parameters.
The computational models agreement and disagreement, with the
experimentally acquired results provides insight for the appropriate
considerations when designing water wash systems in the future to
optimize droplet to gas interaction.
Molecular Modelling: Aspentech on its PatentPending Molecular Characterization of Crude Assays

Author: Dr. Wei Zhang, AspenTech, Bahrain
Abstract: As the price of oil declines, companies are evaluating
new ways to increase efficiencies and reduce costs. AspenTech is
a leading supplier of software that optimizes process manufacturing
for refining & marketing and other industries that manufacture and
produce products from a chemical process. Refineries are better able
to increase capacity, improve margins, reduce costs, and ensure
environmental compliance through the combination of industry best
practices and superior technology.
Aspen PIMS, the leading planning optimization tool for
refineries, supports industry best practices through its in-built
assay management tool. In this session, learn how Aspen Assay
Management and its molecule-based methodology for crude oil
assay characterization represents a superior alternative to the
traditional statistics-based methodology and other empirical
expressions used to interpolate between assay data points or
extrapolate for heavy cuts. The molecule profile further offers a
molecular insight into crude oil for planning, scheduling, and process

Are You Sitting on Untapped Potential?
How New Reactor Internals Can be Used to
Enhance Profitability
Author: Pankaj Desai, Shell Global Solutions (US) Inc., USA
Abstract: Reactor issues such as thermal maldistribution and high
pressure drop are indicators that a refinery may be failing to capture
the maximum value from a hydroprocessing unit.
Fortunately, a low-cost revamp involving the installation of Shell
Global Solutions reactor internals can usually address such
issues. These include High Dispersion trays, which help to prevent
thermal maldistribution by achieving near-perfect wetting and
ultra-uniform utilization of the catalyst, anti-fouling trays designed
to reduce pressure drop buildup, quench internals for uniform
process and quench mixing at the interbeds, catalyst support grids
ultra-low bottom baskets and a vast range of specialty devices to
accommodate required elevations changes for bed optimization.
Moreover, when installing Shell Global Solutions reactor internals,
there are often opportunities to capture additional value. For
instance, depending on the axial temperature gradient, it could be
possible to combine beds to increase catalyst uptake. And, because
these quenches, bottom baskets and filter trays are all designed
to occupy minimal reactor volume, they can enable more catalyst
to be loaded into the reactor. This can be used either to help extend
the catalyst cycle life, lower WABT, process higher throughput
or process heavier, less-expensive feedstock, which results in a
higher margin. In some cases the unit yields can be re-defined for
better economics.
In addition, because these reactor internals are designed for fast
removal and installation, they can help to increase days on stream,
which is worth significant revenue. There are safety advantages,
such as far less confined space residence time, too, because cutting
and welding are not required and manways are large to enable fast
entry and exit. In some cases even no inert entry is required to get
access to the bed.
This paper will discuss many of the most common issues
encountered in a hydroprocessing reactor and, through the inclusion
of case studies, explain how Shell Global Solutions reactor internals
can help to resolve them.
Dynamic Model Integration and Analysis Maximizing

Production During Severe Scrapping
Author: Dr. Kadhim Mohammed, Saudi Aramco, KSA
Abstract: Severe slugging due to scrapping of gas and oil in
multiphase pipelines can cause serious and troublesome operational
problems for downstream receiving production facilities resulting
in significant reduction in production, flaring, and considerable
amount of capital cost investment to accommodate the increase
of liquid volumes resulting in loss of revenue. Performing rigorous
analysis using integrated tool of OLGA dynamic multiphase flow
simulation with HYSYS dynamic process simulation identifying
the types and magnitude of hydrodynamics flow that causes the
15
abnormality in having stable and continuous operation. Results from

field real operations of scrapping and simulation scenarios identified
design and operational constraints. Recent results demonstrating
the feasibility and the potential of applying Chocked Scrapping that
can be deployed with the aim of dampening effects of slug volumes
subsequently stabilizing the operation with minimum capital cost
expenditure. The saving in avoiding loss revenues was significant
and in tens of million dollars and also avoided plants' unplanned
shutdown.
Cost-effective and Flexible Hydroprocessing

Revamps
Author: Matthew Clingerman, DuPont Products, UAE
Abstract: Refiners are challenged to meet increasingly stringent
fuel specifications, even as the slate of available feedstock become
more difficult to process. Significant upgrades to existing facilities
are often difficult to justify in an era of heavy capital restraint.
Refiners must meet specific targets for long-term return on
capital and product quality from cost-advantaged feedstock for
any investment to be attractive. IsoTherming Hydroprocessing
Technology from DuPont provides a solution to the challenges
refiners face to reduce sulfur in finished products to ultra-low levels.
The design of the IsoTherming technology provides greater
flexibility in its application over the traditional process, particularly
for revamps, where highly-customizable designs can deliver a more
cost-effective and robust unit for the refinery.
IsoTherming technology is an innovative, liquid-full hydro-treating
process in which the required hydrogen is made available by
saturating a combined feed stream and a recycle stream of previously
hydro-treated liquid prior to entering the reactor. This design ensures
sufficient hydrogen available for the reactions at all points within a
reactor. This technology has been successfully implemented on a
commercial scale in a number of applications, including ULSD, VGO
hydrotreating and mild hydrocracking, to improve margins and
ensure a safe and sustainable operating environment. In grassroots
designs, significant operating cost savings can be achieved with the
potential for lower capital costs versus conventional technology.
In a revamp situation, improved desulfurization and increased
capacity can be achieved with minimal modification and no
additional recycle gas requirements.
An introduction to the principles of the technology and results
from unit case studies will be presented to show how the process
can deliver benefits to a refiner. Highlights from recent grassroots
and revamp projects will illustrate the versatility and robustness of
the process to increase unit capacity, reduce energy requirements,
and minimize operating expenses.

Dividing Wall Column - Reliable Solution for
Efficient Refinery Separations
Author: Ian Elgey, Director - Refining, KBR, UK
Abstract: Distillation has long been the industrys key separation
method. It is normally very energy intensive and thermodynamically
inefficient especially in refining. Dividing wall columns can provide
efficient solution to satisfy selective separation demands in the
system. They can be designed to reduce cost and/or increase
throughput for a given separation task.
16
Dividing wall column is not a new concept yet its acceptance is

relatively new in the hydrocarbon energy industry. Dividing wall
column technology is widely accepted in the chemicals industry;
what has prevented its widespread use in refinery applications is the
limited design experience and concern about operability & control.
This paper shares KBRs experience in revamp of a Reformate
Splitter column that helped refiner to meet new stringent Benzene
specifications in gasoline product and produced a smaller side stream
concentrated in Benzene for recovery in a downstream Aromatic
complex. The refiner not only benefited in meeting Gasoline product
specifications but also significantly reduced energy consumption
in the downstream separation process due to reduced flow of
Benzene concentrated side stream by allowing sharper distillation
through Distill-MaxTM technology.
It is also demonstrated in this paper that a rigorous design procedure
can mitigate operability risk and control issues. Case studies
presented in the paper take dividing wall column from concept to
reality.
Reliability and Life Enhancement of Heat

Exchangers by Eliminating/Improving the
Design of Impingement Plate
Author: Selvarajan Zachariah, Ma'aden Phosphate Company
Abstract: Heat Exchanger failure is one of the major contributors for
huge production loss in any process industry. Though several kinds
of failures are experienced in industry, one of the major kinds of
failure is due to improper design of impingement plates.
As per TEMA, any heat exchanger with high fluid inlet velocity
resulting in v1500 (FPS unit) is provided with an impingement
plate to avoid damaging of the tubes. In the case of water cooled
exchangers, it becomes a requirement if the velocity exceeds about
1.5m/sec (4.9ft/sec). Several types of impingement plates and
impingement rods could be designed to satisfy this requirement.
However, if these are not properly designed and installed, it would
not only fail but would damage the tubes leading to plant shutdown.
In the Ammonia plant of Maaden Phosphate Company, 227,280kg/hr
of ammonia is condensed in two parallel condensers by 27,900m/hr
of seawater. As the v value is very high, the condenser is provided
with an impingement plate. As the sizing of this impingement plate
is not well designed, the tubes adjacent to the impingement plate
got sheared due to vibration, resulting in 6 days of plant shutdown.
This paper explains the failure in detail and the remedial measures
employed. Also, certain guidelines are also provided so that this
kind of tube failure could be averted in process heat exchangers.
Better Compressor Designs through Advances in

Process Modeling
Author: Dr. Michael Brodkorb, Honeywell Process Solutions, USA
Co-authors: Vicky Athanasiou PhD, Honeywell Process Solutions,
USA
Martin Ross, PhD, Honeywell Process Solutions, USA
This presentation is divided into two parts, of which the first part
gives an update on best practice for deploying process modeling for
compressor design. It covers different practical aspects like:
What level of detail is required for effective compressor modeling?
Which type of model (steady state/dynamics) is required
for which phase during the compressor design project?
What tools are available to reduce the effort for developing and
using (dynamic) process models during compressor design?
Can such models be used to train operators for compressor

start-up?
The second part of the presentation shows in more detail how
the so-called reduced curves approach can significantly reduce
the efforts required to develop dynamic compressor models from
equipment manufacturers data and improves the accuracy of the
resulting model: Compressor manufacturers typically describe the
performance of variable speed centrifugal compressor in terms
of performance maps. Unfortunately, performance maps are not
broadly useful by engineers because the suction conditions and
rotational speed considered in the simulation will inevitably differ
from those at which the performance maps were constructed.
If these differences are not taken into account, the predictions
made by the model will be incorrect and possibly misleading.
This problem is addressed by transforming the performance maps
to a coordinate system in which they are independent of suction
conditions and rotational speed. In this coordinate system, called
reduced coordinates, the performance maps reduce to (or collapse
into) two aggregate curves, one for polytropic head and one for
power.
the operation of the ERU up to 30% of turndown capacity, keeping

the operational flexibility. A steady state rigorous model simulation
was built in HYSYS, integrated with the rigorous modeling of LNG
fin plate cold box and others heat exchangers developed in EDR.
The model developed was validated with several set of test-run data
at different feed compositions and unit capacities.
A methodology was developed to identify bottleneck equipment
while the ERU capacity was reduced. As result, it was found that
a 67% of design capacity feeding ERU with rich gas, the feed
compressor, turbo expander and Demethanizer column fails.
Several operating options were evaluated to debottleneck the ERU
unit at low capacity conditions, establishment that the solution with
less investment cost considers the recycle of Methane and Gaseous
Ethane streams, with control of the Molecular Weight at the inlet
of ERU. The option selected allows operating up 30% design
capacity with the required operational flexibility.

Rigorous Modeling of an Integrated Refinery and
Petrochemical Complex
Author: Gabriel Winter, Saudi Aramco, KSA
Abstract: There is a strategic direction in the Middle East to diversify
revenue generation from upstream down through the product value
chain. This has driven the addition petrochemicals and specialty
chemicals technology to our current infrastructure.
This paper will discuss the methodology to develop modeling
tools used to evaluate changing the disposition of typical refinery
intermediate streams to Ethylene plant feed. Process Simulation
software was used in conjunction with an ethylene pyrolysis yields
engine to evaluate different typical refinery intermediate streams for
use in design and planning models.
The advantage of this type of rigorous simulation is two-fold:
1. To determine the most effective technology investment in terms
of capital investment, upgrades, revamps, and grassroots projects
2. To create vectors to be used in a linear program (LP) models for
economic investment analysis.
The former helps to determine the best technology, while the latter
focuses on maximizing profitability. The combination increases
overall rates of return.
Optimization Solution for Ethane Recovery Unit at

Turndown Capacity
Author: Mariela Gutierrez, Technip, Qatar
Abstract: The Ethane gas used to produce Ethylene is produced
in an Ethane Recovery Unit (ERU) where the Ethane is separated
from Methane and C3+ components. In the present case study, the
ERU is fed with stripped associated gases. When the availability of
stripped gases is reduced, the feed to the ERU changes into rich gas
at less flow rate.
A feasibility study was conducted to find a suitable solution to allow
Power Recovery by Hydraulic Power Recovery

Turbines at Jazan Abha Pipeline
Author: Mussfir Al Shahrani, Saudi Aramco, KSA
Abstract: The primary focus of this study is to evaluate potential
recovery by utilization of hydraulic power recovery turbines (HPRTs)
at Jazan Abha Pipeline. The study explores various types of HPRTs
by identifying the appropriate range of application and identifies the
most suitable type for the subject application. Technical aspects and
economics have been analyzed in order to assess and justify the
economics of this project. The study was conducted for two different
cases namely, case1: with existing pipeline capacity, and case2:
with future upgraded capacity.
The outcome of this study clearly points out the economic viability
and feasibility of this proposed project with NPV of $ 2.65 MM for
case1 and $ 3.907 MM for case2 with investment rate of return
(IRR) of 12%. Case 1 project will result in an annual power recovery
about 3557.5 MWh which will cover 91% of the current power
consumption at Abha Bulk Plant while case 2 will result in an annual
power recovery about 5601.2 MWh which covers 143% of the
current power consumption at Abha Bulk Plant.
Sensitivity Analysis was performed to assess the NPV versus
changes in recovered power, cost of power and pipeline utilization.
This study concludes that case 1 project NPV remains on the
positive side even with a reduction by 44% in recovered power,
60% in cost of power and 52% pipeline utilization. Similarly,
case 2 project NPV remains on the positive side even with reduction
by 40% in recovered power, 60% in cost of power and 45% pipeline
utilization. Out of those analyzed, both cases have been proven to
have an excellent and attractive economic position justifying the
potential investment .
17
The study also includes various proposals from HPRT manufacturers,

technical review of pipeline parameters and products vapor pressure.
Assessment of the recovered power utilization options was also
covered in this study in order to find out the optimum option
and maximize the process efficiency. The study ends by some
recommendation and path forward for implementation of this
project.
Implementation of Adaptive Process Control in

CDU4
Author: Shekha Almansour, KNPC, Kuwait
Abstract: DMCplus Controller is implemented in Crude Distillation
Unit (CDU) several years back with an objective of maximizing unit
throughput and the yield of most valuable products while maintaining
product specifications at the specified limit. The process and the
operating conditions of the unit change over years, this change may
lead to model mismatch, hence there is a need to revise the model
but for that the existing DMCplus Controller needs to be stopped
and further testing for the unit will be required.
Adaptive Process Control is a new control algorithm that has the
ability to control the process by making minor step changes to the
MVs and stabilizing the process while active CVs are kept at or close
to limits. The main purpose of Adaptive controller is to generate data
suitable for modeling while continuing to optimize the operation of
the plant. This technology is used to enable evaluating, re-identifying,
and re-deploying DMCplus models.
This paper presents the implementation of Adaptive controller in
CDU4 and how the models improved after deploying them, which
will lead to maximizing the benefit of APC.

