Critical Variable in Catalytic Reforming and Unit Monitoring Best Practices

 

 

GBHE Te Tech ch ni nical cal B ul leti n CT CTB B #53

Catalytic Reforming Critical Variables in Catalytic Reforming and Unit Monitoring Best Practices

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Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown  Activation Reduction In-situ Ex-situ Specializing Specializing in Refiner Refinery Process Assessm Catalyst Catalyst Performa Performance nce Performance Evaluation Heat & Mass Balance Analysis Catalyst Rema Remaining ining Sulfiding Life Determination Determ ination Catalyst Deactivation Deyactivation Assessment ent Catalyst Performance Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Proces Process s Technology - Hydrog Hydrogen en Catalysts / Process Technology – Ammonia Ammonia Catalyst Process Techn Technology ology - Methanol Catalysts / proces process s Technology – Petrochem Petrochemicals icals Specializing in the Development & Commercializa Commercialization tion of New Technology Technology  in the Refining & Petrochemical Industries Web Site: w ww.GBHEnterprises.com ww.GBHEnterprises.com

 

 

Table of Contents

Best Practice Identify Employ Export Update Critical Variables Variables fo r Catalytic Catalytic Reformi Reformi ng Examples Example: CAT Example: Recycle Gas C1/C2 Ratio

Minimum Critical Variables Variables Conclusion

 Appen  Ap pendi di x Principles and Practices Used in Catalytic Reformer Optimization Management Continuum Catalyst & Equipment Management On-line Optimization Operating Practices

Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown  Activation Reduction In-situ Ex-situ Specializing Specializing in Refiner Refinery Process Assessm Catalyst Catalyst Performa Performance nce Performance Evaluation Heat & Mass Balance Analysis Catalyst Rema Remaining ining Sulfiding Life Determination Determ ination Catalyst Deactivation Deyactivation Assessment ent Catalyst Performance Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Proces Process s Technology - Hydrog Hydrogen en Catalysts / Process Technology – Ammonia Ammonia Catalyst Process Techn Technology ology - Methanol Catalysts / proces process s Technology – Petrochem Petrochemicals icals Specializing in the Development & Commercializa Commercialization tion of New Technology Technology  in the Refining & Petrochemical Industries Web Site: w ww.GBHEnterprises.com ww.GBHEnterprises.com

 

 

Best Practice Identify

 – Variables to be monitored monitored in each section section of the the plant (e.g., (e.g., feed composition in feed section)  – The goal (No LPO or incidents, optimize operating operating costs, maximize maximize product upgrade). Impacts of each variable on that goal  – The relative relative importance importance of each each variable variable  – Who is responsibl responsible e for each variable  – Frequency Frequency of monitoring monitoring and practical practical control range range  – Response to “out of of range” variables variables Employ

 – Refinery data management management system system to automate automate the process process to the extent possible • Alarm data in refinery data management system if possible  – The requisite requisite lab data data to close close a material material balance balance on the unit (+/- 2%)  – Kinetic or empirical programs for catalyst catalyst activity and yield monitoring Export

 – Procedures Procedures and findings findings to operating operating business business unit and other other interested interested parties • Refinery reliability program (bad actors) • Refinery Planning group (LP) • Upstream and downstream units • Process engineering and operator training departments

Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown  Activation Reduction In-situ Ex-situ Specializing Specializing in Refiner Refinery Process Assessm Catalyst Catalyst Performa Performance nce Performance Evaluation Heat & Mass Balance Analysis Catalyst Rema Remaining ining Sulfiding Life Determination Determ ination Catalyst Deactivation Deyactivation Assessment ent Catalyst Performance Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Proces Process s Technology - Hydrog Hydrogen en Catalysts / Process Technology – Ammonia Ammonia Catalyst Process Techn Technology ology - Methanol Catalysts / proces process s Technology – Petrochem Petrochemicals icals Specializing in the Development & Commercializa Commercialization tion of New Technology Technology  in the Refining & Petrochemical Industries Web Site: w ww.GBHEnterprises.com ww.GBHEnterprises.com

 

 

Update

 – The process process annually annually and at at TAR events • Update responsibilities to fill gaps • Reporting procedures • Laboratory methods to streamline data turnaround • New software developments  – More automation automation  – Kinetic programs programs • Flow meters for material balance • Catalyst sampling devices

