PETE 1016 · Hydrotreating and Hydrocracker Technology

Led by Senior Process Plant Engineer Simulacrum

Hydrotreating and hydrocracker technology from reaction chemistry and catalyst systems through operations, monitoring, troubleshooting, applications for naphtha, diesel, VGO, and cracked feeds, hydrocracking configurations, and hydrogen management and debottlenecking.

1. Module 1

   Hydroprocessing Fundamentals: Chemistry, Catalysts, and Thermodynamics

   Led by Senior Process Plant Engineer Simulacrum

   The question

   All hydroprocessing shares a common foundation: hydrogen reacts over a catalyst to remove heteroatoms and saturate bonds — and in hydrocracking, to break carbon-carbon bonds. This module develops the six hydroprocessing reactions (HDS, HDN, HDO, HDM, olefin saturation, aromatic saturation), the catalyst metal/support systems (CoMo, NiMo, NiW — each optimised for a different application), the three deactivation mechanisms (coking, poisoning, sintering), the exothermic temperature profile and interbed quench control, and the hydrogen consumption calculation for each reaction type.

   Outcome

   The student can describe the six reactions, explain the catalyst systems and sulphiding, describe three deactivation mechanisms, explain the quench system, and calculate approximate hydrogen consumption. (Hydroprocessing fundamentals)

   Sub-units

   1. ○ 1.1 The Hydroprocessing Reactions: HDS, HDN, HDO, HDM, and Saturation Open this unit → ✓ ↻
   2. ○ 1.2 Catalyst Systems: Metals, Supports, and Sulphiding Open this unit → ✓ ↻
   3. ○ 1.3 Catalyst Deactivation: Coking, Poisoning, and Sintering Open this unit → ✓ ↻
   4. ○ 1.4 Thermodynamics: Exothermic Profile and Quench Control Open this unit → ✓ ↻
   5. ○ 1.5 Hydrogen Consumption, Purity, and the Recycle System Open this unit → ✓ ↻
   Begin the course → Print certificate of completion
2. Module 2

   Hydrotreating Operations: Conditions, Monitoring, and Troubleshooting

   Led by Senior Instrumentation & Control Engineer Simulacrum

   The question

   The hydrotreater must be operated, monitored, and troubleshot like any reactor system — and the product specification is unforgiving at 10 ppm sulphur. This module covers the four operating variables (WABT, LHSV, hydrogen pressure, H₂/oil ratio) and their effect on conversion, mass and sulphur balance construction for performance verification, reactor temperature profile interpretation for catalyst activity tracking, the five-step diagnostic tree for high product sulphur (WABT, hydrogen purity, feed quality, catalyst deactivation, bypassing), and reactor pressure drop troubleshooting.

   Outcome

   The student can describe the operating variables, construct a sulphur balance, interpret a reactor temperature profile, and diagnose high product sulphur and increasing pressure drop. (Hydrotreating operations and troubleshooting)

   Sub-units

   1. ○ 2.1 Operating Variables: WABT, LHSV, Pressure, and Hydrogen Ratio Open this unit → ✓ ↻
   2. ○ 2.2 Mass Balance, Sulphur Balance, and Hydrogen Balance Open this unit → ✓ ↻
   3. ○ 2.3 Reactor Monitoring: Temperature Profile and Activity Tracking Open this unit → ✓ ↻
   4. ○ 2.4 Troubleshooting: High Product Sulphur Open this unit → ✓ ↻
   5. ○ 2.5 Troubleshooting: Reactor Pressure Drop and Fouling Open this unit → ✓ ↻
   Open this module → Print certificate of completion
3. Module 3

   Hydrotreating Applications: Naphtha, Diesel, VGO, and Cracked Feeds

   Led by Senior Process Plant Engineer Simulacrum

   The question

   Every petroleum fraction has its own hydrotreating challenge — different sulphur compounds, different operating conditions, different catalysts. This module covers naphtha HDS for reformer feed (mild conditions, reactive sulphur), diesel HDS for ULSD (the refractory 4,6-DMDBT challenge, the DDS vs. HYD pathways, and why NiMo outperforms CoMo), VGO hydrotreating (the lead/tail HDM guard catalyst concept), selective HDS for FCC gasoline (preserving olefin octane), diolefin saturation for coker naphtha, and co-processing of biofeedstocks for renewable diesel.