the FCC unit is analysed thanks to in-house software integrating

Pinch analysis and mixed integer linear programming solver for heat
exchanger network optimization. The energy recovery evaluation
is extended to the whole FCC complex including the FCC feed
pre-treatment section as well as the FCC unit itself.
This paper will present a revamping project in the CIS area
highlighting the clear synergy between technology upgrading
and energy efficiency improvement. This project will demonstrate
the feasibility of increasing throughput while lowering energy
consumption in the system.
Value Creation through Maximizing Distillate

Recovery by VDU Efficiency Improvements
Author: Abdullah Al-Ahmed, SATORP, KSA
Abstract: Recently in Q-3 of 2013, SATORP started the newest
refinery processing Heavy Crudes Oil (100% crude slate 400,000
BPD). These crudes are Arabian heavy oil, 26-27 API gravity, rich
in heavy stuff. SATORP, within one year managed to operate the
complex that contains Aromatics complex and high conversion
cracking units, at full load producing high yields of high value
products.
VGO from the vacuum tower is a feedstock to Mild/Distillate Hydro
Cracking (MHC/DHC) and to Fluidized Continuous Cracker (FCC)
units having high conversion to high-value distillates. However,
Vacuum residues (VR) produce low-value products such as LPG,
fuel gas, and Coke. Increasing the yield of VGO is a value creation
and improves the refinery margin.
Vacuum tower operations are quite severe, which any change
may cause changes in VGO composition. In such conditions, the
primary concerns are production of increased levels of Conradson
carbon residues (CCR), larger quantities of high molecular weight
Asphaltenes in VGO which could lead to higher coke make in the
Conversion units and metal contaminants that could poison the
catalysts. Set of improvements were done on Furnace COT, Vacuum
system, and stripping steam in the improvements of the efficiency of
the VDU. 1.5-2.5% decrease of the VR yield was achieved equivalent
to about 40 t/h increase of VGO.
Synergy of Technology Upgrading and Energy

Efficiency in a FCC Complex Revamping
Purge Gas Optimization in Aramco Facilities

Flare Systems
Author: Romain Le Masson, Axens, France
Author: Mahdi Aldajani, Saudi Aramco, KSA
Abstract: Improving refinery margins by technology upgrading

and by reducing energy consumption are key elements in todays
market environment and heavily impact Fluid Catalytic Cracking
(FCC) projects and operations. The reasons for that are two-fold:
(i) the FCC unit is the workhorse of many refineries all over the
world, ensuring most of the required conversion; (ii) the FCC unit is
one of the major contributors in terms of energy consumption and
greenhouse gas emission. Indeed, whether the price of energy is
high or low, controlled and reduced energy consumption combined
with enhanced FCC performance will naturally be key driving factors
for todays FCC revamping projects.
Co-author: Prasad Pantula, Saudi Aramco, KSA
A properly equipped FCC has significant potential to ensure the

highest technical and economical performances of the refinery
thanks to better yield selectivity. The technology upgrading is
achieved by specific and proprietary equipment such as feed
injectors, stripper packing and Riser Separator System (RS2). These
technology features reduce the dry gas and coke production, hence
allowing debottlenecking of the main FCC area of constraints such
as main air blower and wet gas compressor. Energy efficiency of
18
Sufficient purging of a plant flare system is essential to maintain its

readiness, reliability and integrity. Purge gas is required to sweep
any stagnant liquids, corrosive products in the header; prevent air
ingress from the flare stack, protect against flashback in the flare
header and prevent flame outs at the flare tip. However if not
properly optimized, it becomes a waste of useable energy resulting
in unwarranted CO2 emissions and direct economic loss. As part
of Saudi Aramco Flaring Minimization Program (FMP), Purge Gas
Optimization was initiated in all major facilities.
In the past few years, Purge Gas Optimization was successfully
implemented in all Gas Plants, Refineries and Gas Oil Separation
Plants (GOSPs) at Saudi Aramco. This paper summarizes the
methodology adopted and specific measures implemented in this
project. These measures resulted in achieving a 43% reduction
as compared to base level purge usage. This is equivalent to
fuel gas savings of US$ 20MM/year and 200,000 tons per year of
CO2 emissions reduction.
LPG Amine Treating Unit Retrofitted for

Environmental Compliance and Reduced
Operating Costs
Adaptive Process Control Innovative Approach for

Controller Sustainability
Author: Jaydip Bhadaliya, Bahrain Petroleum Company (BAPCO),

Bahrain
The synergy between innovations in model identification, automated

testing and controller operating modes are creating opportunities to
bring new efficiencies to the process of sustaining APC controllers.
These innovations address some of the long-standing challenges
facing APC practitioners: dealing with closed loop data, managing
APC solutions with model mismatch until repairs can be completed,
and reducing the operational impact of step testing. With these
advances, we now have the technology to begin constructing
continuous improvement processes in lieu of the traditional
Sustained Value workflows. We have the ability to switch between
optimizing control and constraint control. We can gently perturb the
process while in constraint control to gather usable process data.
We have improved model identification software to produce good
models using closed-loop data and the data from the background
perturbation of the process. By unifying these new capabilities
with integrated interfaces and workflows within the software,
we're delivering Adaptive Process Control: an iterative, continuous
process for sustaining the value of APC applications.
Abstract: BAPCOs catalytic polymerisation unit converts olefinic

LPG into polymer gasoline for blending. Historically the feed to the
unit was pretreated with caustic (sodium hydroxide) to remove H2S,
mercaptans and COS. Apart from the safety risks and corrosion
issues, this pretreatment process consumed large quantities of
expensive caustic and generated high volumes of spent caustic in
the Refinery waste water effluent.
To enhance environmental compliance and personal safety,
improve reliability and reduce operating costs, BAPCO retrofitted an
LPG amine absorber in late 2014. As a result the Refinery caustic
consumption was reduced by more than 80%.
The revamp was done with minimum capital investment by utilizing
the spare capacity of an existing amine regenerator and maximizing
re-use of existing equipment. The successful completion of the
project was achieved by overcoming several process and operational
challenges including the seamless integration of the new facility
into existing units.
Our presentation describes the challenges and the lessons learned,
from project inception to commissioning and startup. It also covers
the vital role of BAPCOs process engineers in largely driving this
project while working as part of cross-functional teams. The success
of the project highlights the need to develop and maintain in-house
expertise and experience, especially when it comes to revamping
existing process facilities.
Author: Anand Shah, AspenTech, Bahrain
The Concept of Adaptive Process Control is to do everything

required to update the models without the need to turn off the
controller, ensure that the controller exhibits robust behavior during
the periods between model updates, make maintenance a built-in
and continuous part of the process and eliminate the need to wait
for turnarounds to revamp controllers, incorporate knowledge of
control within the products and leave it to the users to leverage their
in-depth knowledge of the production process.
Adaptive Process Control has detect, diagnose, and correct as part of

the workflow. First with detect, we use the model quality analysis to
highlight problems with controller performance and model accuracy.
Next, we diagnose the specific models that are exhibiting issues
in order to focus our efforts to fix the problem. Lastly, there is the
correct step in which online testing, data slicing, and identification
can be used to create candidate models for improvement.
Test Agent is a tool that helps the control engineer conduct and
monitor the steps in the correct workflow.
Reduction of Dust Formation in LDPE Production
Adaptive has several advantages over traditional sustained value

approaches
Author: Rasheed M Al Badran, TASNEE, KSA
The controller model is continually analyzed for accuracy
Abstract: TASNEE LDPE Plant was suffering from a chronic quality

issue which is dust formation. There have been so many customer
complaints acknowledged because of this issue. The nature of LDPE
product (especially non-additive grades) is soft and generates fines
as a result of the friction between the product and the conveying
line which is too long in our Plant; making the situation much worse.
Poorly performing areas of the model are identified
There were actions implemented to remedy the problem such

as rotating the conveying line 180 and installing de-dusters
underneath logistics silos. Rotating the conveying line actions
improved the quality but did not resolve root cause. The installation
of fines De-dusters action has the major contribution in reducing
fines remarkably in LDPE final product. It is worth mentioning that
first pass prime product percentage has increased and no customer
complaints because of fines issues any more. Currently, fines
content in LDPE final product has reduced from 700 ppm to 50 ppm
(negligible) thanks to this implementation.
Non-disruptive background testing collects new process data

New data are monitored in real time and bad data are
automatically identified and removed
New candidate models are automatically created and presented
to the engineer for review
Moves controller maintenance from a project methodology to a
continuous work process.
Eliminates many of the tasks requiring control engineering
resources.
Maintains APC benefits without extended periods where
performance degradation has to be tolerated.
Exhibits robust controller behavior during periods of model
calibration.
Engineer is always in the loop regarding model acceptance
and deployment.
19
Effect of Steel Chemical Composition on

Zinc Coating Appearance and Properties
Author: Dr. Othman Al-Malki, SABIC Technology Center, KSA
Co-authors: Abdullah Al-shahrani , SABIC Technology Center, KSA
Fayes al-harbi SABIC Technology Center, KSA
Keywords: Hot-dip galvanizing, spangle, coating, zinc bath. steel
sheets
Abstract: Steel rusts in almost any environment if it is not protected.
Hot-dip galvanizing Is the most common way to protect steel from
corrosion. Zinc coating protects steel by providing both a physical
barrier and cathodic protection. It is an effective and economical
way to protect steel from corrosion. A protective coating of zinc and
iron-zinc alloys Is developed on the surfaces of Iron and steel
products by immersing them In a bath of molten zlnc at a temperature
close to 460C. Aluminum is added to the zinc bath to suppress the
reaction between iron and zinc by forming the ductile Fe2Ais on the
surface of the substrate. The addition of lead, antimony or bismuth
to the zinc bath results In hot-dip-coated surface structure consisting
of large grains termed spangles. Spangles macroscopic surface
appearance maybe classified as shiny, feathery or dull.
Galvanized coatings corrode and erode slowly. Zinc corrosion
rate correlates with two major factors; time of wetness, and
concentration of air pollutants. The service life of the zinc coating
Is directly proportional to the coating thickness (or weight) in a
given environment. The minimum coating weight is important to
attain the normally expected long-term product life in the application.
Size and appearance of the spangle (surface quality) Is affected
by different process variables including but not limited to stable
galvanizing bath composition, steel surface roughness, control of
dross build-up and cooling conditions.
The surface quality of the coating does not only degrades the
coating appearance but also affects the surface properties of the
coatings fori instance from the point view of the application of
additional finishing treatments. Wettabllity deterioration due to the
oxidation of alloying elements during the annealing process is a
concern. Oxidation of alloying elements such as Mn. Si. and AI is
inevitable by the trace water vapor in the hydrogen gas. The surface
oxides formed resulted in uncoated bare spots found on the steel
product. Thus, the objective of the work done is to study the effect of
base metal chemical composition on ainc-coatlng appearance and
roughness. The investigation was done using optical microscopy
and secondary electron microscopy on surface and cross section of
coated samples. Chemical analysis using SEM/EDX and roughness
measurements were also conducted.
use lies in air distillation and natural gas separation processes.

PFHE are also used in many other types of processes, e.g.
CO/H2 separation, ammonia production, olefin production, syngas
production, LNG, etc. A main feature of these processes is the need
for thermal integration: energy (and cost) savings can be performed
very efficiently by PFHE, in which heat exchange occurs between
many streams simultaneously (cases with more than 12 streams
are common).
ProSec, a PFHE simulation software, used in the industry since the
1990s, is the result of many years of research conducted with the
Laboratoire de Gnie Chimique (LGC) [1] and Fives Cryo [2], leading
manufacturer of this type of heat exchanger and founding member
of the ALPEMA [3]. This collaborative development on one hand
provided a rigorous validation of modeling as well as the correlations
used to calculate the heat exchange coefficients and pressure drops.
Most of all, the full complexity of this type of equipment has been
considered. The ProSec software is powerful because:
Thermodynamic properties of fluids allow an accurate computation,
The actual stacking pattern and topology of the exchanger are fully
considered,
Robust numerical methods are used to allow the convergence of
very complex industrial cases and trip cases.
Until now, ProSec was only available as a stand-alone unit operation
software, whereas only simplified models were used within process
simulators. The development of a new version of ProSec, as a fully
CAPE-OPEN [4] compliant unit operation, will be presented here.
This new version allows the full complexity of the ProSec model
to be used within the (1) simulation of a complete process with
ProSimPlus, the general steady-state process simulator of ProSim
[5], and also (2) makes it readily available in other CAPE-OPEN
compliant simulation environments (Aspen Plus, Aspen HYSYS,
PRO/II). This ability to interoperate with other programs will
improve the everyday workflow of process engineers by avoiding
handmade data transfer between different tools. This ensures full
consistency and enhances the quality of results, particularly when
PFHE are integrated into complex processes with several recycling
streams.
ProSec CAPE-OPEN capability will then allow access to the software
full potential to companies using any CAPE-OPEN compliant process
simulator.
REFERENCES
[1] http://lgc.inp-toulouse.fr
[2] http://cryogenics-energy.fivesgroup.com/
[3] www.alpema.org
A New Cape-Open Unit Operation Module for

Simulation of Brazed Plate-Fin Heat Exchangers
Author: Philippe Leurent, ProSim, France
Co-authors: Olivier Baudouin, ProSim, France
David Averous, ProSim, France
Stephane Dechelotte, ProSim, France
[4] http://colan.org/
[5] www.prosim.net

Renaud Egal, ProSim, France

Florian Picard, ProSim, France
Rodolphe Sardeing, ProSim, France
Alain Vacher, ProSim France
Abstract: Plate fin heat exchangers (PFHE) are frequently used in
cryogenic process industries. During the last fifty years, several
hundreds of thousands of units have been manufactured and are
now in operation all over the world. Their most commonly known
20
Optimization of Combined Heating, Cooling and

