Hydrocarbon Processing - June 2022 - 63

History of the HPI-The 1970s
Sulzer Chemtech
Sulzer Chemtech Mellapak™ CC
structured packing
Decarbonization is a leading opportunity
to drive oil plant competitiveness It is well
established that changing customer and
production requirements led by a focus on
achieving a net-zero future are shaping the
oil sector. By leveraging advanced separation
technologies, companies can turn this
into an opportunity and adapt their existing
equipment to future-proof operations,
improve environmental footprints, and create
new revenue streams. Understanding the benefits
of the available solutions and which ones
are most suitable are key steps to thriving in
an evolving market. The decarbonization of
hydrocarbon processing plants should not be
seen solely as a requirement that is expected
to meet net-zero targets. In fact, there are
multiple options for emissions reductions
that offer key opportunities to advance and
intensify existing processes.
CUTTING ENERGY USE
AND EMISSIONS
With separation activities being among
the most energy intensive, oil facilities should
first look at how to improve them in order to
cut their environmental footprint. Perhaps
the most intuitive step that can be taken is
increasing the efficiency of these processes,
which can be easily achieved by leveraging the
latest generation of mass transfer components
within columns. For example, the replacement
of third generation structured packing with
fourth generation alternatives, such as Sulzer
Chemtech's MellapakPlus™, can maintain
the same energy consumption rates while
increasing capacity by 30-50% within existing
manufacturing footprints (Moser & Kessler,
2000). Similarly, the upgrade from third-generation
random packing to fourth-generation
rings, such as Sulzer Chemtech's NeXRing™,
can expand column capacity by 10% without
increasing energy usage (Ausner, et al., 2018).
When these most recent solutions are used to
replace even older equipment, plants benefit
from much greater improvements. Ultimately,
with limited capital expenditure, even already
energy-efficient plants can achieve more while
enhancing their throughput. Taking this to the
next level, companies committed to larger
investments can go carbon neutral by building
post-combustion carbon capture facilities,
which are able to prevent up to 90% of
produced CO2 from entering the atmosphere.
These units remove CO2 from flue gases by
leveraging chemical separation methods, thus
the same considerations on mass transfer
components apply here. To deliver optimum
performance in these columns, Sulzer has
developed Mellapak™ CC structured packing,
which was designed specifically for carbon
capture applications (Sulzer, 2022). More precisely,
this cost-effective technology increases
efficiency by 20% compared to conventional
structured packing.
ADAPTING OIL PROCESSING
OPERATIONS
Oil processors can also modify their existing
facilities to process more sustainable feedstocks
effectively. Advanced separation solutions
can help plants process more economical
alternatives to crudes as well as renewable,
plant-based oils or upcycle waste materials,
which typically feature higher concentrations
of impurities and harsh chemicals. In addition
to handling new input materials, advanced
separation solutions can help hydrocarbon
processing facilities deliver highly profitable
petrochemicals, making the entire downstream
sector more sustainable. For example,
pyrolysis gasoline (pygas), a byproduct from
steam crackers, can be used to extract styrene
monomers from renewable resources.
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Hydrocarbon Processing - June 2022

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