Critical Variables Variables fo r Catalytic Catalytic Reformi Reformi ng Examples

Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown  Activation Reduction In-situ Ex-situ Specializing Specializing in Refiner Refinery Process Assessm Catalyst Catalyst Performa Performance nce Performance Evaluation Heat & Mass Balance Analysis Catalyst Rema Remaining ining Sulfiding Life Determination Determ ination Catalyst Deactivation Deyactivation Assessment ent Catalyst Performance Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Proces Process s Technology - Hydrog Hydrogen en Catalysts / Process Technology – Ammonia Ammonia Catalyst Process Techn Technology ology - Methanol Catalysts / proces process s Technology – Petrochem Petrochemicals icals Specializing in the Development & Commercializa Commercialization tion of New Technology Technology  in the Refining & Petrochemical Industries Web Site: w ww.GBHEnterprises.com ww.GBHEnterprises.com

 

 

Example: CAT Goals: 1. Run reliably/ incident prevention 2. Optimize operating costs 3. Maximize yields  All three apply apply Importance:  A. Critical to daily operation; operation; large large impact on on goals B. Impacts long-term operation C. Troubleshooting  A. Applies Who monitors  – Operations Operations and Process Process Engineering Engineering Frequency  – Once per shift  Alarm on Critical Critical Variable Variable monitoring monitoring program program (Refinery (Refinery Data management management system

Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown  Activation Reduction In-situ Ex-situ Specializing Specializing in Refiner Refinery Process Assessm Catalyst Catalyst Performa Performance nce Performance Evaluation Heat & Mass Balance Analysis Catalyst Rema Remaining ining Sulfiding Life Determination Determ ination Catalyst Deactivation Deyactivation Assessment ent Catalyst Performance Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Proces Process s Technology - Hydrog Hydrogen en Catalysts / Process Technology – Ammonia Ammonia Catalyst Process Techn Technology ology - Methanol Catalysts / proces process s Technology – Petrochem Petrochemicals icals Specializing in the Development & Commercializa Commercialization tion of New Technology Technology  in the Refining & Petrochemical Industries Web Site: w ww.GBHEnterprises.com ww.GBHEnterprises.com

 

 

Example: Recyc Recycle le Gas C1/C2 C1/C2 Ratio Goals: 1. Run reliably/ incident prevention 2. Optimize operating costs 3. Maximize yields 1. Applies Importance:

 A. Critical to daily operation; operation; large large impact on on goals B. Impacts long-term operation C. Troubleshooting B. Applies Who monitors  – Process Engineerin Engineering g Frequency  – At performance performance test or Troubleshoot Troubleshoot No alarm Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown  Activation Reduction In-situ Ex-situ Specializing Specializing in Refiner Refinery Process Assessm Catalyst Catalyst Performa Performance nce Performance Evaluation Heat & Mass Balance Analysis Catalyst Rema Remaining ining Sulfiding Life Determination Determ ination Catalyst Deactivation Deyactivation Assessment ent Catalyst Performance Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Proces Process s Technology - Hydrog Hydrogen en Catalysts / Process Technology – Ammonia Ammonia Catalyst Process Techn Technology ology - Methanol Catalysts / proces process s Technology – Petrochem Petrochemicals icals Specializing in the Development & Commercializa Commercialization tion of New Technology Technology  in the Refining & Petrochemical Industries Web Site: w ww.GBHEnterprises.com ww.GBHEnterprises.com

 

 

Minimum Critical Variables Variables

Conclusion Create  – A refinery specific monitoring monitoring program program • Start with a minimum critical variable list and create a refinery specific list • Include engineering, operations, planning, and reliability • Set goals for the program Update  – The program program frequently frequently • Audit to ensure goals are met  – Profitability Profitability  – Availability Availability  – Reliability Reliability

Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown  Activation Reduction In-situ Ex-situ Specializing Specializing in Refiner Refinery Process Assessm Catalyst Catalyst Performa Performance nce Performance Evaluation Heat & Mass Balance Analysis Catalyst Rema Remaining ining Sulfiding Life Determination Determ ination Catalyst Deactivation Deyactivation Assessment ent Catalyst Performance Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Proces Process s Technology - Hydrog Hydrogen en Catalysts / Process Technology – Ammonia Ammonia Catalyst Process Techn Technology ology - Methanol Catalysts / proces process s Technology – Petrochem Petrochemicals icals Specializing in the Development & Commercializa Commercialization tion of New Technology Technology  in the Refining & Petrochemical Industries Web Site: w ww.GBHEnterprises.com ww.GBHEnterprises.com