Power Systems through Modeling
Author: Emad Darweesh, GAP-Tech, Egypt
Abstract: Combined Heating, Cooling and Power (CHCP) system
represents three layers of energy networks inside a process plants.
Heat production and consumption layer in the form of steam, hot
oil or firing is the most important and the highest energy consumer.
Power layer includes all the rotating equipment drivers, either
mechanical or electrical power, is interfaced with heat layer during

generation from COGENs or consumption on steam turbines.
Refrigeration or Cooling Layer includes the power driven refrigeration
cycles, or heat driven chilling packages. While these layers can be
optimized independently to achieve a local optimum target, it should
be optimized together combined to achieve the global optimum for
the plant that guarantee the minimum energy consumption.
Modeling of the CHCP system should ensure optimum design and
sizing of the system components that satisfy the plant operation
scenarios efficiently. It can be also used to optimize the operation
of an existing system or to identify potential areas of improvement.
Identification of each layer components operating windows,
mechanical limitations, reserve and sparing philosophy are
constrains to optimize the overall performance of the system.
Optimization of the Refrigeration Cycle will impact power
requirement on the refrigerant compressor that is driven by steam
turbine, electric motor or shared power from both drivers. Most of
the plants configuration includes several refrigeration cycles with
variation of the compressor drivers. Selection of the right driver type
and optimizing the refrigeration duty may not positively impact plant
overall economics unless steam and power networks are positively
affected.
Optimization of the pipeline network schedule leads to effective

inventory management, mitigation of shipping delays, reduction in
product downgrading, minimization of product transition losses, and
maximization of capacity usage.
This presentation will discuss the challenges in the development of
this countrywide application, its implementation by Saudi Aramco
in one of the pipelines networks, and the realized benefits. It will
conclude with a path forward for the complete implementation of this
scheduling application with short range planning, ship scheduling
and truck movement in the refined products supply chain.
Effective Utilization of Olefins Plant Simulation

Model Before Plant Startup
Author: Faisal Baksh, Sadara Chemical Company, KSA
Abstract: Process Simulation models of varying detail have
successfully been applied by operating plants for performance
monitoring, troubleshooting and capacity revamp. However
utilization and even assembly of a simulation model is seldom done
by operating companies for plants that have not yet been started up.
In this presentation, we advocate the necessity of a plant model for
providing the necessary in-house support to plant operations and
other plant teams before and during startup. A complete simulation
model was developed on Aspen plus for an olefins plant, excluding
the complex interactions within the steam cracking furnaces.
The Sadara Mixed Feed Cracker (MFC) produces polymer grade
ethylene and propylene, feeds aromatics to downstream units,
and utilizes both ethane and naphtha as feedstock. The model is
successfully used to answer questions that arise for operating the unit
at modes other than those evaluated by licensor and for capacities
that are precariously close to minimum turndown of the plant.
We will also demonstrate how the model evaluations were done in
close cooperation with other teams for support of their functions,
e.g., Flux Oil composition evaluation and respective suitability for
use in the Oil Quench Tower done with the Flux Oil project team, and
utility load evaluations at different operating scenarios, done with
the Site Integration Team, to optimize and manage the overall plant
material balance.

Application of Optimization and Algorithm
Techniques to Enhance Schedule Forecasting of the
Distribution of Refined Products through Pipeline

Author: Ahmed Alshaikh, Saudi Aramco, KSA
Sterically Hindered Amines Thirty Five Years of

Practice
Abstract: Saudi Aramcos refined products distribution network

consists of refineries, terminals, bulk plants, storage facilities,
air fueling operations (AFO) facilities, and an associated product
transportation network. To cope with the continuous challenges of
producing pipeline schedules that effectively manage product
inventory on a daily basis while meeting local demand, managing
truck and marine movements, and while considering the operational
requirements of the refined products distribution system Saudi
Aramco has embarked on a recent project to implement the Refined
Products Distribution & Pipeline Scheduling Application (RPD&PSA).
The RPD&PSA uses monthly short-range operating plan targets,
disaggregated to daily demand as a basis. It generates an optimized
sequence of pipeline batches, on a continuous basis, for the current
and next planned month, to transport products within the Eastern,
Central and Western regions. The application helps the corporate
scheduling organization to generate an optimized batching plan
(sequence and schedule). In streamlining scheduling process
for marine supply, there is more time for coordination activities.
Author: Girish Chitnis, ExxonMobil, USA

Abstract: The sterically hindered amine FLEXSORB SE solvent
with enhanced selectivity for H2S was discovered by ExxonMobil
Research and Engineering Company in the late 1970s. The FLEXSORB
SE system was first commercialized in 1983 in a refinery sulfur plant
Tailgas Cleanup (TGCU) application. Since then, the FLEXSORB
SE/SE Plus systems have been extended to include applications in
Acid Gas Enrichment (AGE), onshore/offshore natural gas treating
and FLEXICOKING flexigas treating. To date, more than 6 BCF/D
of gas is being treated by this amine system to selectively remove
H2S and reject CO2. A number of applications, representing
more than 4 BCF/D gas treating, are in the engineering evaluation
and design phase. This paper will describe the development of
FLEXSORB commercial applications from TGCU service to these
other applications and provide comparative operating data on
selectivity with MDEA based systems. The paper will present a
21
detailed economic evaluation between FLEXSORB SE/SE Plus and

MDEA designs using the Life Cycle costing approach to illustrate
how the technology is best suited to meet emerging environmental
regulations in the most cost effective way.
Early Detection of Adsorbent Degradation in

Processes for para-Xylene Purification
Author: Rakan Bilaus, Saudi Aramco, KSA
Co-author: Bruce Beadle, Saudi Aramco, KSA
Innovative Changes Improved CO2 Removal

Systems Performance and Sustainability
Innovative Changes
Author: Abdul Daiyan Sheikh, SAFCO-SABIC, KSA
Co-authors: Abdul Daiyan Sheikh, SAFCO-SABIC, KSA
Dhiya T Al-Khaleefa, Indian Institute of Technology, Kharagpur,
India
Nabeel Al Marzouq, King Fahad University of Petroleum and
Minerals (KFUPM), KSA
Faisal Al-Sharani, King Saud University (Chemical Engineering),
KSA
Zuhair Al-Taha, King Fahad University of Petroleum and Minerals
(KFUPM), KSA
Abstract: SAFCO-4, the largest single stream Ammonia plant in the
world was commissioned in 2006. aMDEA CO2 removal process
was used for Synthesis gas purification. High CO2 slippage and
partial venting of flashed gas were observed since commissioning.
Considering the improvement opportunities, SAFCO engaged
licensors to study in detail and give recommendations for
improvement. Several recommendations were implemented to
improve CO2 absorption but could not improve significantly.
Moreover, the recommended measures resulted in number of side
effects like higher H2 content in CO2 gas, higher consumptions of
chemicals, frequent failure of CO2 stripper internals, etc. in addition
to continuous loss of production, high CO2 slippage frequently
forced operation to reduce plant load in summer season.
An in-depth in-house study for CO2 removal section performance
improvement was started in 2011. Opportunity for improvement
were categorized into three different heads like, high CO2 in the
synthesis gas, high H2 in the CO2 stream and continuous flaring of
flash gas. Ideas collected were studied in detail from both engineering
and economic feasibility point of view. On line trials were conducted
to check the applicability of the idea. For some ideas, dummy trials
were done through process simulator. Based on trial results, ideas
were selected for implementation after concurrence from plant
licensor. Enhancement of solution regeneration through LP flash
column pressure reduction was selected for reducing CO2 slippage,
improvement of filtration system was selected for reducing H2
content in the CO2 and replacement of the flash gas fuel valve with
bigger size was selected for stopping continuous flaring of flash gas.
Detailed engineering, were carried out by SAFCO in consultation
with Licensor. Implementation of CO2 coolers modification and
flash gas valve replacement were completed in 2013. Filtration unit
modification is expected to be completed this year.
Since implementation of ideas and temporary mobile filtration
arrangement; CO2 slippage reduced to <100 ppm, Ammonia
production increased by ~67 MTPD with same feed and fuel, specific
energy consumption reduced by ~2%, Chemical consumption
reduced to ~10% of the previous values, flash gas venting
stopped completely in addition to plant reliability & sustainability
improvement. Two summers passed without any hindrance to plant
load due to high CO2 slippage.
Abstract: The important industrial petrochemical para-Xylene (pX)

is derived from naphtha reformate, used to produce terephthalic
acid for production of polyester (poly[ethylene-terephthalate], or
PET). Because pX cannot be separated from the other co-boiling
C8 aromatics ethylbenzene and meta- and ortho-xylene (EB, mX
and oX) by fractionation, pX is most commonly purified using a
selective adsorption process. The zeolite-based adsorbent used in
the process is subject to degradation by physical breakdown in a
system with the following: imperfect flow patterns, high velocities
and adsorbent particles subject to powdering. As adsorbent
particles break down to powders, areas of localized plugging form,
leading to poor flow distribution and increased pressure drop across
the adsorbent chambers. The process may be subject to early
unplanned shutdown, requiring a reload of the adsorbent chambers,
with a turnaround time of 7 to 20 weeks.
Localized plugging in the adsorbent beds and the resultant backmixing will decrease the maximum attainable pX purity. Monitoring
the C8 aromatic contaminants in the pX product allows early
detection of adsorbent degradation, allowing changes to operations
to prevent the source of degradation or allowing advance notice for
turnaround planning. Since operators typically maintain pX purity by
adjusting flows in the Purification Zone to control EB contamination,
evidence of powdering is strongly indicated by increasing mX
and oX contamination while EB is reduced to maintain purity.
Early detection of powdering can allow mitigation by reducing
feed rates to reduce internal velocities below the fluidization velocity,
or provide early warning of the next unplanned turnaround.

Achieving High Performance Separator System
Using Computational Fluid Dynamics
Author: Marie-Amlie Lambert, Axens, France
Abstract: In todays digital age, the use of Computational Fluid
Dynamics (CFD) is widespread to predict the performance and
behavior of different systems. It is especially interesting in the
field of Fluid Catalytic Cracking (FCC) where gas-solid environment
behavior requires extensive studies and experimentation which are
costly and time consuming.
One of the best features of the FCC technology licensed by Axens,
in collaboration with the other FCC Alliance partners (IFPEN,
Technip Stone & Webster Process Technology, and Total) is the
Riser Separator System (RS2). The RS2 has been developed thanks
to the extensive use of CFD techniques. This riser termination device
has been successfully implemented in numerous industrial units
to segregate catalyst from the hydrocarbon vapor exiting the FCC
riser and has demonstrated a perfect alignment between CFD studies
and industrial results. Following the RS2 success for grassroot
FCC units, novel applications of this technology feature are further
explored using, again CFD techniques.
This paper describes two practical examples of RS implementation
in highly constrained FCC units: external riser separator in confined
plot and compact RS2 for bottlenecked regenerator; both allow
delivering significant value to the plant operator.
22
Role of the Process Engineer in Development of the

Operator Training Simulator
Author: Muhammad Ilyas, Sadara Chemical Company, KSA
Co-author: Walter Papadopoulos, Sadara Chemical Company, KSA
Abstract: The surge of construction projects in the process industry
has prompted a new interest in operator training simulators (OTS).
Owners of grassroots plants are facing the issue of training and
keeping a skilled workforce of control room and field operators in
the context of scarce human resources and growing concerns with
safety and environmental issues. High-fidelity dynamic training
simulators are part of the strategy to properly train and certify
plant operators. However, their implementation is not always an
easy task. The essential lesson learned from recent projects is that
proper engineering and maintenance of the controls database and
process models are major prerequisites to long-term capture of
OTS benefits. Involvement of the process engineer from day one
as a team member in development of the OTS is vital for successful
completion of project.
The primary benefit of the OTS is to provide plant operational staff
with practical experience on how to operate complex plant process
systems in various situations. These include:
Normal operations at different throughputs and feeds
Plant malfunctions and upsets
Normal startups and shutdowns of the process units
Emergency shutdowns
Recovery from various malfunctions and upsets
The role of the process engineer during project execution is
very critically related to scope definition, system integration,
performance checking and execution schedule, which could pose
serious obstacles on the road to success. The following activities
are expected from the process engineer during the engineering
phase of the OTS:
Help project manager to schedule timely execution of OTS
implementation
Scoping definition
Defining process model boundaries
Defining training scenario
Defining process model fidelity
Providing process data for dynamic model development
Engineering design review
Coordinating with licensor for proprietary data
The process engineer can play an active role during testing and
acceptance:
Model acceptance testing
Pre-factory acceptance testing
Factory acceptance testing
Once the OTS has been delivered and implemented at the plant site,
the process engineer still cannot keep himself away from the OTS
training room. Process engineers could use the OTS for checking the
dynamics of process units under new operating conditions. Process
engineers could also take major responsibility for keeping the OTS
models tuned to the actual plant configuration and regularly checking
the heat and mass balances and the models' dynamic responses.
In addition, plants could benefit if the process engineers use the
capabilities of the OTS to improve process design and validate new
operating modes.
UOP-Honeywell Advanced MTO Process:

Monetization of Natural Gas of Coal-Derived
Methanol by Conversion to Polymer-Grade
Propylene and Ethylene
Author: Geoffrey Fichtl, UOP-A Honeywell Company, USA
Abstract: As the global demand for light olefins increases at a
steady pace topping 4% annually, the need for alternatives to
traditional steam cracking processes has increased. The advanced
Methanol to Olefins (MTO) process provides a pathway to convert
cost advantaged alternative feedstock such as coal, natural gas,
biomass and pet coke to ethylene and propylene. Advanced MTO
has an intricate development story, incorporating advances across
multiple process development efforts.
In the 1980s, Union Carbide discovered SAPO-34 molecular sieve,
which created a selective route for methanol conversion to ethylene
and propylene. The difference in light olefin selectivity between
other candidate catalysts, such as ZSM-5, and SAPO-34 is largely
due to differences in pore size and acidity. SAPO-34 has smaller
4 pores compared to 5.5 pores for ZSM-5. The smaller pore size
restricts diffusion of heavy and branched hydrocarbons, favoring
high selectivity to light olefins. The optimized acidity of SAPO-34
relative to ZSM-5 reduces the occurrence of undesirable hydride
transfer reactions, in which olefins are converted to paraffins.
Additionally, SAPO-34 produces a C4-C6 olefin fraction that is
suitable for upgrading to light olefins by olefin cracking. A joint
venture was formed between UOP and Union Carbide in 1988 which
transferred SAPO technology to UOP.
In the early 1990s UOP and Norsk Hydro A.S. (later absorbed by
INEOS) formed an alliance to develop MTO technology. Taking
advantage of UOPs extensive Fluidized Catalytic Cracking (FCC)
experience and Norsk Hydros unique MTO development, this
collaboration led to the development of the UOP/HYDRO MTO
Process.
In parallel, olefin cracking was actively investigated by ATOFINA
in the 1990s. In 2000, ATOFINA (now part of Total Petrochemicals)
and UOP formed an alliance to further develop olefin cracking
technology.
This collaboration led to development of the Total Petrochemicals/
UOP Olefin Cracking Process (OCP).
The unique combination of MTO and OCP, referred to as Advanced
MTO, achieves overall carbon conversion efficiency of methanol to
light olefins near 89%. The Advanced MTO propylene/ethylene
ratio can be adjusted online between 1.3 and 1.8. A single train
UOP/HYDRO MTO unit can process up to 4600 kMTA methanol, or
~1500 kMTA light olefin production. The Advanced MTO Process
single train capacity can be extended up to 1800 kMTA light olefin
production from the same amount of methanol. UOP/Hydro MTO
and Advanced MTO processes have the largest single-train light
olefins production capacities of all available methanol-to-olefins
technologies.
The Advanced MTO process development story is not complete
without highlighting the successful start-up of the first commercialscale unit at Wison Clean Energy in 2013, China. Shortly after startup the Wison unit met all process guarantees and is performing
as designed. Six additional MTO complexes have been licensed,
several of which are scheduled to begin production in 2015 and
2016.
23
Digital iPoster Program
Advanced Approach to Opimizing Process Energy

