The Challenges of Renewable Feedstocks and Opportunity Crudes
Modcon Systems Ltd.
Innovative technologies of process analysis and AI-enabled?optimization.
As the global energy landscape shifts towards sustainability, refineries are increasingly turning to alternative feedstocks such as vegetable oils, animal fats, cooking oil, pyrolysis oil, and crude tall oil. Renewable feedstocks complement traditional crude oil processing, allowing for greater diversification of feedstock supply chains. However, the complexity of these feedstocks, combined with the challenges associated with opportunity crude oils, underscores the importance of real-time quality measurement. Accurate monitoring of key parameters is essential for ensuring smooth refinery operations, maintaining product quality, and mitigating risks like corrosion and fouling.
This article explores the importance of renewable feedstock utilization, discusses the inherent challenges of processing diverse feedstocks, and highlights how the Modcon MOD-4100 crude oil analyzer facilitates precise, on-line measurement of critical feedstock parameters, ensuring refinery efficiency and longevity.
The Growing Importance of Renewable and Opportunity Feedstocks in Refining
The shift towards renewable energy is driving the refining industry to adapt to a wider array of feedstocks. Renewable feedstocks, such as vegetable oils and animal fats, offer a lower carbon footprint compared to traditional fossil fuels, aligning with global sustainability goals. Additionally, feedstocks like pyrolysis oil and crude tall oil, derived from waste and biomass, present opportunities for refineries to integrate circular economy principles, reducing reliance on crude oil while minimizing environmental impact.
However, renewable feedstocks come with their own set of challenges. For example, vegetable oils and animal fats can contain higher levels of oxygenated compounds, leading to issues with thermal stability and increased acidity, which can accelerate corrosion in refinery equipment. Similarly, pyrolysis oil, a product of waste plastic and biomass conversion, exhibits significant variation in chemical composition, making it more difficult to process consistently. These challenges necessitate accurate, real-time quality control during processing to avoid operational inefficiencies and equipment degradation(
Opportunity crudes, such as heavy or high-sulfur crudes, are attractive due to their lower market price, but they introduce significant processing challenges. High levels of sulfur, metals, and salts can increase the risk of corrosion, fouling, and desalter inefficiencies, ultimately reducing equipment reliability. Additionally, renewable feedstocks such as cooking oil and animal fats are prone to instability, with issues like emulsification and higher levels of contaminants that can compromise downstream refining processes(
Blending renewable and traditional feedstocks introduces another layer of complexity. Variations in viscosity, emulsion stability, hydrogen sulfide concentration, and salt content can have a cascading effect on refining operations if not properly controlled. In particular, sulfur and water content in the feedstock can affect catalyst performance in hydrotreaters and create off-spec products if not continuously monitored.
A Solution for Precise Feedstock Quality Measurement
The Modcon MOD-4100 crude oil analyzer offers a robust solution to the challenges of processing diverse feedstocks, providing real-time, on-line analysis of critical parameters that affect refinery operations. This modular, factory-tested system is designed for seamless integration into refinery infrastructure, delivering accurate measurements that correlate directly with ASTM standards.
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Key parameters measured by the MOD-4100 include:
The MOD-4100 analyzer's modular design allows for customizable configurations to meet specific refinery needs. It is pre-calibrated, factory-tested, and ready for immediate installation, significantly reducing downtime and allowing for rapid commissioning. This reduces the risk of human error associated with manual sampling and laboratory analysis, providing continuous, real-time insights that allow for better decision-making and faster response to potential feedstock quality issues.
Correlation to ASTM Standards and Improved Operational Efficiency
By correlating its on-line measurements to ASTM standards, the MOD-4100 ensures that refineries can confidently monitor critical parameters. These standards provide a consistent framework for measuring quality, ensuring that refineries meet product specifications and avoid costly penalties associated with off-spec products. For instance, ASTM D3230 for salt content ensures that refiners can mitigate the risks of corrosion in crude distillation units, while ASTM D2622 and D4294 ensure compliance with sulfur content regulations, critical for both environmental and operational reasons.
The ability to continuously monitor feedstock quality allows for real-time adjustments in processing, leading to better energy efficiency, reduced waste, and longer equipment lifespans. Additionally, by identifying off-spec feedstocks early, refineries can take corrective actions, avoiding costly shutdowns or extensive repairs.
Conclusion
The integration of renewable feedstocks into refinery operations is an important step towards a sustainable energy future. However, the inherent variability in these feedstocks, combined with the challenges posed by opportunity crudes, requires precise, real-time quality monitoring. The Modcon MOD-4100 crude oil analyzer provides refineries with a powerful tool for maintaining operational efficiency, ensuring product quality, and protecting refinery infrastructure. Its ability to measure a wide range of critical parameters, in real-time, makes it indispensable for refineries looking to adapt to the evolving energy landscape while maintaining economic and environmental performance.