Page : 1 of 70

KLM Technology
Group

Rev: 02

Practical Engineering
Guidelines for Processing
Plant Solutions

www.klmtechgroup.com

Rev 01 April 2013

Rev 02 July 2013

Co Author

KLM Technology Group

#03-12 Block Aronia,
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HYDROTREATING
(ENGINEERING DESIGN GUIDELINE)

Rev 01 Aprilia Jaya

Rev 02 Aprilia Jaya

Karl Kolmetz

KLM Technology Group is providing the introduction to this guideline for free on
the internet. Please go to our website to order the complete document.
www.klmtechgroup.com
TABLE OF CONTENT
INTRODUCTION
Scope

General Design Consideration

DEFINITIONS

28

NOMENCLATURE

31

THEORY OF THE DESIGN

33

Prefractionation Section

34

Reactors Design and Operation

34

A. Feed System

35

B. Reactor System

35

C. Wash Water System

36

D. Separator System

36

KLM Technology
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HYDROTREATING

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Stripping Section

43

Other Equipment

43

Liquid Maldistribution

45

General Effects of Process Variables

46

Catalysts

50

Common Problem in Hydrotreating Unit

52

APPLICATION
Example Case 1: Material Balance and H2 Consumption

61

Example Case 2: Hydrotreating Design with Liquid Feed

63

Example Case 3: Hydrotreating Design with Gas Feed

65

REFEREENCES

67

CALCULATION SPREADSHEET

68

Material Balance and H2 Consumption.xls

68

Hydrotreating Design with Liquid Feed.xls

69

Hydrotreating Design with Gas Feed.xls

70

LIST OF TABLE
Table 1: Feeds and product objectives for different kinds of hydrotreaters

Table 2: Standard solid copper reagent towers

16

Table 3: Catalysts for naphtha hydrotreating

20

These design guideline are believed to be as accurate as possible, but are very general and not for specific design
cases. They were designed for engineers to do preliminary designs and process specification sheets. The final
design must always be guaranteed for the service selected by the manufacturing vendor, but these guidelines will
greatly reduce the amount of up front engineering hours that are required to develop the final design. The guidelines
are a training tool for young engineers or a resource for engineers with experience.
This document is entrusted to the recipient personally, but the copyright remains with us. It must not be copied,
reproduced or in any way communicated or made accessible to third parties without our written consent.

KLM Technology
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Practical Engineering
Guidelines for Processing Plant
Solutions

HYDROTREATING

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Table 4: Process condition of hydrotreating

26

Table 5: Hydrogen consumption for typical feedstock

27

Table 6: Selectivity of the various combinations

53

LIST OF FIGURE
Figure 1: Sulfur removal

Figure 2: Difficulty of desulphurization

Figure 3: Denitrogenation mechanism

Figure 4: Oxygen removal mechanism

10

Figure 5: Aromatic saturation

11

Figure 6: Non regenerative caustic

14

Figure 7: Naphtha hydrotreater

21

Figure 8: Distillate hydrotreater

23

Figure 9: Oil hydrotreater

25

Figure 10: Hydrotreating flow scheme

33

Figure 11: Hydrotreater reactor

39

Figure 12: Hydrotreater reactor quench zone

40

Figure 13: Catalyst shape

52

These design guideline are believed to be as accurate as possible, but are very general and not for specific design
cases. They were designed for engineers to do preliminary designs and process specification sheets. The final
design must always be guaranteed for the service selected by the manufacturing vendor, but these guidelines will
greatly reduce the amount of up front engineering hours that are required to develop the final design. The guidelines
are a training tool for young engineers or a resource for engineers with experience.
This document is entrusted to the recipient personally, but the copyright remains with us. It must not be copied,
reproduced or in any way communicated or made accessible to third parties without our written consent.

KLM Technology
Group
Practical Engineering
Guidelines for Processing Plant
Solutions