Use Through Integrated Pinch and Simulation
Solutions
Author: Farooq Gulam, AspenTech
Transient Heat Transfer Simulation in a Molecular

Sieve Pilot Plant
Author: Dr. Daniel Longstaff, Saudi Aramco, KSA
Abstract: A two story tall, 1 MMSCFD molecular sieve pilot plant
(MSPP) was designed, fabricated and installed in a Saudi Aramco
gas plant. The pilot plant was designed to have eight parallel 1.8 m
high desiccant cells. It was intended to conduct desiccant screening
tests through hundreds of cycles, consisting of desiccant saturation,
thermal regeneration and cool-down.
The molecular sieve pilot plant had a fundamental design flaw
which prevented the desiccant beds from heating to the required
regeneration temperature during the thermal regeneration step.
The molecular sieve pilot plant was operated as fabricated to
theorize the reason for the poor heat-ups. It was postulated that it
was because of heat losses to the piping between the regeneration
heater and the desiccant bed.
In order to confirm that the heat losses were the cause of the poor
performance, a transient heat transfer simulation program was
developed, programmed and executed to predict the heat up before
and after the modification of the pilot plant piping. The objective
was to be sure that the change would be correct before any actual
modifications were made.
The results of a simulation are presented in Figure 1 and confirmed
the positive effect of the proposed modification. Following
implementation it was found that the predicted and actual results
matched. The MSPP was then successfully used to conduct three
pilot plant studies in seven parallel cells to make comparisons of
desiccant aging and pressure drop.
Abstract: With falling oil prices and increased focus by organizations

to reduce new expenditure and optimize current operation there is an
increased responsibility on process engineers to review and ensure
development of designs that make economic sense. Further they
are obligated to advise their management to ensure that strategic
projects are not ignored or delayed that may result in loss of potential
profits in the future. However, we find that most process engineers
are cautious about performing economic analysis due to perceived
lack of estimation skills. The author will highlight how advances
in process simulation software are aiding in the development
and augmentation of estimation skills, in process engineers, to
perform feasibility and economic studies with a significant degree
of confidence. The author will also how model based estimating
software offers a higher degree of accuracy over only adopting a
factored estimation approach. In conclusion, simplicity of integrating
economic evaluation with process simulation will be demonstrated.
Improving Capital Projects and Reducing Project Risk through
Improved Owner - Epc Collaboration On Fel And Feed
Combination Filtration for Removing Divalent Salts

and Contaminants from Monoethylene Glycol (MEG)
Reclamation Units
Author: Barry Perlmutter, BHS-Sonthofen Inc.
Abstract: For the transport of Liquefied Natural Gas (LNG),
monoethylene glycol (MEG) is injected as corrosion inhibitor and to
reduce the freezing point of the water in the LNG, both in onshore
and offshore installations.
In the reclamation unit, rich MEG (up to 70% water and dissolved
salts) is converted to lean MEG (water reduced to 10%) by
evaporation. During MEG reclamation, there are divalent salts,
such as carbonates (Ca, Na) and hydroxides (Mg, Fe, etc.) whose
concentration increases during the evaporation. In the reclamation
unit, there is normally a pH-adjustment step, allowing the divalent
salts to precipitate after adding NaOH and seeding crystals. These
salts along with pipeline debris and oxidation products end up in the
heat exchangers and reduce the efficiency of the process and must
be removed from the rich MEG prior to the thermal regeneration
section.
This paper discusses a combination solid-liquid filtration system
for as an alternative to static thickeners, centrifuges, filter presses
and cartridges. In addition, the conventional pre-coat process is
discussed. The rich MEG solids slurry is first concentrated using
candle filters for a solids-free filtrate and a concentrated sludge
of approximately 4-5 % solids. Next, pressure plate filters are
used to wash and dry the cake to produce an MEG-free cake for
non-hazardous disposal.
The paper begins with laboratory tests to determine the pressure
for filtration, filter media, precoat material and similar process
parameters. It continues with case histories and installation details
including maintenance and reliability. In the conclusion, information
is presented that engineers need before deciding on a solid-liquid
separation technology.
24
Improved Blend Quality Control Using Process

Simulation Results
Author: Arvind Ramachandran, GASCO, UAE
Abstract: The main objectives of this work are:
1) To find a simple equation that predicts the blend RVP (Reid Vapor
Pressure) from the inlet stream flows and their compositions.
2) To study the effect of the ratio of the feed-streams (first stream
having a LOW RVP and the second stream having a HIGH RVP) on
the blend RVP.
3) To apply the findings in 1 and 2 to design a simple process control
philosophy that can be implemented in the plant for stable and
automatic control of the blend RVP specification.
The main methodology of the study consists of case studies using
standard off-the-shelf process simulator tools like HYSYS 8.6 to
understand the dependency of the desired parameter blend RVP
on inlet stream parameters like composition, flow rates and RVPs.
It is then subject to fine-tuning and data validation against actual
Lab composition results, measured flow rates and RVP of blend
measured.
Moreover, when installing Shell Global Solutions reactor

internals, there are often opportunities to capture additional value.
For instance, depending on the axial temperature gradient, it could
be possible to combine beds to increase catalyst uptake. And,
because these quenches, bottom baskets and filter trays are all
designed to occupy minimal reactor volume, they can enable more
catalyst to be loaded into the reactor. This can be used either to
help extend the catalyst cycle life, lower WABT, process higher
throughput or process heavier, less-expensive feedstock, which
results in a higher margin. In some cases the unit yields can be
re-defined for better economics.
In addition, because these reactor internals are designed for fast
removal and installation, they can help to increase days on stream,
which is worth significant revenue. There are safety advantages,
such as far less confined space residence time, too, because cutting
and welding are not required and manways are large to enable fast
entry and exit. In some cases even no inert entry is required to get
access to the bed.
This paper will discuss many of the most common issues encountered
in a hydro-processing reactor and, through the inclusion of case
studies, explain how Shell Global Solutions reactor internals can
help to resolve them.
Key Results are as under:

1) The Optimum (LOW RVP stream / HIGH RVP stream) ratio to
maintain the blend RVP is determined by analyzing the case study
results.
Triple Bore Hollow Fiber Membrane for Liquid

Desiccant Based Dehumidification
2) Blend RVP is actually quite non-linear with respect to the inlet feed
rates, composition and inlet RVPs.
Author: Dr. Srivatsa Bettahalli, King Abdullah University of

Science and Technology (KAUST), KSA
3) We have studied the variations in the predicted blend RVP between

a simplified, linearized equation and the actual non-linear equation.
Co-authors: Ryan Lefers, King Abdullah University of Science and

Technology (KAUST), KSA
The observation is that the linear equation predicts a higher RVP

than the non-linear equation at lower feed ratios. It is specifically
this low-ratio region that we want to avoid in the blending operation.
Torove Leiknes, King Abdullah University of Science and

Therefore, by using the simplified linear equation, we can actually

utilize the positive deviation for more conservative and effective
control of blend RVP.
Conclusion
1) Use of process simulation results for simplified and easily
implementable process control philosophy.
2) Innovative use of simplified linearization to our advantage in terms
of more conservative process control.
Use of Lp Tool for Optimum Configuration and

Technology Selection
Author: Pankaj Zawar, IOG Solutions, India
Co-author: Satish Kalluri, IOG Solutions India
Abstract: Reactor issues such as thermal maldistribution and high
pressure drop are indicators that a refinery may be failing to capture
the maximum value from a hydroprocessing unit.
Fortunately, a low-cost revamp involving the installation of Shell
Global Solutions reactor internals can usually address such
issues. These include High Dispersion trays, which help to prevent
thermal maldistribution by achieving near-perfect wetting and
ultra-uniform utilization of the catalyst, anti-fouling trays designed
to reduce pressure drop buildup, quench internals for uniform
process and quench mixing at the interbeds, catalyst support grids
ultra-low bottom baskets and a vast range of specialty devices to
accommodate required elevations changes for bed optimization.
Suzana Nunes, King Abdullah University of Science and

Abstract: Dehumidification is a significant component of cooling
systems in high humidity environments worldwide. Conventional air
cooling system handles both air dehumidification (latent heat load)
and air cooling (sensible heat loads) simultaneously. Mechanical
dehumidification involves cooling to the dew point of air and then
reheating, leading to high energy consumption. Liquid desiccants
offer a promising solution for dehumidification as desired levels
of humidity removal can be regulated by conditioning the liquid
desiccant, but direct contact with desiccant has regulatory issues in
many countries due to chances of formation of aerosols. Membrane
contactors are attractive for liquid desiccant dehumidification
because they prevent direct contact between the humid air and the
desiccant, preventing the potential for desiccant carryover to the air.
However, the additional mass transport barrier of the membrane
surface can lower the expected desiccation rate per unit of desiccant
surface area. In this context, hollow fiber membranes present
an attractive option for membrane liquid desiccant contactors
because of their high surface area per unit volume. The following
study provides the experimental results of one such hollow fiber
membrane liquid desiccant contactor for dehumidification of hot
and humid air. In this work hydrophobic Polyvinylidene fluoride
(PVDF) based triple bore hollow fiber were fabricated which are
mechanically stable and characterized using scanning electron
microscopy, pore size distribution, liquid entry point etc. Lab scale
experiments were carried out in controlled environmental chamber
maintained at 70% relative humidity (%RH) and 35C temperature
and 43% calcium chloride solution as liquid desiccant. Experiments
with different flow rates, constant desiccant feed temperature and
24-hour feed replenishing batch mode operation were carried out
for 5 days to check the performance of the fabricated triple bore HF
25
in long term. The results were characterized based on water vapor

permeability of 450mg/m2sec which is distinctly higher than that
reported in literature.
An Optimization Approach for Maximizing Heat

Recovery by Considering Properties Changes
Author: Faysal Al Khulaifi, King Fahad University of Petroleum and
Co-author: Eid Al Mutairi, King Fahad University of Petroleum and
Abstract: In recent years, demands for highly efficient processes
have grown substantially due to environmental concerns, increase
in global demand for high-quality products and search for more
cost-effective ways to maintain operational goals. The design and
synthesis of optimum process networks has managed to alleviate
the aforementioned concerns but not to the desired extent. In the
implementation phase, a promised reduction in energy costs of 15%
by design might only lead to a 7 or 9% reduction in reality. In order
to give decision makers in the industry and government regulators
more accurate, precise and actionable information regarding process
optimization and network synthesis, we must improve the tools by
which we design and synthesize process networks. These efforts
will ultimately bridge the gap between design and implementation
and offer outcomes that are more representative and practical.
This paper will focus on heat exchanger networks (HEN) and how
to improve optimization algorithms to achieve better predictions.
For more than 30 years, research in the field of process optimization
has brought us closer to achieving rigorous mathematical models
that can best describe an efficient, reliable heat exchange network
for a process in order to reduce utility and resource costs while
improving returns on investments. In this paper, mathematical
HEN models were designed to consider flexibility of operational
conditions, such as temperature and flow rate, to reach an optimized
process. This was done by proposing a novel approach to modeling
that will investigate the effects of stream property profiles (such
as heat capacity, viscosity and overall heat transfer coefficient)
when considered as variable functions of temperature, contrary to
classical models where these properties were assumed constant.
The results were obtained by utilizing HYSYS and using optimization
software GAMS. The minimum total annual cost in two case studies
has changed in the range of -0.9% to 7.2% compared to base cases
(where properties are assumed constant). It was also observed
that investment costs are mostly affected by heat exchanger
design variables (heat transfer coefficient, viscosity and thermal
conductivity), while utility costs are mostly affected by variable
heat capacity. These results have demonstrated that relaxing the
assumptions of constant stream properties (unaffected by variable
temperature) can have a considerable effect on the predictability and
accuracy of optimization models.
Application of Pole Placement Control to Double

Inverted Pendulum (DIP) for the Enhanced Stability
and Linear Response
istics of non-linearity and instability that can create numerous

problems during implementation of control scheme. This work
describes the application of control strategy of pole placement
method for the analysis of double inverted pendulum (DIP).
Mathematical model of DIP plays a key role to influence on it control,
and its eigen values which are the poles of the DIP system intensively
affects the stability and response of DIP. Euler-Lagrange equations
were used for mathematical modelling, which generates the
equations of motion in nonlinear form. These nonlinear equations
were linearized around Up-Up position of equilibrium. A control
scheme of pole placement design was employed to control the
double inverted pendulum and it has the ability to place the poles
of the DIP system at the desired location by using its gain matrix.
The proposed strategy was successfully employed to achieve the
stability and linear response.
Carbon Nanotubes-Metal Oxide Membrane:

A New Frontier in Water Treatment Technology
Author: Ihsan Ullah, King Fahad University of Petroleum and
Co-authors: Muataz Ali Atieh, King Fahad University of Petroleum
and Minerals (KFUPM), KSA
Adnan M. Jarallah Al-Amer, King Fahad University of Petroleum
Aamir Abbas, King Fahad University of Petroleum and Minerals
(KFUPM), KSA
Tahar Laoui, King Fahad University of Petroleum and Minerals
(KFUPM), KSA
Abstract: Reliable access to safe and clean drinking water is
considered to be one of the most basic humanitarian goals, and
remains a major challenge for the 21st century. In this work, a novel
synthesis concept of carbon nanotube based membrane, comprising
dispersed CNTs and metal oxide nanoparticles is presented.
These membranes have the advantage over typical inorganic
membranes, in that they enhance the removal efficiency by coupling
the adsorption and sieving. CNTs were impregnated with different
amounts of metal oxide via a wet chemistry technique, compacted
and sintered at high temperature to form a compact disk. Powder
materials were characterized by Scanning Electron Microscopy
(SEM), Energy-dispersive X-ray spectroscopy (EDS), BET surface
area analyser, X-ray diffraction (XRD) and Thermogravimetric
analysis (TGA), while the prepared membranes were analysed by
measuring their density, porosity, contact angle measurement and
water flux. The antifouling behaviour of the membrane was studied
using E. coli bacteria and sodium alginate.
Development of Surface Modified Zeolite Catalysts

for the Application in Hydrocarbon Cracking
Author: Umer Chauhdry, King Fahad University of Petroleum and
Author: Murad Ali, King Fahad University of Petroleum and