 

 

 Appen  Ap pendi dix x Principl es and Practices Practices Used Used i n Cata Catalytic lytic Reformer Reformer Optimization

Overview of Reformer Optimization: Key Questions • What is the purpose of reformer optimization? • Where does reformer optimization fit in an operating plant? • What is Reformer Optimization? Oil refineries process crude oil into gasoline and other transportation distillates. Principl e 1 of Reformer Optimization: Define the Objective Function! Must be Quantifiable -

Maximizing Octane Barrels

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Maximizing Cash Flow

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Maximizing Return on Investment

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Maximizing Through-put

Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown  Activation Reduction In-situ Ex-situ Specializing Specializing in Refiner Refinery Process Assessm Catalyst Catalyst Performa Performance nce Performance Evaluation Heat & Mass Balance Analysis Catalyst Rema Remaining ining Sulfiding Life Determination Determ ination Catalyst Deactivation Deyactivation Assessment ent Catalyst Performance Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Proces Process s Technology - Hydrog Hydrogen en Catalysts / Process Technology – Ammonia Ammonia Catalyst Process Techn Technology ology - Methanol Catalysts / proces process s Technology – Petrochem Petrochemicals icals Specializing in the Development & Commercializa Commercialization tion of New Technology Technology  in the Refining & Petrochemical Industries Web Site: w ww.GBHEnterprises.com ww.GBHEnterprises.com

 

 

Principl e 2 of Reformer Reformer Optimi za zation: tion:  Layered Practices -

Implementation Implementatio n and Execution of the Plan

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Planning and Scheduling Activities

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Fundamental Process Design and Maintenance

Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown  Activation Reduction In-situ Ex-situ Specializing Specializing in Refiner Refinery Process Assessm Catalyst Catalyst Performa Performance nce Performance Evaluation Heat & Mass Balance Analysis Catalyst Rema Remaining ining Sulfiding Life Determination Determ ination Catalyst Deactivation Deyactivation Assessment ent Catalyst Performance Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Proces Process s Technology - Hydrog Hydrogen en Catalysts / Process Technology – Ammonia Ammonia Catalyst Process Techn Technology ology - Methanol Catalysts / proces process s Technology – Petrochem Petrochemicals icals Specializing in the Development & Commercializa Commercialization tion of New Technology Technology  in the Refining & Petrochemical Industries Web Site: w ww.GBHEnterprises.com ww.GBHEnterprises.com

 

 

Optimizing Operating Operating Practices   -

Active Supervision Operating Targets Review Performance

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Engineering Support Catalyst Performance Monitoring Environment Monitoring / Control LP Vectors for Planning and Scheduling

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Best Practices Laboratory Techniques Catalyst Regenerations Reactor Loading Procedures

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Use of Experts for Support Operator / Engineer Training Proprietary Techniques Performance Audits

Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown  Activation Reduction In-situ Ex-situ Specializing Specializing in Refiner Refinery Process Assessm Catalyst Catalyst Performa Performance nce Performance Evaluation Heat & Mass Balance Analysis Catalyst Rema Remaining ining Sulfiding Life Determination Determ ination Catalyst Deactivation Deyactivation Assessment ent Catalyst Performance Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Proces Process s Technology - Hydrog Hydrogen en Catalysts / Process Technology – Ammonia Ammonia Catalyst Process Techn Technology ology - Methanol Catalysts / proces process s Technology – Petrochem Petrochemicals icals Specializing in the Development & Commercializa Commercialization tion of New Technology Technology  in the Refining & Petrochemical Industries Web Site: w ww.GBHEnterprises.com ww.GBHEnterprises.com

 

 

Optimization thr ough Catalyst Catalyst & Equipment Management Management Catalyst Management  Activity Control Control Catalyst Selection Catalyst Replacement Equipment Management – Maintenance Exchanger Cleaning Fired Heaters  – Tube Cleaning Cleaning  – Tube Replacement Replacement  – Box Management Management Equipment Management – Capitol Projects -