HYDROTREATING

Page 4 of 70

(ENGINEERING DESIGN GUIDELINES) Rev: 02

July 2013

KLM Technology Group is providing the introduction to this guideline for free on
the internet. Please go to our website to order the complete document.
www.klmtechgroup.com
INTRODUCTION
Scope
This design guideline covers the basic elements in the field of hydro treating in sufficient
detail to allow an engineer to design a hydro treater with the suitable process
parameters; size of diameter, velocity, and pressure drop. This design guideline
includes; design of reactor, catalyst, pressure drop and hydrogen consumption.
Hydrotreating or catalytic hydrogen treating removes objectionable materials from
petroleum fractions by selectively reacting these materials with hydrogen in a reactor at
relatively high temperatures and moderate pressures. The sizing of the unit and the
choice of catalyst is important to give the optimum efficiency of hydrotreating.
The design of hydrotreating may be influenced by factors, including process
requirements, economics and safety. .All the important parameters use in the guideline
are explained in the definition section which help the reader more understand the
meaning of the parameters or the terms utilized.
In the application section of this guideline, three case studies are shown and discussed
in detail, highlighting the way to apply the theory for the calculations. The theory section
explains reactor sizing, hydrotreating catalyst, and common problems in hydroteating.
Example Calculation Spreadsheets are part of this guideline. This Example Calculation
Spreadsheets are based on case studies in the application section to make them easier
to understand.

These design guideline are believed to be as accurate as possible, but are very general and not for specific design
cases. They were designed for engineers to do preliminary designs and process specification sheets. The final
design must always be guaranteed for the service selected by the manufacturing vendor, but these guidelines will
greatly reduce the amount of up front engineering hours that are required to develop the final design. The guidelines
are a training tool for young engineers or a resource for engineers with experience.
This document is entrusted to the recipient personally, but the copyright remains with us. It must not be copied,
reproduced or in any way communicated or made accessible to third parties without our written consent.

KLM Technology
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Guidelines for Processing Plant
Solutions

HYDROTREATING

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July 2013

INTRODUCTION
General Design Consideration
Oil and natural gas are the most important raw materials for the organic chemical
industry. Oil is a complex mixture, its composition depends on the location where it is
produced. The most important components are:
1.
2.
3.
4.

Hydrocarbons (alkanes, alkenes, cycloalkanes, aromatics)

Sulphur compounds
Nitrogen compounds
Oxygenates.

There are many methods that may be employed to remove acidic components (primarily
H2S and CO2) and other impurities from hydrocarbon streams. The available methods
may be broadly categorized as those depending on chemical reaction, absorption,
adsorption or permeation.
Hydrotreaters are the most common process units in modern petroleum refineries.
hydrotreating catalysts represent 10% of the annual sales of the total market of
catalysts. In hydrotreating units, reactions that convert organic sulfur and nitrogen into
H2S and NH3 also produce light hydrocarbons.
In hydrotreating catalytic hydrogenation takes place in which double bonds are
hydrogenated and S, N, O and metals, are removed from molecules and aromatic
molecules are hydrogenated using hydrogen as a reactant. These processes use
catalysts based on transition metal sulfides.
The common objectives and applications of hydrotreating are listed below:
1. Naphtha (catalytic reformer feed pretreatment) : to remove sulfur, nitrogen, and
metals that otherwise would poison downstream noble metal reforming catalysts
2. Kerosene and diesel : to remove sulfur and to saturate olefins and some of the
aromatics, resulting in improved properties of the streams (kerosene smoke point,
diesel cetane number or diesel index) as well as storage stability
3. Lube oil : to improve the viscosity index, color, and stability as well as storage
stability
These design guideline are believed to be as accurate as possible, but are very general and not for specific design
cases. They were designed for engineers to do preliminary designs and process specification sheets. The final
design must always be guaranteed for the service selected by the manufacturing vendor, but these guidelines will
greatly reduce the amount of up front engineering hours that are required to develop the final design. The guidelines
are a training tool for young engineers or a resource for engineers with experience.
This document is entrusted to the recipient personally, but the copyright remains with us. It must not be copied,
reproduced or in any way communicated or made accessible to third parties without our written consent.

KLM Technology
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Guidelines for Processing Plant
Solutions

HYDROTREATING

Page 6 of 70

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July 2013

4. FCC feed : to improve FCC yields, reduce catalyst usage and stack emissions
5. Resids : to provide low sulfur fuel oils to effect conversion and/or pretreatment for
further conversion downstream.
Table 1: Feeds and product objectives for different kinds of hydrotreaters
Feed

Products from Hydrotreating

Naphtha

Catalytic reformer feed

Straight-run light gas oil

Kerosene, jet fuel

Straight-run heavy gas oil

Diesel fuel

Atmospheric residue

Lube base stock, low-sulfur fuel oil, RFCC* feed

Vacuum gas oil

FCC feed, lube base stock

Vacuum residue

RFCC* feed

FCC light cycle oil

Blend stocks for diesel, fuel oil

FCC heavy cycle oil

Blend stocks for diesel, fuel oil

Visbreaker gas oil

Blend stocks for diesel, fuel oil

Coker gas oil

FCC feed

Deasphalted oil

Lube base stock, FCC feed

*RFCC = residue FCC unit or reduced crude FCC unit, which are specially designed to process feeds
that contain high concentrations carbon-forming compounds.