Co-author: Oki Muraza, King Fahad University of Petroleum and

Co-authors: Muhammad Hawwa, King Fahad University of

Petroleum and Minerals (KFUPM), KSA
Abstract: Due to the shortage of conventional light crude, production

of heavy oil is increasing, so in recent years more attention has been
given to pyrolysis of heavy oil. Steam is injected in oil reservoirs to
recover heavy oil from wells. This process involves cracking of heavy
hydrocarbons which results in viscosity reduction. This process may
be speeded up in the presence of catalysts. Pyrolysis took place in
the presence of steam and a catalyst in a process known as catalytic
hydrous pyrolysis. In this hot aqueous environment, catalysts to be
employed should be hydrophobic and thermally stable. Many zeolite
Ihsan Ullah, King Fahad University of Petroleum and Minerals

(KFUPM), KSA
Muhammad Yasir Khan, King Fahad University of Petroleum and
Abstract: The double inverted pendulum possesses the character-
26
catalysts have shown excellent cracking applications and surface

modification of such catalysts may increase its stability in a hot
aqueous environment. The objective of this work was to synthesize
and modify heterogeneous acid catalysts for the application of
upgrading heavy oil in the presence of steam and hydrogen. Zeolite
catalysts with different Si/Al ratios were synthesized using different
techniques including microwave assistant hydrothermal treatment.
Synthesized catalysts were modified using different silane groups
to enhance their thermal stability in hot water. Surface modified
catalysts were characterized using different techniques such as XRD,
SEM, FT-IR, BET and NH3-TPD. Application of catalysts in cracking
of heavier hydrocarbons was reported. Cracked hydrocarbons were
analyzed using GC-MS and viscosity meter.
Evaluation of CO2 Bio-Fixation Potential of

Microalgae Culturing in Closed Photobioreactors:
Advancement Toward Addressing Global
Environmental Challenge
Author: Muhammad Ilyas, King Fahad University of Petroleum and
Minerals (KFUPM),KSA
Abstract: Greenhouse gases (GHGs) are a major environmental
concern worldwide and scientists consider these gases responsible
for global warming. CO2 is a major constituent of it, produced by
burning fossil fuels worldwide. A lot of research is being done for
the CO2 mitigation to preserve the planets environment. Trends
are shifting towards renewable energy sources and minimization
of CO2 emission. Biological CO2 fixation methods using
photo-bioreactors by growing microalgae is a potential technology
being explored worldwide. Due to its benefits of CO2 fixation,
wastewater treatment and biofuel production, it has gained world
attention. The Middle East region has large power plants that are CO2
emitting sources and wastewater as nutrients source for microalgae
growth and higher solar irradiations to accelerate photosynthesis. In
this work with the purpose of CO2 fixation, different parameters of
photobioreactors affecting growth kinetics, CO2 bio-fixation rate and
biomass productivity are discussed in an experimental prospective.
This research will be helpful to define optimum operating parameters
for culture developing of microalgae with maximum CO2 utilization
and biomass production which will contribute towards reduction of
environmental concerns caused GHGs.
Di-Methyl Ether Conversion Into Olefins Over

Hzsm-5: Effect Of SiO2/Al2O3 Ratio on Surface
Chemistry and Reactivity Properties
Author: Dr. Abdullah Dughaiter, SABIC, KSA
Co-author: Hugo de Lasa, Western University, KSA
Abstract:
Objectives
This study investigates HZSM-5 as a potential catalyst for light
olefins production from di-methyl ether (DTO). The aim of this
study is to provide an in-depth understanding of the unique effect
of SiO2/Al2O3 ratio on the physico-chemical and reactivity
properties of the HZSM-5 zeolite.
Materials and Methods
This study was carried out using three commercial HZSM-5 with
SiO2/Al2O3 ratio of 30, 80, and 280. For reactivity investigation,
HZSM-5 was pelletized by adding 5% binder (Al(OH)O) and 70%
filler (Al2O3). N2 isotherm and XRD tests were performed to assess
the structural and porosity properties. NH3-TPD experiments were
carried out to establish acidity and provide insights on intrinsic
desorption kinetics. Desorption parameters were estimated
numerically using MATLAB solver. Pyridine FTIR was also

employed to evaluate the influence of Brnsted and Lewis acid sites
while changing the SiO2/Al2O3 ratios of the HZSM-5. The reactivity
runs were performed in a gradient-less Berty reactor unit operating
at 9.5 h-1 weight hourly space velocity of pure DME, 5 hrs time-onstream, 1 barg total pressure, and 330, 410, and 450 C temperatures.
Results and Discussion
Zeolite SiO2/Al2O3 ratio shows no effect on specific surface
area, pore volume and pore size distribution. NLDFT cylindrical
model, however, confirmed the characteristic 5.5 micropores in
HZSM-5 framework. NH3-TPD results exhibit weak and strong acid
sites in which both of these acidities being reduced with increasing
SiO2/Al2O3 ratio.
NH3-desorption kinetics allows prediction of desorption energies
and the rate constants for both strong and weak acid sites. Kinetic
parameters are reported with the following statistical indicators:
a) small spans for the 95% confidence interval, b) degree of freedom
in the 170-330 range, and c) cross-correlation coefficients between
parameters consistently much smaller than one. It is on this basis
shown that the HZSM-5 studied displays higher activation energy
for the stronger sites (39-61 kJ/mol) and lower activation energies
for the weaker sites (30-50 kJ/mol). Additionally, changes of
NH3-desorption kinetic constants with a SiO2/Al2O3 ratio follow
similar trends to the ones observed for NH3-TPD acidity areas
and Pyridine-FTIR peaks areas. One can also observe that there is
a decrease of the weak to strong acidities fraction with increasing
SiO2/Al2O3 ratio. These findings demonstrate that acidity in
HZSM-5 zeolites can be correlated with Al2O3 content.
Regarding DTO over HZSM5, one can postulate an in series
reaction where the formed olefins may continue reacting and
yielding heavier paraffin and aromatic hydrocarbons. In this
respect, lower conversion with less deactivation was observed as
SiO2/Al2O3 ratio increased. Conversely, HZSM-5 become more
selective towards olefins as Al2O3 content is reduced.
Conclusions
A thorough understanding of SiO2/Al2O3 ratio on HZSM-5 physical
and reactivity characterization leads to a significant olefin selectivity
optimization in the context of the DTO process. To our knowledge
and in spite of their great significance for DTO future implementation,
there is no reported study addressing these topics in the open
literature.
Oxidative Dehydrogenation of Ethane Over

W-Doped Movmn Mixed Oxides
Author: Adel Al-Dossari, SABIC, KSA
Co-authors: YongMan Choi, SABIC, KSA
Mohammed H. Al-Hazmi , SABIC, KSA
Abstract: The oxidative dehydrogenation (ODH) of ethane to
ethylene offers a potentially valuable alternative to the thermal
cracking of ethane. The performance of MoVMnW based catalysts
were investigated at different reaction conditions using oxygen
as an oxidant. The effect of contact time, reaction temperature,
conversion, and the amount of W on the selectivity of ethylene
was examined. A series of MoVMn mixed oxide catalysts
were prepared with different doping of W, such as MoV0.4Mn
0.18W0Ox, MoV0.4Mn0.18W0.063Ox, and MoV0.4Mn0.18W0.14Ox.
The catalysts were carefully characterized by using X-ray diffraction,
temperature-programmed reduction, and scanning electron
microscopy. The experiments were carried out in a fixed bed reactor
at temperatures of 235, 255 and 275 C and at 200 psi. Contact times
of 0.08, 0.12, 0.16, 0.24, 0.32, 0.49, and 0.65 sec were applied.
The gas feed was composed of 15 vol.% ethane in 85 vol.% air.
The highest conversion of ethane (21.0 %) was achieved using a
27
MoVMn sample with W = 0.063. At 275 C and at a reaction time

of 0.65 sec the conversion of ethane was observed to decrease
with the increased amount of W doping while the selectivity to
ethylene increased with a maximum selectivity (74 %) achieved at
W = 0.063. Increasing the contact time leads to a decrease in the
ethylene selectivity at all examined temperatures over the catalyst.
The maximum selectivity was achieved at a reaction temperature
of 235 C . Similarly, increasing the reaction temperature from
235 C to 275 C leads to a reduction in the selectivity of ethylene. Also,
it was observed that the selectivity of ethylene decreases as ethane
conversion increases. In this study it was observed that the activity of
the MoVMn mixed oxide catalysts towards ethylene was improved
with addition of W. At 235 C the maximum ethylene selectivity was
achieved (~90%). However, the selectivity of ethylene was observed
to decrease considerably by increasing the reaction temperature
from 235 C to 275 C .
Scale-Up Analysis for Washing Agitation

Author: Dr. Mohanrao Rampure, SABIC, KSA
Co-author: Ramsey Bunama , SABIC, KSA
Abstract: Polymer washing is general practice for color reduction in
polymeric solutions. This paper describes the comparison study of
polymer washing by water between the two scales of vessels, pilot
scale and commercial scale. Both units consist of standard stirred
vessel, but with different design and operating conditions. The pilot
scale unit showed better reduction in color as compared to the
commercial scale unit. Washing agitation of Liquid-liquid immiscible
occurs in the turbulent regime and mass transfer characteristics
depend on the geometry, impeller shape and intensity of mixing.
Therefore in this work, analysis of hydrodynamic characteristics
such as circulation time, droplet breakup rate, Sauter mean drop
diameter, interfacial area for both the scale vessels is predicted using
VisiMix tool. Following comparison study of base case commercial
scale with pilot scale, further sensitivity analysis also carried out
for different impeller speed, impeller type to achieve similar mixing
performance as pilot scale vessel. Figure 1. below shows the fluid
flow patterns and sensitivity analysis results.
Accounting for Boron Levels in SWRO Desalination

Networks
Author: Sabla Alnouri, Texas A&M University at Qatar
Co-author: Patrick Linke, Texas A&M University at Qatar
Abstract: Reverse osmosis is one of the most prominent
technologies employed for seawater desalination. Effective seawater
reverse osmosis (SWRO) desalination networks must be able to
meet an overall defined process performance, often dictated by a
number of design constraints in terms of product water flow and
quality, whilst accounting for the economic efficiency of the system.
The development of effective design strategies for SWRO networks
are often based on superstructure optimization techniques that allow
optimal designs to be exploited. We have previously introduced a
systematic approach based on a two-step strategy which involves
the determination of optimal SWRO networks, by incorporating a
design analysis technique that explores different possible trends
across a number of defined design classes for a SWRO system
[1]. The main motivation was to subsequently extend the proposed
method by allowing for detailed water quality information to be
integrated into the process network synthesis stage. This entailed
developing simple but realistic membrane element models, based
on commercial simulators, so as to account for membrane rejection
values that pertain to the individual constituents of a seawater
stream. All membrane element models that were developed to
capture these relationships were predicted according to data from
major membrane element simulator tools, e.g. ROSA (Dow) and
IMSDesign (Hydranautics) [2]. The RO models utilized were found to
improve the overall design process, since the incorporation of more
specific product water constraints becomes possible for the design
problem defined. Moreover, the superstructure optimization problem
was also extended to handle boron removal design conditions,
by accounting for optimum pH conditions for the various streams
within the network, given the choice to select from a number of RO
membrane element types. Since Boron removal is also affected by
standard process conditions such as temperature, pressure and feed
concentration, all models that have been extracted using predicted
from commercial simulators were updated to account for boron
removal predictions, based on the pH of the system as well as the
membrane type used. Ultimately, the optimization process allows
for the selection of optimal combinations of different membrane
element types, along with optimum pH conditions for the respective
membrane element choices. An illustrative case study was used
to demonstrate the proposed approach, as well as highlight the
variation in optimal designs depending on the given feed water
quality, the desired salinity of the product water stream, as well as
acceptable boron levels in the permeate stream.
New Hydrocracking Catalyst

Author: Dhabia Al-Mohannadi, Texas A&M University at Qatar
Co-authors: Patrick Linke, Texas A&M University at Qatar
Sabla Alnouri, Texas A&M University at Qatar
Sumit Binshu , Texas A&M University at Qatar
Abstract: The direct link between climate change and anthropogenic
industrial activity resulted in a need more prominent than ever to
cut emissions. Industrially, several methods exist to reduce carbon
emissions including improvements in energy efficiency, the use of
renewables and less carbon intensive fuels, and Carbon Capture and
Sequestration (CSS). Stationary processes, often concentrated in
industrial parks, are considered the worlds major carbon emitting
sources. Given the close proximity, large carbon flows and variation
of sources on industrial park scale, opportunities for carbon utilization
are possible. Utilizing carbon dioxide could reduce the overall
capture costs and can create economic motivation to approach
emissions cuts. Carbon dioxide emitted from different sources could
be captured in several possible sinks where carbon dioxide could be
28
stored or utilized geologically as in CCS and Enhanced Oil Recovery

(EOR) or utilized through biological or chemical conversion to value
added products. Carbon integration was developed to systematically
determine low cost carbon integration networks for industrial
parks through allocations of carbon dioxide from sources to
potential sinks to achieve footprint targets. The approach takes into
account the analysis of different sources, sinks including utilization
and storage options, as well as capture, separation, compression
and transmission options. Network transition overtime along with
possible renewable power incorporation was studied. The multisite
optimization identified the most effective areas to apply renewable
energy alongside carbon allocation, while the overtime integration
investigated different reduction scenarios taking into account
the improvements in carbon capture technology and expansion
of the industrial city over time. The work was carried through
Mixed-Integer Nonlinear Programming (MINLP) and strives to
provide policy makers and regulators with an effective tool for
planning of industrial cities and developing reduction strategies both
nationally and regionally.
The Optimization of Ammonia Synthesis Reactor

