New Regulations

The client refinery was configured to produce Jet Fuel and Low Sulfur Diesel as finished products and unfinished naphtha as an intermediate product.  With new diesel regulations rapidly approaching, the project schedule was compressed.  The Low Sulfur Diesel would not qualify as a finished product once the regulations went into effect and the disposition of Low Sulfur Diesel in an Ultra-Low Sulfur market would be economically distressing.  The unfinished naphtha was an undesirable intermediate product and utility power cost and natural gas costs were high.

 Revamp Solution

The Polaris solution was to revamp the refinery to meet the new Ultra Low Sulfur Diesel regulations.  The Revamp included three new, grass roots process units: a 6 MBPD ULSD Unit, a 6 MBPD Naphtha Hydrotreater (NHT) and Catalytic Naphtha Reforming Unit.  The ULSD would produce Ultra Low Sulfur Diesel.  The reformer would upgrade the low value, unfinished naphtha to high value, high octane reformate blend stock.  At the same time, it would produce the hydrogen needed for the ULSD unit and the NHT.  All the units were engineered in house by Polaris using familiar and proven, open art technology.  As a result of this approach, the client was not subject to royalties or other technology fees.

In addition to upgrading both the diesel and the naphtha, Polaris was able to use the new fuel gas balance to produce steam and power for the facility.  An idled steam turbine generator was located, purchased and installed.  The steam/turbine generator was designed to export power to the local grid should the fuel gas balance require it.  Ancillary to the steam/turbine generator, a new flare and flare system was designed and installed to accommodate the new Pressure Protection and Relief System.

Like the steam turbine generator, other process equipment with long lead times was  sourced from idled supplies to meet the compressed schedule.

Strategy Results in Meeting New Regulation Timeline

Our strategy saved project schedule, allowing the client’s diesel production to meet the new regulations on time.  Production of the highly profitable Jet Fuel was preserved, finished diesel met the new environmental regulations and unfinished naphtha was upgraded to high value, high octane reformate.  The new fuel gas balance reduced natural gas purchases and reduced purchased electrical power from the local utility.

Scope of Work

Process / Chemical




Refining, Oil & Gas