The following chemical steps and/or reactions occur during the hydrotreating process
(depending on the impurities present):
1. Sulfur removal, also referred to as desulfurization or hydro-desulfurization (HDS) in
which the organic sulfur compounds are converted to hydrogen sulfide
2. Nitrogen removal, also referred to as denitrogenation or hydro-denitrogenation
(HDN) in which the organic nitrogen compounds are converted to ammonia
These design guideline are believed to be as accurate as possible, but are very general and not for specific design
cases. They were designed for engineers to do preliminary designs and process specification sheets. The final
design must always be guaranteed for the service selected by the manufacturing vendor, but these guidelines will
greatly reduce the amount of up front engineering hours that are required to develop the final design. The guidelines
are a training tool for young engineers or a resource for engineers with experience.
This document is entrusted to the recipient personally, but the copyright remains with us. It must not be copied,
reproduced or in any way communicated or made accessible to third parties without our written consent.

KLM Technology
Group
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Guidelines for Processing Plant
Solutions

HYDROTREATING

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(ENGINEERING DESIGN GUIDELINES) Rev: 02

July 2013

3. (Organo-metallic) metals removal, also referred to as hydro-demetallation or

hydrodemetallization, in which the organo-metals are converted to the respective
metal sulfides
4. Oxygen removal, in which the organic oxygen compounds are converted to water
5. Olefin saturation, in which organic compounds containing double bonds are
converted to their saturated homologues
6. Aromatic saturation, also referred to as hydro-dearomatization, in which some of the
aromatic compounds are converted to naphthenes
7. Halides removal, in which the organic halides are converted to hydrogen halides
i.

Sulfur removal

Sulfur removal occurs via the conversion to H2S of the organic sulfur compounds
present in the feedstock. This conversion is sometimes referred to as desulfurization or
hydro-desulfurization (HDS). The hydrotreated naphtha sulfur content should be
maintained well below the 0.5 weight ppm maximum. Commercial operation at 0.2
weight ppm sulfur or less in the hydrotreater product naphtha is common. In the
naphtha to atmospheric residue range, can all be classified as belonging to one of the
following six sulfur types: mercaptans, sulfides, di-sulfides, thiophenes, benzothiophenes, and di-benzo-thiophenes. The mechanism for the desulfurization reaction is
shown below

Typical sulfur removal reactions are shown below.

a.

(Mercaptan)

C-C-C-C-C-C-SH + H2

C-C-C-C-C-C + H2S

b.

(Sulfide)

C-C-C-S-C-C-C + 2H2

2 C-C-C + H2S

c.

(Disulfide)

C-C-C-S-S-C-C-C + 3H2

2 C-C-C + 2 H2S

These design guideline are believed to be as accurate as possible, but are very general and not for specific design
cases. They were designed for engineers to do preliminary designs and process specification sheets. The final
design must always be guaranteed for the service selected by the manufacturing vendor, but these guidelines will
greatly reduce the amount of up front engineering hours that are required to develop the final design. The guidelines
are a training tool for young engineers or a resource for engineers with experience.
This document is entrusted to the recipient personally, but the copyright remains with us. It must not be copied,
reproduced or in any way communicated or made accessible to third parties without our written consent.

KLM Technology
Group

HYDROTREATING

(ENGINEERING DESIGN GUIDELINES) Rev: 02

Practical Engineering
Guidelines for Processing Plant
Solutions

.d.

Page 8 of 70

July 2013

(Cyclic sulfide)

Figure 2: Sulfur Removal

Mercaptans sulphides
Dissulphides

Easy

Increasing difficulty

Thiophines

Benzothiophenes
Moderate difficulty

Substituete
dibenzothiophenes

Difficulty

4,6-Substituete
dibenzothiophenes

Extremely difficulty

Figure 2: Difficulty of desulphurization

These design guideline are believed to be as accurate as possible, but are very general and not for specific design
cases. They were designed for engineers to do preliminary designs and process specification sheets. The final
design must always be guaranteed for the service selected by the manufacturing vendor, but these guidelines will
greatly reduce the amount of up front engineering hours that are required to develop the final design. The guidelines
are a training tool for young engineers or a resource for engineers with experience.
This document is entrusted to the recipient personally, but the copyright remains with us. It must not be copied,
reproduced or in any way communicated or made accessible to third parties without our written consent.

