Cost-Effective Solution

Our client operated a refinery on the USGC.  The primary focus was to produce jet fuel from local crude oils.  Other than jet fuel and high sulfur diesel, the other products were unfinished.  With new regulations mandating ultra-low sulfur diesel (ULSD), the finished diesel product would now become an unfinished product at an economic disadvantage.  Polaris was engaged to recommend a cost-effective solution to upgrade the unfinished diesel product and provide an EPC proposal to execute that work.

Synergistic Opportunities

Polaris evaluated the refinery and discovered several synergistic opportunities.  A diesel hydrotreater was recommended to produce ULSD.  Since the refinery made unfinished naphtha, Polaris recommended a naphtha hydrotreater and semi-regenerative reformer to A) make finished gasoline and/or high-octane blend stocks and B) produce hydrogen for use on the ULSD hydrotreater.  In addition, Polaris recommended process units to recover LPG generated from the reformer and the hydrotreaters.  The rest of the gas would be directed to the refinery fuel gas system, completely backing out purchased natural gas.  The gas generated would provide more fuel gas than the refinery could consume, so a boiler and steam-turbine generator was also recommended.  Polaris recommended “open art” technology to save the client from paying royalties and to allow Polaris to design the process units in house.

Safe Installation and Successful Operations

The resulting EPC project was engineered, fabricated and safely installed by the Polaris team.  The units have been operating successfully per design for over 15 years.  The client was able to maintain his finished jet production and diesel production as ULSD and produce a valuable high-octane blend-stock.  LPG, which had been burned in the fuel gas system, was recovered and marketed.  Natural gas purchases were backed out of the fuel gas system and purchased electrical energy from the utility was backed out and, occasionally, reversed as power sales to the utility.  The natural gas import and utility power import/export act as a “fly-wheel” during unit startup and other special operations to balance the fuel gas system.

Scope of Work