Using Matlab
Author: Abdulla Al Meshal, University of Bahrain, Bahrain
Co-author: Elamin Elkanzi, Universtiy of Bahrain, Bahrain
Abstract: Ammonia is an important precursor in the petrochemical
industry. It is raw material for the production of explosives, synthetic
fertilizers, polymers, and pharmaceuticals. The cost of production
of production of ammonia may thus determine the economic
feasibility of these products. The ammonia synthesis reactor plays
a significant role in the cost of production of ammonia. Therefore
the optimum design of the ammonia reactor is vital because it is a
topic of high interest in industry as the market continues to expand
and demand increases. In this study different design configurations
were investigated and optimized. As the reaction is limited by the
unfavorable position of the chemical equilibrium and by the low
activity of the promoted iron catalysts with high pressure and
temperature, the classical reactor design methodology involving
mole balance, energy balance and rate laws was followed. The inlet
temperature and pressure to the converter were optimized using
Minitab statistical. The number of quenching stages was optimized
using MATLAB code using Runge-Kutta method for solving the
differential equations numerically. The optimal design problem
requires obtaining the optimal reactor volume with minimum total
annual cost (TAC) corresponding to the various inlet temperatures.
As the conversion per pass in the reactor is small, the unreacted
nitrogen and hydrogen were recycled back to the quench streams
which also serve as a heat source. An optimum conversion that
minimizes the TAC was sought. The TAC comprises the annualized
cost of reactor, the recycle flow, and the effect of the recycle flow
on the annualized cost of equipment. Optimization results show that
the optimum quench temperature is about 502 K, and the maximum
conversion at the exit is 23% for 25.4 cubic meter converter divided
into 4 beds.
Removal of 1,2-Dichloroethane from Water Using

Advanced Oxidation Process
Author: Anwar ul Haq Khan, University of Punjab, Pakistan
Co-author: Hafiz Muhammad Anwaar Asghar, University of Punjab,
Pakistan
Muhammad Imran Qureshi, King Fahad University of Petroleum
and Minerals, KSA
Abstract: This study involves the facts of removal of the contaminant
1,2-dichloroethane from deionized water using chlorine with a
combination of UV as well as chlorine alone. 1,2-dichloroethane is
carcinogenic and toxic. It is found readily in waters near industry
saturated areas. The eradication of 1,2-dichloroethane has been
studied at bench scale. The study indicates that by the use of 50ppm
and 100ppm Cl2 without UV, the concentration falls from 40ppb
to 4.206ppb and 3.381ppb respectively during a reactor run of
1 hour. Using the same concentrations of chlorine with UV decreases
the concentration of 1,2-dichloroethane from 40ppb to 2.948ppb
and 3.127ppb respectively. Varying the initial concentration of
1,2-dichloroethane from 40ppb to 60ppb in water has different
concentration drops. Using 50ppm and 100ppm Cl2 without UV
decreases the concentration from 60ppb to 9.150ppb and 3.540ppb
respectively. The same concentrations of chlorine with the use of
UV decrease the concentration of the contaminant from 60ppb to
4.475ppb and 3.085ppb respectively. AOP utilizes the degradation
power of the OH radicals. With the combination of UV with Cl2
much better quantity of OH radicals are formed which helps in the
treatment. A bench scale photo reactor was used for this purpose.
The concentrations of 1,2-dichloroethane at different intervals of
time were detected by the use of gas chromatography (the GC-MS).
This study concluded with the fact that Cl2, when used as an oxidant
for the removal of 1,2-dichloroethane is quite effective and it brings
down the contaminant level way below the limit set by EPA for it,
however the same study would be of enhanced importance once the
removal is done using the local ground water.
Flexsorb Se Solvent - A Guide for Deployment in

the Right Applications
Author: Bill DeWees, WorleyParsons, USA
Abstract: Worley Parsons offers ExxonMobil Research and
Engineering Companys (EMREs) proprietary FLEXSORB
SE process for treatment of acid gas and SRU tail gas. It is well
understood that FLEXSORB solvent is highly selective for H2S,
resulting in effective CO2 slip and extremely efficient H2S
removal, thus making it one of the few technologies of choice
when ultra-high sulphur recovery efficiencies are required. What
is not always so well understood is the extent of the commercial
advantage offered by EMREs FLEXSORB technology when
employed in the right application, irrespective of whether high
sulphur removal efficiency is required. This lack of understanding
can lead to the propensity for prospective licensees to disregard
the technology strictly on the basis of solvent cost, which is known
to be greater than that of MDEA.
Unequivocally, solvent cost cannot be used as the sole comparator
in a commercial evaluation of gas treating technologies. Rather, all
factors affecting capital, operating and maintenance expenditures
must be considered in the assessment of facility lifecycle cost. In the
appropriate applications, FLEXSORB technology offers commercial
benefits that far outweigh its higher solvent cost and render it the
most attractive option.
This study differs from many other FLEXSORB studies in that it does
not endeavor to display the merits of the technology in applications
having particularly stringent performance specifications, as these
benefits are already well known to the industry. Instead, the
study explores the employment of FLEXSORB over a range of
29
conventional acid gas enrichment and tail gas treating applications

and quantifies net present cost savings, as compared to MDEA.
The intent is to equip the reader with a guide for deployment of
FLEXSORB technology in the right applications; not only those
that are technically challenging (e.g. ultra-high recovery efficiency),
but also in what may be considered more routine sulphur recovery
installations.
Linde/WorleyParsons Integrated Rectisol

AGRU/SRU/TGTU Flow Scheme for Cost-Effective
Zero Emissions
Abstract: The gasification process was first developed in the 1700s
and commercialized in the early 1900s, at which time it was used
to supply synthesis gas (syngas) for many different applications,
including the production of many chemicals. Most gasification
feedstock contains significant quantities of sulphur, which must be
removed from the produced syngas prior to utilization; thus, sulphur
recovery from gasification is a somewhat significant area of focus
for the sulphur industry. Employment of the technology declined
in the mid-1900s when natural gas became readily available;
however, in the past decade, the technology has experienced
resurgence due to an abundance of gasification raw feedstock
materials (e.g. coal, petroleum coke, residue oil, biomass, etc.) and
concomitant need to minimize carbon emissions. Most gasification
feedstock contains significant quantities of sulphur, which must be
removed from the produced syngas prior to utilization; thus, sulphur
recovery from gasification is a somewhat significant area of focus
for the sulphur industry.
Rectisol is a physical acid gas removal process, which employs
an organic solvent (typically methanol) at subzero temperatures to
purify shifted, partially shifted or unshifted syngas that emanates
from the gasification of raw feedstock containing sulphur. Rectisol
can purify syngas down to 0.1 ppmv total reduced sulphur and
CO2 in the ppm range. Well-known advantages of the Rectisol
process include low utility consumption, use of an inexpensive and
readily available solvent, and flexibility in process configuration.
Linde has vast experience in designing Rectisol plants for
feedstock containing high sulphur loads, which offer wide flexibility
in handling product and byproduct streams. One example
of the process' flexibility is its ability to treat tail gas from
sulphur recovery units (SRUs), thereby eliminating the need for a
dedicated amine system within the tail gas treatment unit (TGTU).
Treatment of the SRU tail gas stream in the Rectisol acid gas
removal unit (AGRU) achieves extremely stringent process
performance (overall sulphur recovery efficiency in excess of
99.99%), while also reducing capital and operating expenditures,
as compared to a conventional approach.
This paper provides an in-depth description of the integrated
Rectisol AGRU/SRU/TGTU process configuration and presents
a techno-commercial comparison of this configuration versus
a more conventional sulphur plant scheme comprising of SRU
and standalone, MDEA-based TGTU. Ecological merits such as
ultra-high sulphur recovery efficiency, minimal fuel consumption
in the incinerator, and the possibility for SRU tail gas
carbon-capture are highlighted, showcasing the ability of the
integrated Linde AGRU/WorleyParsons SRU/TGTU to achieve lowest
environmental impact while also realizing lowest net present cost.
30
Something for Nothing - How Middle Eastern

SRUs Can Benefit from Increasing Sox Emission
Stringency
Abstract: Many existing sulphur recovery units (SRUs) in the Middle
East are currently designed for 99.0% sulphur recovery efficiency
(SRE) or lower. Tightening SO2 emissions regulations make it likely
that these facilities will be required to increase recovery efficiency to
99.9% or greater in the near future. Cansolv Technologies, Inc. offers
SO2 removal technology which can be economically employed
in tail gas treating applications, downstream of existing SRUs,
to meet this objective. In addition to increasing recovery efficiency,
concentrated SO2 from the CANSOLV regenerator provides
free debottlenecking of the existing SRU. Similar to the effects
of oxygen enrichment, SO2 injection into the existing SRU reduces
nitrogen concentration due to reduced air demand for combustion
of H2S to SO2 in the reaction furnace.
This paper provides a techno-commercial comparison of the
CANSOLV 2-for-1 offer of increased recovery efficiency plus
existing SRU capacity increase, versus a more conventional
approach, whereby the employment of two separate technologies
would be required to meet the same objectives: conventional
MDEA-based tail gas treating unit (TGTU) for increased recovery
efficiency, plus oxygen enrichment for capacity increase.
A techno-economic case study is utilized to compare the options
and demonstrate that employment of CANSOLV-SO2 technology
can give Middle Eastern SRU operators increased SRU capacity
at no additional cost - essentially something for nothing.

An Approach to Management of Crude Preheat Train
Fouling Using Engineering Tools
Author: Saifuddin Sheikh, AspenTech, Bahrain
Co-author: Dhanasekar Periyasamy, AspenTech, Bahrain
Abstract: Fouling of heat exchanger surfaces reduces the rate of
heat transfer in heat recovery systems requiring more energy to be
consumed from primary sources. In refinery applications this means
that more fuel must be burned in the furnaces, increasing the cost
of production and the increasing emissions of CO2. If the furnace is
bottlenecked (at practical operating limits) then the operator will be
forced to reduce feed throughput with a major impact on profitability.
Heat recovery from pump-around streams is present on most key
refinery units including atmospheric and vacuum crude distillation,
FCCs, delayed Cokers hydrotreaters etc. and the world-wide cost
can be estimated at 10sB$/year. Management of fouling in crude
systems hinges on decisions around on-line and off-line cleaning
and essential to these are effective monitoring of exchanger fouling.
In this paper, we describe a framework in which worlds leading
process simulation tool Aspen HYSYS can be used in conjunction
with Aspen Shell & Tube Heat Exchanger and Aspen Simulation
Workbook to monitor the preheat train heat exchanger performance
and establish which exchangers can be cleaned to give most impact
on overall performance
Improve Relief Sizing with Integrated Simulation

and Relief Environment
Author: Saifuddin Sheikh, AspenTech, UAE
products (Ethane plus) figures will increase around 300 Ton/day. The
other cases in between 4% & 0.5% CO2 content will increase Ethane
recovery proportionally.
Co-author: Mohamed Darbas, AspenTech, UAE

Abstract: Pressure relief sizing is of high priority to a variety of
industries, as accurate relief sizing reduces the potential risk of
damages to: personnel, equipment, and production schedule.
Specifically, external pool fire scenarios and associated safety valve
sizing calculations are of great concern across many industries, as
fire cases must be considered when analyzing each pressure relief
system. Implementing rigorous fire scenarios for both wetted and
unwetted vessels within process simulation software optimizes
the time and resources involved with relief sizing. Previous fire
relief sizing workflows required labor-intensive calculations since,
during fire scenarios, temperature, pressure, and fluid composition
are constantly fluctuating. Through integration with simulation
software, these fire relief load and orifice sizing calculations
can now be automated. Independent organizations, such as the
American Petroleum Institute (API) 521 and the Design Institute
for Emergency Relief Systems (DIERS), publish standards and
best practices to facilitate the overpressure analysis of pool fires.
Additional advancements in simulation software include the
automatic generation of documentation, enabling engineers to
procure devices and maintain records. This paper will examine the
advancements that process simulation software has made in fire
relief load calculations by discussing the technical implementation
of the associated standards. Furthermore, this paper will discuss
how, through process simulation, these results can be automated to
create a much faster, streamlined, and accurate work flow.
Cost-Effective Heat Exchanger Network Retrofit

Author: Ahmed Aseeri, GAP-Tech, Egypt
Abstract: This presentation will introduce a new methodology for
Cost-Effective Heat Exchanger Network retrofit. This methodology
targets the easy retrofits requiring minimum modifications to the
network and therefore minimum disruption to plant configuration
and lower cost. The methodology helps in identifying the heat
recovery alternatives at an order of increasing complexity and cost;
hence giving the plant owners the ability to select the depth of
modifications to the plants configuration they want to adapt.
This methodology can also be used for new projects review,
especially during the later stages in the design when revolutionary
changes that come from Pinch Analysis cannot be accepted due to
limitations of the project schedule.
Sample case studies will be also presented to demonstrate the
advantages of this approach and to show that evolutionary heat
recovery improvements can be more practical than changing the
Heat Exchanger Network design, especially for existing plants.
Effect of CO2 Removing on Ethane Recovery at

Amerya Lpg Plant
Author: Abd El-Rahman Sayed, Egyptian Natural Gas Company
(GASCO), Egypt
Abstract: Amerya LPG recovery plant is designed to handle 330
MMSCFD of gases of feed gases from Western Desert in Egypt to
produce Low/High vapor pressure LPG, Sales Gas and Condensate.
Amerya plant is located in Alexandria North Egypt.
A new NGLs recovery train is added to recover Ethane Plus from
Sales Gas of Amerya Plant. The new NGLs recovery train employs
a mix of Refrigeration and Turbo-expander technologies to produce
C2+ stream which transport to Western Desert Gas complex Plant
to be fractionated into Ethane/Propane Mixture, Propane, LPG,
and Condensates products based upon boiling point differences.
Due to CO2 content in feed gas (4%), currently Ethane recovery in
NGLs train is limited with 59% maximum at -88C temperature in 1st
tray at De-methanizer Column (28 trays) and 23.3 Kg/cm2.g pressure
at the bottom of De-methanizer column. The limitations of ethane
recovery due to CO2 freeze-out at the top of De-methanizer column.
This paper studies the impact of installing CO2 removal unit in the
inlet area of Amerya LPG plant on Ethane recovery in NGLs recovery
train. CO2 content in feed gas reduces from 4% to 0.5% after
installing CO2 removal unit. A steady state flow sheeting simulator
(Aspen HYSYS) is used to simulation of new CO2 removal unit using
Amine solvent and calculate the impact of CO2 removing gradually
and additional produced C2 plus in NGLs recovery unit, considering
equipments design margin and products specifications to maximize
plant facilities utilization and avoid any bottlenecking.
The expected Amine charge flow rate in 20-trays Amine contactor
to remove CO2 from feed gas is 1200 GPM and Amine reboiler duty
is 80 MMBTU/hr. In addition, decreasing CO2 content in feed gas
leads to increasing of Ethane recovery to 98% and subsequently the
The SMC - Catalyst & Technology, Targeting H2s and

