Heavy Coker Gas Oil String Wound Upgrade Case Study

One of the largest plastics, chemicals and refining companies in the world. They operate one of the largest refineries in the United States located on the Houston Ship Channel. The refinery has a heavy, high-sulfur crude oil processing capacity of approximately 268,000 barrels per day. This facility produces gasoline and fuel components, low-sulfur diesel, jet fuel and lubricants.

The Hydro Desulphurization unit removes sulfur from the cat cracker feed. The unit, also known as the Cat Feed Hydrotreater, is located in the Hydrotreating unit. This unit receives feed from a Crude Unit and receives feed stream from a coker fractionator, which takes feed stream from Heavy Coker Gas oil. This effectively processes heavy gas oil, heavy vacuum gas oil, medium vacuum gas oil, and heavy coker gas oil.

THE CHALLENGE

String wound elements were breaking down and infiltrating the reactor.

Jonell System’s challenge was to create a solution that would solve the particulate contamination problem. A process needed to be developed to prevent the particulate matter from reaching the reactor. A special cartridge to bypass the string would filters was required.

THE SOLUTION

Jonell Systems constructed a media variation process to eliminate monthly change-outs. 

Engineers at Jonell Systems initially employed a standard design solution which improved the results to some degree however, it did not meet all expectations for an effective solution. Lab testing was used to determine the exact media layers required to eliminate all contaminants from reaching the reactor and design enhancements were made. By changing the core to stainless steel components, the concern for corrosion was substantially diminished and additional variations were made. 

THE RESULTS

By installing Twist-LOK filters, Jonell Systems ensured reduction of the frequency of filter change-outs. 

Jonell Systems used the LiquiPleat Series, which consisted of various grades of performance cotton medias to suit their process. This higher quality solution substantially improved efficiencies within the operation and effectively prevented contaminants from reaching the reactor. Our customer successfully prevented contaminants from reaching the reactor, which improved operations and ultimately lowered costs.