   Outcome

   The student can describe the conditions and catalyst for each feed type, explain selective HDS for FCC gasoline, explain the HDM guard catalyst concept, and describe the co-processing pathway for renewable diesel. (Hydrotreating applications)

   Sub-units

   1. ○ 3.1 Naphtha Hydrotreating for Reformer Feed Open this unit → ✓ ↻
   2. ○ 3.2 Diesel Hydrotreating: ULSD and the Refractory Sulphur Challenge Open this unit → ✓ ↻
   3. ○ 3.3 VGO Hydrotreating: FCC/Hydrocracker Feed Preparation Open this unit → ✓ ↻
   4. ○ 3.4 Cracked Feed Hydrotreating: FCC Gasoline and Coker Naphtha Open this unit → ✓ ↻
   5. ○ 3.5 Emerging Trends: Co-Processing Biofeedstocks and Renewable Diesel Open this unit → ✓ ↻
   Open this module → Print certificate of completion
4. Module 4

   Hydrocracking: Chemistry, Catalysts, Reactors, and Configuration

   Led by Senior Process Plant Engineer Simulacrum

   The question

   Hydrocracking is the most versatile refinery conversion process — any heavy feed converted to any lighter product by adjusting the catalyst and configuration. This module develops the bifunctional mechanism (cracking on acid sites, hydrogenation on metal sites, and why the balance between them controls product selectivity), the zeolite and amorphous catalyst systems, the three reactor designs (fixed-bed, ebullated-bed for high-metals residue, slurry-phase), the three process configurations (once-through, single-stage recycle, two-stage) and their conversion levels, and the product quality advantages of hydrocracker diesel, jet fuel, and naphtha.

   Outcome

   The student can describe the bifunctional mechanism, explain the acid-metal balance, compare the three reactor designs, describe the three configurations with their conversion levels, and state the quality parameters for hydrocracker diesel and jet fuel. (Hydrocracking)

   Sub-units

   1. ○ 4.1 The Bifunctional Mechanism: Cracking and Hydrogenation Open this unit → ✓ ↻
   2. ○ 4.2 Hydrocracking Catalysts: Zeolite Type, Metal Loading, and Selectivity Open this unit → ✓ ↻
   3. ○ 4.3 Reactor Design: Fixed-Bed, Ebullated-Bed, and Slurry-Phase Open this unit → ✓ ↻
   4. ○ 4.4 Process Configuration: Once-Through, Single-Stage Recycle, and Two-Stage Open this unit → ✓ ↻
   5. ○ 4.5 Product Quality, Yields, and Hydrocracker Integration Open this unit → ✓ ↻
   Open this module → Print certificate of completion
5. Module 5

   Hydrogen Management, Equipment Design, and Debottlenecking

   Led by Senior Rotating Equipment Engineer Simulacrum

   The question

   Hydrogen is the enabler of all hydroprocessing — and the refinery that runs short must cut throughput or produce off-spec product. This module covers the refinery hydrogen balance (reformer + hydrogen plant vs. hydrotreaters + hydrocracker), the three-pressure-level hydrogen network and hydrogen pinch analysis, the steam methane reformer process (reforming, shift, PSA purification), hydrogen recovery from purge gases by PSA and membrane, reactor metallurgy (hydrogen attack, 2.25Cr-1Mo-V steel, the recycle compressor as the most critical machine), and five debottlenecking strategies with their economics.

   Outcome

   The student can describe the hydrogen balance and network, describe the SMR process, explain PSA hydrogen recovery, describe the reactor metallurgy requirements, and identify five debottlenecking strategies. (Hydrogen management and debottlenecking)

   Sub-units

   1. ○ 5.1 The Refinery Hydrogen Balance and Network Open this unit → ✓ ↻
   2. ○ 5.2 The Steam Methane Reformer: Hydrogen Production Open this unit → ✓ ↻
   3. ○ 5.3 Hydrogen Recovery: PSA and Membrane Systems Open this unit → ✓ ↻
   4. ○ 5.4 Reactor Design and Metallurgy Open this unit → ✓ ↻
   5. ○ 5.5 Debottlenecking: Strategies for Increasing Capacity Open this unit → ✓ ↻
   Open this module → Print certificate of completion