The document summarizes a study evaluating the feasibility of modifying an existing facility to produce ultra-low sulfur diesel (ULSD) in compliance with new regulations. Key recommendations include: 1. Installing a new feed tank and pump to ensure constant feed flow during shutdowns. 2. Replacing old heat exchangers and adding a new one to adequately heat the feed. 3. The compressor and fractionating tower are adequate with some modifications like extra safety devices. 4. The economic analysis shows the project has an IRR of 141.7%, NPV of $913 million, and payback period of 1.8 years, demonstrating strong financial viability.

1. Clean Fuels Project
Diesel Hydrotreating Unit
Scoping Study
Lauren Brickner
Chi Lo
Pamela Morse
Jacobs Engineering Liaisons:
Daniel LaRiviere
Gary Gough

2. Project Description and Scope
l New regulations require highway diesel to
have below 15 ppm of sulfur (reduced from
500 ppm)
l Benefit of producing ultra low sulfur diesel
(ULSD) is about $0.10/gal
l Evaluate ability of existing equipment to adapt
to modified process to produce ULSD
l Economic feasibility of producing ULSD

4. Design:
Material & Energy Balances
Reactor
Quench
Treat
87 mol% H2
3,500 scf/bbl
H2 consumed =
6,022,500 SCFD
ΔHrxn = 29,408
Btu/bbl
Recycle
86.12 mol% H2
Hydrogen Plant
99.9 mol% H2
Reformer
81.53 mol% H2
FRH
90 mol% H2
Oil Feed
Qquench
Qin
Qout
Mole Balance
FRH = Freformer + FHplant
nRH*FRH = nreformer*Freformer + nHplant*FHplant
FRH + Frecycle = FTreat
nRH*FRH + nrecycle*Frecycle = nTreat*FTreat
Energy Balance
Qin + Qquench + ΔHrxn = Qout
Qquench
1579 lbmol/hr

5. Design: Heaters
Heater
HPHS
Reactor
Oil
Feed Hydrogen
Feed
Feed/Effluent
Exchangers
Heater
HPHS
Reactor
Oil
Feed
Hydrogen
Feed
Feed/Effluent
Exchangers
Current Configuration
Proposed Configuration

6. Design: Water
Injections System
Process
Stream
Fan Cooler
Water
Injection
Design Considerations:
1. 25% of injected water remain in the liquid phase
downstream of the injection point.
2. Concentration of ammonia bisulfide in the HPHS
sour water be maintained at or below 4 wt%

7. Design: Compressors/Pumps
Recycle
Hydrogen
Plant and
Reformer
Given From HYSYS TM
Capacity (ACFM) Efficiency Capacity (ACFM) Horsepower
Stage 1 GC1 1111:= E1 .903:= C1 877.2:= H1 610.5hp⋅:=
Stage 2 GC2 488.5:= E2 .928:= C2 469.4:= H2 820.1hp⋅:=
Stage 3 GC3 231.7:= E3 .914:= C3 204:= H3 565.6hp⋅:=
Stage 4 GC4 562.8:= E4 .76:= C4 452.3:= H4 395.5hp⋅:=
P-101 Pump Curves
2000
2500
3000
3500
4000
4500
5000
5500
0 100 200 300 400 500 600
Flow (GPM)
TDH(ft)
9.35" 9.88"

8. Design: Separators and
Fractionator
Specifications Naphtha Kerosene Diesel (ULSD)
Distillation Sim Dist. D-86 D-86
10%, °F - 401 max -
90%, °F - 550 max 640 max
End Point, °F 400 max 572 max -
Product Specifications
Design Goals:
1. Ensure products are
separated to desired
specifications
2. Ensure adequate
vapor/liquid
disengagement
3. Ensure adequate surge
capacity

9. Design Conclusions /
Recommendations
1. New Feed Tank
§ To ensure constant feed flow
§ Be a holding tank for catalyst change out and shutdowns
2. New Feed Pump
§ Flow = 590 GPM
§ Total dynamic head (TDH) = 4142 ft
§ Max impeller diameter TDH = 3200 ft
3. Heat Exchangers
§ Replace reactor feed/effluent exchangers
§ Add heat exchanger to feed
4. Compressor
§ Required hp = 2378 (motors rated at 4000 hp)
§ Adequate capacity
§ No changes to be made

10. Design Conclusions /
Recommendations
5. Water Injection System
§ 8330 lb/hr water required to remove ammonia bisulfide
6. High Pressure Hot Separator
§ Adequate vapor/liquid disengagement
§ Surge capacity too small
§ Will not replace – install safety devices to prevent overflow
7. Fractionating Tower
§ Produces adequate product specifications
§ Replace trays to prevent weeping
8. Piping
§ Sized to fit constraints of: maximum velocity, slug flow, ΔP/100 ft

11. Economics – Equipment Bare Module
Costs
Total bare module cost ~ $5 million
Equipment Costs
Instruments
7%
Piping
7%
Reactor &
Fractionator
Internals
50%
Equipment
36%

12. Total Variable Costs
Catalyst
4%
Heating Fuel Oil
71%
Electricity
11%
Steam
2%
Hydrogen
10%
Water
2%
Economics – Annual Costs
& Product Selling Prices
Annual Cost Breakdown
Variable Costs: $14.7 Million
Crude Oil Cost: $365 Million
Operating Costs: $541 Million
Product Selling Prices
ULSD: $1.93 / GAL
Naphtha: $1.53 / GAL
Kerosene: $1.94 / GAL

13. Economics: Cash Flow Analysis
Ultra Low Sulfur Diesel Process Cash Flow
Selling Price = 1.93
-$20,000
$0
$20,000
$40,000
$60,000
$80,000
$100,000
$120,000
$140,000
$160,000
2007 2008 2009 2010 2011 2012 2013 2014 2015 2016 2017 2018 2019 2020
Years
CashFlow($k)
l IRR = 141.7%
l NPV = $913M
(at the beginning
of each period)
l ROI = 56.5%
l PBP = 1.8 years

14. Comments and Future
Recommendations
l Liaison/Student Communication
l Project description and equipment
documentation
l Time constraints
l Project scope

15. To our liaisons
(Dan and Gary)
and Jacobs
Engineering