Feed / Effluent Heat Exchange

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Add a new reactor

Equipment Management – Instruments -

Instrument Selection

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Instrument Tuning

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Functional Analyzers

On-line Optimization Opportunity for significant Return on Investment Chemicals operations Multiple reformers Multiple degrees of freedom Multiple unit constraints

Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown  Activation Reduction In-situ Ex-situ Specializing Specializing in Refiner Refinery Process Assessm Catalyst Catalyst Performa Performance nce Performance Evaluation Heat & Mass Balance Analysis Catalyst Rema Remaining ining Sulfiding Life Determination Determ ination Catalyst Deactivation Deyactivation Assessment ent Catalyst Performance Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Proces Process s Technology - Hydrog Hydrogen en Catalysts / Process Technology – Ammonia Ammonia Catalyst Process Techn Technology ology - Methanol Catalysts / proces process s Technology – Petrochem Petrochemicals icals Specializing in the Development & Commercializa Commercialization tion of New Technology Technology  in the Refining & Petrochemical Industries Web Site: w ww.GBHEnterprises.com ww.GBHEnterprises.com

 

 

Not for all Applications -

Significant cost

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On-going manpower requirements

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Wide range of Return on Investment

RTO - Traditional Thinking -

Thinking of of the process in terms of the process unit configuration

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Matching the process instrumentation instrumentat ion - detailed feed-back system to ensure model consistency with measured process variables

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Matching the process yields

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Precise process modeling

Leads to False Approaches 1. If the unit is modeled in sufficient detail, the economics economics can be calculated 2. Make the optimizer a “Super-Controller” “Super-Controlle r”

 An Alter Al ternat nate e Way of o f Thin Th in ki ng: ng : Op Opti ti mi ze the Proc Pr ocess ess -

Economic Boundaries

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Economic Drivers

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Where in the process are the “Economic Flex Points”

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On-line optimization - a “Planning Tool” not a “Super-controll “Super-controller”. er”.

Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown  Activation Reduction In-situ Ex-situ Specializing Specializing in Refiner Refinery Process Assessm Catalyst Catalyst Performa Performance nce Performance Evaluation Heat & Mass Balance Analysis Catalyst Rema Remaining ining Sulfiding Life Determination Determ ination Catalyst Deactivation Deyactivation Assessment ent Catalyst Performance Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Proces Process s Technology - Hydrog Hydrogen en Catalysts / Process Technology – Ammonia Ammonia Catalyst Process Techn Technology ology - Methanol Catalysts / proces process s Technology – Petrochem Petrochemicals icals Specializing in the Development & Commercializa Commercialization tion of New Technology Technology  in the Refining & Petrochemical Industries Web Site: w ww.GBHEnterprises.com ww.GBHEnterprises.com

 

 

Economic Drivers: Internal Drivers • Unit severity • Utilities • Incremental product recoveries External Drivers • Feed allocation between units • Alternate feed specifications Economic Flex Points Points :

Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown  Activation Reduction In-situ Ex-situ Specializing Specializing in Refiner Refinery Process Assessm Catalyst Catalyst Performa Performance nce Performance Evaluation Heat & Mass Balance Analysis Catalyst Rema Remaining ining Sulfiding Life Determination Determ ination Catalyst Deactivation Deyactivation Assessment ent Catalyst Performance Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Proces Process s Technology - Hydrog Hydrogen en Catalysts / Process Technology – Ammonia Ammonia Catalyst Process Techn Technology ology - Methanol Catalysts / proces process s Technology – Petrochem Petrochemicals icals Specializing in the Development & Commercializa Commercialization tion of New Technology Technology  in the Refining & Petrochemical Industries Web Site: w ww.GBHEnterprises.com ww.GBHEnterprises.com

 

 