Low Fuel Value Gas
Author: Niklas Bengt, Haldor Topsoe, Netherlands
Abstract: The SMC technology is targeting sulfur abatement for
low fuel value gas. The conventional way to treat such gases is by
using support fuel in combination with thermal oxidation. Another
alternative is to blend the low fuel value gas with the feed gas to
a Claus or a sulfuric acid plant, which often results in an increased
demand for support fuel and an increase of the size of such a unit.
The core of the SMC technology is the SMC catalyst, which
selectively oxidizes H2S and other sulfur compounds to SO2 and
oxidizes higher hydrocarbons, hydrogen and carbon monoxide to
CO2 and water. The SMC catalyst operates at temperatures from
200C, and the unique design of the catalyst enables operation
with a very low pressure drop, low surplus of oxygen, low formation
of SO3 and without formation of NOx. If required, SO2 is removed
in a caustic scrubber.
Areas of application include lean H2S gas from amine and physical
solvent units within gas processing and LNG, Claus tail gas
31
incineration and incinerating permeate from membrane separation

units.
The low operation temperature and using a feed-effluent heat
exchanger enable operation without supplementary fuel in most
cases, and the low pressure drop further reduces the operation
cost. The technology complies with the strictest environmental
regulations, and the low temperature operation also provides
simple construction using carbon steel and avoiding refractory lined
equipment.
The technology, catalyst, and benchmark cases will be presented.
Innovation in Reactor Internal Design - Saving you

Shutdown Time and Cost
Author: Waddah Al-Zaabi, Haldor Topsoe, Bahrain
Many refiners worldwide have to deal with the many problems
resulting from bad liquid distribution within their hydro processing
reactor. Liquid misdistribution can cause hot spots, shorter cycle
lengths, higher pressure drop, and overall bad performance.
Haldor Topsoe has invested heavily in order to ensure good liquid
distribution. Through innovation and focus on refiner need Topsoe
was able to develop state-of-the art reactor internals that ensure
optimal performance through perfect liquid distribution. This
translates directly to savings in the form of longer cycle length. It
also addresses the safety concern of hot spot formations within the
reactor since radial temperature spread is controlled. As an added
benefit, since the catalyst now undergoes uniform deactivation
profile, catalyst unloading has proven to be easier.
Further developments on Topsoe internals has focused on
shortening the shutdown time. With the help of Topsoes innovative
Quick ReleaseTM technology shut down time involving opening of
the reactor has been reduced significantly. Feedback from refiners
using new Topsoe internals shows that overall cycle length has
improved, utilization rate has been increased, and overall shutdown
time required has been reduced on average by at least three
days based on previous shutdown records.
Engineering Approach for Flare Network

Revalidation
Author: Dr. Miquel ngel Alos, Inprocess Technology & Consulting
Group, Spain
Abstract: Changes in regulations, or the revamping of an existing
plant, could imply the revalidation of the plant flare system
configuration, in order to analyze if an upgrade of the involved
equipment is required. Such revalidation implies the recalculation of
the flare load and the evaluation of the adequacy of the equipment
size (Relief Valves, Headers and Flare Tip).
In this presentation, Inprocess is going to detail how to face these
design aspects by using Simulation Software: Aspen HYSYS Steady
State, Aspen Flare Analyzer and Aspen HYSYS Dynamics are
necessary to evaluate the size of the Relief Valves, the Headers and
the Flare Load, respectively.
The attendees to the presentation will take the opportunity of
discovering how, by applying a consistent engineering approach
and using Dynamic Simulation, the Flare Load can be calculated
in a more accurate way than by using conventional Steady State
approaches. This enhancement in accuracy could result in detecting
additional or enough capacity in the existing Flare System.
Consequently, the use of this methodology in the engineering
studies could conclude in a CAPEX reduction.
32
Non-Conventional Debottleneck Approach

Author: Sameh Abdulqader Younis, Khebra House, Bahrain
For any process retrofitting and debottlenecking, we need to always
look at the process data and the operating parameters not as figures
and numbers, but rather in a deeper and wider spectrum and see
what is behind them.
In certain cases, certain equipment may show a certain constraint .
Normally, a process engineer would conclude, "let us change it" and
will start to look at the economics of changing it and start indulging
in the economics behind it. This is considered as the "Lazy Solution".
In some cases, a professional process engineer needs to take a
"Non-conventional Approach" by looking at what is behind the
process data and the operating parameters.
By this approach, you will be surprised to discover ways of
overcoming such an equipment bottle neck. This approach has
been successfully implemented in industries where a plant through
put was increased by around 3-5% and saved severe operation of
supporting units such as boilers, etc.
In some cases, certain operating data may not represent a bottleneck
for a process engineer, as the plant has reached its maximum through
put. In reality, he would be wrong, as those operating data can be
modified and the plant through put would increase substantially.
We have seen it in cases where the plant through put has hit 25-35%
over and above the design capacity, with almost zero investment!
There are however cases where the unit and/or equipment is
malfunctioning.The following basic steps should be taken:
1. Review the design of the unit/equipment and compare it to actual
conditions.
2. Check if support units are utilized or not.
3. Check for similar units and compare design data for each, even if
they are not at the same through put.
4. Check for internals design.
5. Do not jump to downstream units debottleneck solution to
overcome the main unit in question.
Note: Illustration diagrams can be submitted later as this whole
approach depends upon the human approach towards problem
solving.
Use Multistage Integrated Chilling to Debottleneck

Ammonia Plants
Author: V.K. Arora, KPI, USA
Abstract: This paper will present a new approach to increase the
capacity and efficiency without any expensive upgrades of the
limiting compressors & their drivers in Ammonia plants. A new
technique of Multistage Integrated Chilling (MIC with patent pending)
is used which can increase the Ammonia plant capacity by 15%
and energy savings of 3 MMBtu/t with minimum capital and
turnaround time.
A comprehensive study was carried out using the Multistage
Integrated Chilling (MIC) for large Ammonia plant. The Capex
savings are realized by avoiding the expensive upgrades of limiting
compressors in the plant. The energy savings are achieved as a
result of maintaining the same compression power for all major
compressors despite increase in Ammonia capacity.
A case study will be presented with changes in the key technical
parameters along with the overall economics. The sensitivity
analysis demonstrates an attractive payout even with gas price as
low as $1.5/MMBtu with Ammonia sale price above $400/t.
Challenge for Stable Operation of Integrated HOFCC

and ECR Units
Author: Rayan Haddad, Petrorabigh, KSA
Abstract: Rabigh Refining and Petrochemical Company (PRC) is
a unique complex in middle-east area which receives crude oil as
feedstock at the very end of upstream and produces a large variety of
products, from conventional refinery products to polymer products.
The main core element of PRC complex is the integration between
high Olefins Fluid Catalytic Cracking (HOFCC) - one of the worlds
largest deep catalytic cracking Unit - and Ethane Cracker (ECR).
As its name indicates, HOFCC is aimed at producing olefins from
low-value heavy oil feedstock (hydro-treated vacuum gas oils).
Technip S&W licenses such a petrochemical FCC process known as
Deep Catalytic Cracking (DCC) to produce polymer grade propylene
(PGP) with 18% yield (900 KTA) and certain amount of ethylene
under high severity operating conditions. ECR receives low cost
ethane as base feed and produces polymer grade ethylene (PGE) as
its main product. Also, certain amount of C3 is produced from ECR.
Main purpose of the integration of HOFCC with ECR is to maximize
olefin products and for this purpose, light end gas from HOFCC
which contains certain amount of ethylene is sent to ECR to recover
ethylene, and heavy product from De-ethanizer bottom stream
which contains C3 heavier is sent to HOFCC to recover propylene
from that stream.
Now, fluid catalytic cracking and ethane cracking are operated in
many places in many countries. They have a long history in refinery
and petrochemical industry respectively and they are very well
studied already. However, such integration of FCC and ECR is still
not common practice in the world. It is still a big challenge for
process engineers to operate those units stably and efficiently.
The article then goes through the next major phase of Evaluation;
which is the changeover. Monitoring and control of changeover are
critical steps. The article describes in detail the way changeover is
monitored in SAMREF. This is followed by the Post-Audit where you
take a look at the objectives versus the realized benefits; and try
to quantify the advantages and disadvantages of the changeover.
This will also lead to the next step for reformulation and improvement
and any recycling to the future selection process.
The article takes the reader through all these steps with an example
of how this is adopted in SAMREF with the last catalyst changeover
which resulted in a major margin improvement in its FCC operation.
API Low Pressure Tank Safety - Cost Effective and

Safe Design of a Nitrogen Blanketing System
Author: Ahmer Irshad, Saudi Aramco, KSA
Abstract: N2 blanketing system offer an intermediate layer of
protection before the activation of pressure/vacuum vent on an
API Low Pressure Tank. The system prevents oxygen ingress that
could cause an internal explosion and loss of containment. However,
the new edition of API 2000 is a source of confusion for designers
when determining the size and requirement of a nitrogen blanketing
system. This is because in API, the design basis and guidelines in
the Appendix section diverge from the design offered in the main
body of API. Therefore, implementation of uninformed design may
result in overly burdensome requirements with implementations that
are impractical often resulting in significant capital and operational
expenditure.
More than 5 years have passed since PRC started to operate this
integrated unit of HOFCC and ECR. Now, it can be said that those
units are operated stably, but to achieve it, we had to face with
several challenges. Through the presentation PRC will explain more
about the major challenges, (L&L) , and sharing how PRC achieved
stable operation.
The presentation will outline the fundamental variables required to

design a N2 blanketing system on low pressure tanks. The analysis
squares design with other industry standard (NFPA 69). A case study
from a refinery will be discussed to illustrate how N2 blanketing
system could be reasonably defined based on the regional data and
also clear confusion between normal and emergency N2 blanketing
requirements.
Fluid Catalytic Cracking Catalyst Evaluation Process

at Samref
Breakthrough Technology Solution for P-Xylene

Production
Author: Abdullah Radadi, Samref, KSA
Author: Dr. Jose Carrazza, UOP a Honeywell Company, USA
Co-author: Pacheeri Siva, Samref, KSA
Abstract: p-xylene, a precursor for polyester, remains one of the

fastest growing petrochemical products. UOPs technologies have
been at the forefront of p-xylene production for more than 40 years,
due to continuous innovations that have resulted in improved capital
deployment and reduced operating cost.
Abstract: Selection of right catalyst is a very important step in the

operation of a Fluid Catalytic Cracking plant. No two units operate
at the same conditions and each one requires a specific formulation
of catalyst to cater to the operational and economical strategies.
Deciding on the right formulation is a tricky process and requires
close co-ordination and interactive communication between the
catalyst vendor and the refinery. A well-studied and carefully
planned catalyst selection process can result in major improvements
in the unit operation and product selectivity and thus improve the
margin in a greater magnitude.
SAMREF has clearly grasped the importance of this critical process
and has developed a well laid out plan. This article outlines the
process adopted at SAMREF for an effective selection process.
It starts from the preparation of objective document where we
outline all the objectives in the order of priority based on the current
unit operating conditions and expected strategies. The article goes
through the next steps where the process of communications with
vendors is explained including the information exchange; sending
of feed and equilibrium catalyst. The next process will be to help
vendor in arriving at the right formulation based on the exchanged
data. The shortlisted catalyst formulations will be then tested
in a pilot plant for evaluating it further. Based on the testing and
modelling, the winner catalyst will be decided for trying in the unit.
Over the last five years UOP has introduced significant advancements, both on the process and product side, resulting in significant
improvements in ROI for new unit designs (up to 50% in some cases)
and less than three year paybacks on revamps projects. These
solutions have accumulated a significant track record of successful
commercial experience, validating their fit over many customer
configurations. UOP continues to innovate in this field and further
improvements in process design and product formulation will soon
be introduced. This presentation will exemplify value from our latest
offerings, demonstrated by several commercial case studies, and a
preview of next generation offering.
33
The Training and Development of

New Engineers
Author: Edward Casey, UOP a Honeywell Company, USA
Abstract: Every year, companies in the process industries make
major investments by hiring new engineers out of universities or
other industries.
UOP has faced this challenge for decades. UOPs Career Development
Program (CDP) has evolved over time to meet the needs of
bringing new engineers into a company such as UOP with a
wide technology portfolio and multitude of functions. The task of
on-boarding them efficiently includes both providing formal
training and on-the-job training during rotational assignments
in UOPs Research and Development, Technical Service, and
Engineering departments. Over a 24-month period, this prepares a
new employee to join UOPs Field Service department to work as
a Field Technical Advisor for UOPs customers who are constructing,
commissioning, and starting up new or revamped UOP licensed
process technologies.
UOP has worked with operating companies in the Middle East and
around the world to incorporate select elements of UOPs Career
Development Program into their own programs to develop young
engineers. These programs have enabled the new employees to
become more productive members of their organizations, whether
in operations, projects, development, or other technical areas
within their organizations. Under an ongoing, multi-year alliance
with a major Middle East refiner, UOP is jointly delivering a sevenweek training program covering the fundamentals of key refining
processes, business economics, and process design.
units using alkanolamines is practiced extensively in the oil and gas

industries. There are several challenges in designing these units.
The general design practice is heavily dependent on Licensor data
as implementation of these projects involves process guarantees.
Current Modeling Technology involving design of acid gasamine
contactors are often based on equilibrium stage models with
enhancements to tray efficiencies for acid gas components.
Key variables in design are include: Temperature rise in Absorber,
Rich Amine loading, Lean Amine loading, Reboiler duty, Reboiler
temperature, Amine circulation rate, Absorber details ( No. of trays,
Pressure drop), Regenerator column (packed bed pressure drop)
and DM water make up rate.
The Rate based Technology for AGRU design uses the robust
non-equilibrium stage mass transfer rate based models. These
models include additional transport equations, i.e. i) solute
equilibrium across interfaces, ii) the effect of chemical kinetics on
mass transfer rates, particularly in the liquid phase, and iii) mass and
heat transfer rate models for transport across interfaces. Thus, it is
possible to capture the actual performance of the columns. This is a
major development over the traditional equilibrium approach.
The model is also suited for adding the effect of heat stable salts and
acids addition effect on the stripper performance which can help in
designing an energy efficient design. It can also be used in conjunction
with Activated Economics in Hysys to quickly define CAPEX/OPEX
of design options for Optimization. With the New Aspen Hysys the
entire Gas Plant model inclusive of Acid Gas Cleaning, Dehydration
& Compression and NGL recovery can be incorporated in a single
flow sheet thus optimizing the time for process engineers who can
work with on a single platform to design AGRUs.
Innovative Refinery Planning Technologies Driving Results
Design & Optimization of Solids Processing
Author: Satyadev Susarla, AspenTech
Abstract: The refining market is under increasing pressures

competition, declining expertise in the field, and crude price declines.
Recent advancements in planning and scheduling technologies
are helping companies not only manage these driving forces, but
to gain competitive advantage with more efficient crude selection
and processing. aspen PIMS, the leading planning technology in
75 percent of global refineries is bringing to the market a whole
new way to plan. Through innovative aspenONE PIMS Platinum,
the solution now offers web-based anytime, anywhere planning,
and advanced optimization combined with plan vs schedule in real
time. aspenONE PIMS Platinum combines a robust solution with
best-in-class analytics for easier, faster decision making. In this
session, well explore the refining solutions available today, citing
real-world client results, to gain the competitive edge in refining.
Solids are used in many chemical processes and modeling them

is vital to optimizing these processes. Specialty Chemicals and
Extractive industries are examples of fields where simulation of
fluid and solid processes is important. About 60% of the products
in the chemical industry are at least at one time in the production
process a granular solid. Solids sections may have a significant
influence on the overall process performance, product quality and
energy demand. Ignoring or poorly modeling the solids sections
in a process may lead to lost opportunities like improved quality,
Improved throughput and reduced energy demand. From solid
Caustic soda production to Polymers downstream process solids
play a critical role, not to mention; the complexity of the design
increases through time and it becomes very challenging to model
and optimize the process. Reduction of the energy consumption
is one of the main goals of all solids process operators. Another
goal is to control PSD (Particle Size Distribution) and moisture
content in the process, which is hard with the lack of modelling tool.
The Challenge is met with rigorous modeling capabilities in Aspen
Plus wherein both the solids and fluids sections can be modelled in
a unified environment with sound physical properties and varying
degrees of rigor. Customer success with the Solids Technology will
be discussed.
Efficient Gas Sweetening Unit Design with

Mass Transfer Based Models
Abstract: The removal of hydrogen sulfide Acid Gases (H2S) and
carbon dioxide (CO2) from natural gas, LPG or sour gas treatment
34
Theres No Silver Bullet for Improving Asset

Utilization in the Process Industries
Author: Christiaan Badenhorst, AspenTech, Bahrain
Co-author: Mohamed Hasan, AspenTech, Bahrain
Abstract: Unplanned downtime, lower throughput, reduced quality
and other operational barriers are top-of-mind in the process
industries. Especially in the light of the recent dramatic shift in
global oil prices, and the ripple-through effect thats happening in
the energy and chemicals markets, there is a renewed interest in
automation for production operations.
From procedural automation to predictive analytics to planning and
scheduling with the detail required to accurately model processes,
there are new tools to be brought to bear on these problems.
But more than just new technology, these innovations are changing
the nature of the way we collaborate to solve these problems.

Managing asset effectiveness and achieving operational excellence
is a challenge that will require new ways of working and new tools to
enhance our productivity.
Design of Three Products Divided Wall Column
Process Engineering is central to the solutions to these issues.

Process Engineers are at the heart of efforts to improve the
parameters used in planning and scheduling of plant assets. They
are critical resources in analyzing, diagnosing and addressing issues
limiting asset utilization. They are the architects of the performance
information driving process improvements. They are involved
in every aspect of improving operational performance and that
is driving a need for new ways of creating end-to-end visibility
from the as-built view of the assets to the as-is state of production
performance.
Co-authors: Sheraz Bashir, King Fahad University of Petroleum

This presentation will illustrate how technology innovations in

visualization and analytics are expanding the value process engineers
bring to the organization. It will highlight how new approaches are
creating a common, contextualized view of the information needed
to drive out costs and maximize the value of production assets.
Autothermal Reforming Process is the Right Choice

For Modern Large-Scale Methanol Plants
Author: Sandra Winter-Madsen, Haldor Topsoe, The Hague,
Netherlands
Abstract: The global demand for methanol is continuing its steady
rise, and improvements in methanol plant capacity are becoming
increasingly important in order to remain competitive in todays
market. Large-scale production plants take advantage of economy
of scale, leading to significant reductions in costs. The modern-day
large-scale methanol plant produces twice as much as the typical
capacity at the beginning of the millennium. Specialized technology,
both for syngas generation and for methanol synthesis, is essential
in order to achieve world-class production capacities.
Topsoe has invested significant efforts in developing and
commercializing the stand-alone autothermal reforming (ATR)
technology for syngas generation. The ATR technology operating
at low steam-to-carbon ratio is a fully proven process for large-scale
synthesis gas production. A combination of ATR technology with
an optimized Topsoe methanol reactor layout and high-performance
Topsoe methanol synthesis catalyst leads to optimal feedstock
utilization, maximum operation efficiency, and lowest cost of
production.
This paper will describe Topsoes industrial operating experiences
within autothermal reforming, as well as process conditions,
catalysts, and design requirements to ensure high availability and
reliability in large-scale methanol plants.
Author: Dr. Shams Uzzoha, King Fahad University of Petroleum

Abdallah Al-Shammari, King Fahad University of Petroleum and

Abstract: Distillation process is the most common separation
process for separating multicomponent liquid mixtures into pure
components in chemical process industries. It consumes around
3% of the worlds energy consumption. Dividing wall column
(DWC) is currently receiving a lot more attention from industry.
DWC where two columns are located in a single shell has gained
increasing acceptance in industry due to its potential advantages
of lower energy consumption, lower capital cost and low space
requirements as compared to conventional distillation column.
DWC offers savings in both energy consumption and economics.
Design and operation of DWC is more complex than the conventional
distillation column. In this study, an efficient design method has
been proposed to determine the DWC design. The initial design
parameters of DWC have been fixed on the basis of shortcut method
(Fenske-Underwood-Gilliland method). Based upon extensive
simulation study, initially the design structure of DWC is determined
by applying the shortcut design method to the sloppy configuration
and then the internal distribution of vapor flow and liquid flow is
found from the corresponding rigorous sloppy configuration.
Cost evaluation of DWC including column vessel, sieve trays,
condenser and reboiler is also carried out on the basis of minimum
energy consumption. DWC is also very helpful in reducing the
CO2level in the process industries. The results indicate that proposed
design method provides good initialization for rigorous simulation
of DWC and also provide energy efficient, cost effective DWC
with 35% savings in energy consumption as compared to traditional
distillation system for separating three component feed mixture
into three pure products.
Effect of Steel Chemical Composition on

Zinc Coating Appearance and Properties
Author: Dr. Othman Al-Malki, SABIC, KSA
Co-authors: Abdullah Al-Shahrani, SABIC, KSA
Fayes Al-Harbi, SABIC, KSA
Keywords: Hot-dip galvanizing, spangle, coating, zinc bath.
steel sheets
Steel rusts in almost any environment if it is not protected. Hot-dip
galvanizing Is the most common way to protect steel from corrosion.
Zinc coating protects steel by providing both a physical barrier and
cathodic protection. It is an effective and economical way to protect
steel from corrosion. A protective coating of zinc and iron-zinc
alloys is developed on the surfaces of Iron and steel products by
Immersing them in a bath of molten zinc at a temperature close to
460C. Aluminum is added to the zinc bath to suppress the reaction
between iron and zinc by forming the ductile Fe2AI5 on the surface
of the substrate. The addition of lead, antimony or bismuth to the
zinc bath results in hot-dip-coated surface structure consisting
of large grains termed spangles. Spangles macroscopic surface
appearance maybe classified as shiny, feathery or dull.
Galvanized coatings corrode and erode slowly. Zinc corrosion
rate correlates with two major factors; time of wetness, and
concentration of air pollutants. The service life of the zJnc coating Is
directly proportional to the coating thickness (or weight) in a given
environment. The minimum coating weight is important to attain the
normally expected long-term product life in the application. Size and
appearance of the spangle (surface quality) is affected by different
35
process variables including but not limited to stable galvanizing bath

composition, steel surface roughness, control of dross build-up and
cooling conditions.
The surface quality of the coating does not only degrades the
coating appearance but also affects the surface properties of the
coatings for Instance from the point View of the application of
additional finishing treatments. Wettabllity deterioration due to the
oxidation of alloying elements during the annealing process is a
concern. Oxidation of alloying elements such as Mn, Si, and AI is
inevitable by the trace water vapor in the hydrogen gas. The surface
oxides formed resulted in uncoated bare spots found on the steel
product. Thus, the objective of the work done Is to study the effect
of base metal chemical composition on zinc-coating appearance and
roughness. The investigation was done using optical microscopy
and secondary electron microscopy on surface and cross section of
coated samples. Chemical analysis using SEM/EDX and roughness
measurements were also conducted.
Environment Friendly Flare Gas

Author: Wael Alblaies, Saudi Aramco, KSA
Abstract: In 2010, Saudi Aramco total gas flaring was significantly
reduced compared to 20 years back (around 4 BSCFD). This
achievement was a result of the Master Gas System project
commissioned in the early 80s. Since then, our daily flaring was
limited daily routine flaring and emergency flares. In 2012, we have
successfully reduced flaring to less than 50%. Because of this,
Saudi Aramco was recognized as a global leader in flaring reduction.
Now, in order to achieve further reduction i.e. near zero flaring,
we needed to capture as much of gas flaring and utilize it gainfully
by installing Flare Gas Recovery Systems (FGRS). This paper
describes the challenges of implementing this smart technology at
Saudi Aramco sites as is the case with any pioneer and leading efforts,
the successful accomplishments of developing in-house designs
at four major gas plants as a starting point as well as great
environmental, social and economic benefits will be realized post
installation of FGRS.
Overview of Isolation Valves Failure in

Steam Service
Author: Mohammed Alotaibi, Saudi Aramco, KSA
Abstract: Most of isolation valve failures are attributed to wrong
selection of trim design. In high pressure and temperature
applications, the configuration and type of sealing surfaces play
major role in leaks prevention. For instance, in Steam and Boiler
Feed Water (BFW) service, the seat ring shall be of welded or
integral construction. However, renewable (screwed type) seat ring
in valves can lead to nuisance passing issues during operation.
As a result, proper selection of seat design for the intended
application shall be taken into consideration since not all valve
vendors have standard integral design. A case history for gate
and globe valves were investigated and will be presented in this
paper to illustrate the particulars of the issue and set the remedial
measures taken for future selections. This problem has led to several
operational interruptions and undue associated material costs.
36
Producing High-Value Products with

UOP UnicrackingTM Technology
Author: Kiran Kashibhatla, UOP a Honeywell Company, India
Abstract: Global demand for transportation fuels continues to
increase, with a projected annual growth of about 1% through
2040. In addition, fuel quality specifications continue to tighten in all
corners of the world. Hydrocracking technology and catalysts have
taken on an increasingly prominent role as solutions in many refinery
configurations. UOPs extensive experience in hydrocracking, with
over 210 licensed units globally, enables refiners to successfully
respond to these market demands.
UOP UnicrackingTM technology is a flexible solution with process
configurations and catalysts which can be tailored to meet a variety
of processing objectives. Recent advancements in process, catalyst
and equipment have resulted in a hydrocracking portfolio that
delivers the highest value to our customers.
This presentation will cover advances in hydrocracking catalysts
for optimized yield and product properties, new reactor internals
for improved performance and easier installation, and process
innovations that reduce both capital and operating expenses.
A review of commercial operating experience will be included.
SPECIAL THANKS TO MEPEC 2015 SPONSORS

Diamond Sponsors
Platinum Sponsors
Gold Sponsors
Silver Sponsors
Academic Partner
AIChE Middle East Chem-E-Car Comptetion

Sponsored by
Main Supporting Organization
AIChE Global Partner
Powered by
Supporting Organizations
37
SPECIAL THANKS TO MEPEC 2015 MEDIA & EVENT PARTNERS

Regional Business Publication Partner
Official Publications
Official Daily Newspaper
Recruitment Consultancy Partner
Official Online Partner
AIChE Publication
International Media Partner
Regional Media Partner
Media Partners
Travel Partner
Catering Partners
Hospitality Partner
Advertising & Communication Partner
38
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MEPEC 2015 Abstract Book 30 09 2015

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15-17 September 2015

Bahrain International Exhibition &

Under the Patronage of His Royal Highness

Prince Khalifa bin Salman Al Khalifa

Process Synthesis, Modelling and Optimization ........................................................................................... Pg 3

Process Synthesis, Modelling and Optimization ............................................................................................ P

Process Synthesis, Modelling and Optimization .......................................................................................... P

Process Synthesis, Modelling and Optimization .......................................................................................... Pg 14

Process Synthesis, Modelling and Optimization .......................................................................................... Pg 17

Process Synthesis, Modelling and Optimization .......................................................................................... Pg 20

15th September 13:15 14:45

Co-authors: Khaled Alshammari, SABIC, KSA

There are technologies available (commercially and under

Mathematical Formulation of Saudi Aramcos Short

Implementation of Clean Development Mechanism

Besides refinery local models, including full Aspen PIMS distributive

Integrating of weight based refinery models with volume based

a leveraged automated technology serving the Refinery objective

Refinery product optimization, namely, how refinery production

The results of this great automation have been captured in many

Local versus Global optimization: Case studies highlighting

In terms of Safety and Environment:

Regional demand optimization

Breakthrough in C4 Alkylation Technology

15th September 13:15 14:45

The Refinery managed to avoid regular operator dilution which

Efficient Reforming Process for New Plants and

Debottlenecking Techniques using

Diesel Hydrotreater Optimization to Maximize

15th September 13:15 14:45

This EProcess tool has been tested in a reactive distillation column

Optimizing FCC-PT Performance with Albemarle

Right On Schedule: AspenTech On Managing Crude

The Role of Scheduling and Rigorous Process

The purpose of this paper is to discuss the technological and

15th September 16:15 17:45

Oman LLC (AOL) and Oman Polypropylene Company (OPP). Orpic

Author: Tariq Khan, Schneider Electric, KSA

Sohar Refinery - Conversion Refinery (SR)

Abstract: Todays global economy and volatile economic climate

Polypropylene Plant - Petrochemical Plant (PP)

Controlling the unit processes for conversion and transformation of

Aromatics Plant - Petrochemical Plant (AP)

Orpic on Leveraging XPIMS for Multiplant

New Approach for Anticoking Technologies

15th September 16:15 17:45

Monetize Off-Gases to produce low cost Ammonia

Heat Exchangers Network Retrofit With Retrofit in

with minimal additional surface areas required to optimize the heat

Utilize LC-Fining Platform to Retrofit an Existing

15th September 16:15 17:45

Relief load calculations must be performed very carefully in order

Online Dynamic Plant Simulator

How to Avoid Pitfalls in Design Basis

Visualization of Plant Conditions

16th September 10:45 12:30

emission and stimulus to national and local economies.

Optimization of Paraxylene Recovery via Double

Utility Optimization through Combined Heat and

Utilization of CO2 to Chemicals Activation of

16th September 10:45 12:30

identify suitable modification in the system including the pump.

Abstract: Todays rapidly changing energy industry presents many