Structure of On-line Optim Optim ization Solution

Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown  Activation Reduction In-situ Ex-situ Specializing Specializing in Refiner Refinery Process Assessm Catalyst Catalyst Performa Performance nce Performance Evaluation Heat & Mass Balance Analysis Catalyst Rema Remaining ining Sulfiding Life Determination Determ ination Catalyst Deactivation Deyactivation Assessment ent Catalyst Performance Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Proces Process s Technology - Hydrog Hydrogen en Catalysts / Process Technology – Ammonia Ammonia Catalyst Process Techn Technology ology - Methanol Catalysts / proces process s Technology – Petrochem Petrochemicals icals Specializing in the Development & Commercializa Commercialization tion of New Technology Technology  in the Refining & Petrochemical Industries Web Site: w ww.GBHEnterprises.com ww.GBHEnterprises.com

 

 

Modeling Approaches Rigorous models – used where needed FCC Reactor Reformer Reactor Simplified Models – used as applicable Fractionation Naphtha Hydrotreater Optimization Model Structure

Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown  Activation Reduction In-situ Ex-situ Specializing Specializing in Refiner Refinery Process Assessm Catalyst Catalyst Performa Performance nce Performance Evaluation Heat & Mass Balance Analysis Catalyst Rema Remaining ining Sulfiding Life Determination Determ ination Catalyst Deactivation Deyactivation Assessment ent Catalyst Performance Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Proces Process s Technology - Hydrog Hydrogen en Catalysts / Process Technology – Ammonia Ammonia Catalyst Process Techn Technology ology - Methanol Catalysts / proces process s Technology – Petrochem Petrochemicals icals Specializing in the Development & Commercializa Commercialization tion of New Technology Technology  in the Refining & Petrochemical Industries Web Site: w ww.GBHEnterprises.com ww.GBHEnterprises.com

 

 

Three Keys Keys for Selection Selection of On-line Optimization o f Reformer Opera Operation tion Feedstock Naphtha Splitting Severity of Reaction Optimization – Example 1

Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown  Activation Reduction In-situ Ex-situ Specializing Specializing in Refiner Refinery Process Assessm Catalyst Catalyst Performa Performance nce Performance Evaluation Heat & Mass Balance Analysis Catalyst Rema Remaining ining Sulfiding Life Determination Determ ination Catalyst Deactivation Deyactivation Assessment ent Catalyst Performance Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Proces Process s Technology - Hydrog Hydrogen en Catalysts / Process Technology – Ammonia Ammonia Catalyst Process Techn Technology ology - Methanol Catalysts / proces process s Technology – Petrochem Petrochemicals icals Specializing in the Development & Commercializa Commercialization tion of New Technology Technology  in the Refining & Petrochemical Industries Web Site: w ww.GBHEnterprises.com ww.GBHEnterprises.com

 

 

Optimization – Example 2

On-line Online Optimi zation: zation: Intangible Benefits Benefits -

Exploration of new modes of operation

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S t r e t c h i n g of bounds bounds

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Brings economics into the control room

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Accountability Accountabilit y in financial terms

Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown  Activation Reduction In-situ Ex-situ Sulfiding Specializing Specializing in Refiner Refinery y Process Catalyst Catalyst Performa Performance nce Evaluation Heat & Mass Balance Analysis Catalyst Rema Remaining ining Life Determination Determination Catalyst Deactivation Deactivation Assessm Assessment ent Catalyst Performance Performance Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Proces Process s Technology - Hydrog Hydrogen en Catalysts / Process Technology – Ammonia Ammonia Catalyst Process Techn Technology ology - Methanol Catalysts / proces process s Technology – Petrochem Petrochemicals icals Specializing in the Development & Commercializa Commercialization tion of New Technology Technology  in the Refining & Petrochemical Industries Web Site: w ww.GBHEnterprises.com ww.GBHEnterprises.com

 

 

Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown  Activation Reduction In-situ Ex-situ Sulfiding Specializing Specializing in Refiner Refinery y Process Catalyst Catalyst Performa Performance nce Evaluation Heat & Mass Balance Analysis Catalyst Rema Remaining ining Life Determination Determination Catalyst Deactivation Deactivation Assessm Assessment ent Catalyst Performance Performance Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Proces Process s Technology - Hydrog Hydrogen en Catalysts / Process Technology – Ammonia Ammonia Catalyst Process Techn Technology ology - Methanol Catalysts / proces process s Technology – Petrochem Petrochemicals icals Specializing in the Development & Commercializa Commercialization tion of New Technology Technology  in the Refining & Petrochemical Industries Web Site: w ww.GBHEnterprises.com ww.GBHEnterprises.com