KLM Technology
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Solutions

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ii. Nitrogen removal

Nitrogen is mostly found in the heaviest end of petroleum fractions in five- and six
member aromatic ring structures. Both the molecular complexity and quantity of
nitrogen containing molecules increases with increasing boiling range, making them
more difficult to remove. In denitrogenation, the aromatic is saturated first and then the
nitrogen is removed. This is shown below.

(A) Aromatic hydrogenation

(B) Hydrogenolysis

(C) Denitrogenation

Figure 3: Denitrogenation mechanism

These design guideline are believed to be as accurate as possible, but are very general and not for specific design
cases. They were designed for engineers to do preliminary designs and process specification sheets. The final
design must always be guaranteed for the service selected by the manufacturing vendor, but these guidelines will
greatly reduce the amount of up front engineering hours that are required to develop the final design. The guidelines
are a training tool for young engineers or a resource for engineers with experience.
This document is entrusted to the recipient personally, but the copyright remains with us. It must not be copied,
reproduced or in any way communicated or made accessible to third parties without our written consent.

KLM Technology
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Guidelines for Processing Plant
Solutions

HYDROTREATING

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iii. Oxygen removal

Most petroleum crudes contain low levels of oxygen. The oxygen-containing
compounds are converted, by hydrogenation, to the corresponding hydrocarbon and
water. The lower molecular weight compounds are easily hydrogenated, however, the
higher molecular weight compounds such furans can be difficult to remove. Shown
below are typical examples of de-oxygenation.
(A) Phenols

(B) Oxygenates

(C) Naphthenic acids

Figure 4: Oxygen removal mechanism

These design guideline are believed to be as accurate as possible, but are very general and not for specific design
cases. They were designed for engineers to do preliminary designs and process specification sheets. The final
design must always be guaranteed for the service selected by the manufacturing vendor, but these guidelines will
greatly reduce the amount of up front engineering hours that are required to develop the final design. The guidelines
are a training tool for young engineers or a resource for engineers with experience.
This document is entrusted to the recipient personally, but the copyright remains with us. It must not be copied,
reproduced or in any way communicated or made accessible to third parties without our written consent.

KLM Technology
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Oxygenate removal is favored by high pressure and high temperatures. For high feed
concentrations, lower liquid space velocities are required. Processing of such
compounds should be done with care. Complete oxygen removal is not normally
expected and may only be 50%. However, MTBE has been shown to be essentially
removed, but not completely, depending on the feed concentrations.
iv. Aromatic saturation
Saturation of aromatics is desirable for improvement of the properties of petroleum
products e.g. smoke point, diesel index, etc. The aromatics found in the naphtha to gas
oil boiling range are present as one, two, and three ring aromatics often referred to as
mono, di, and tri aromatics. Typical reactions are shown below
(A) One ring Toluene

(B) Two ring Naphthalene

(C) Three ring Phenanthrene

These design guideline are believed to be as accurate as possible, but are very general and not for specific design
cases. They were designed for engineers to do preliminary designs and process specification sheets. The final
design must always be guaranteed for the service selected by the manufacturing vendor, but these guidelines will
greatly reduce the amount of up front engineering hours that are required to develop the final design. The guidelines
are a training tool for young engineers or a resource for engineers with experience.
This document is entrusted to the recipient personally, but the copyright remains with us. It must not be copied,
reproduced or in any way communicated or made accessible to third parties without our written consent.

KLM Technology
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Solutions

HYDROTREATING

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July 2013

Figure 5: Aromatic saturation

v. Metals removal
Most metallic impurities occur in naphtha and middle distillates at ppm or even ppb
levels. They are present as organo-metallic compounds. In naphtha hydrotreating, the
most commonly occurring metals are arsenic from certain crude sources, mercury from
certain condensates and silicon from anti-foam agents used in visbreakers and cokers.
These compounds decompose in the hydrotreater and the metal is deposited on the
catalyst in the form of metal sulfide as shown below.
R-Me + H2S R-H2 + MeS
Removal of metals is essentially complete, at temperatures above 315C (600F), up
to a metal loading of about 2-3 weight percent of the total catalyst. Some Hydrotreating
catalysts have increased capability tp remove Silicon, up to 7-8 wt% of the total
catalyst. Above the maximum levels, the catalyst begins approaching the equilibrium
saturation level rapidly, and metal breakthrough is likely to occur. In this regard,
mechanical problems inside the reactor, such as channeling, are especially bad since
this results in a substantial overload on a small portion of the catalyst in the reactor.

These design guideline are believed to be as accurate as possible, but are very general and not for specific design
cases. They were designed for engineers to do preliminary designs and process specification sheets. The final
design must always be guaranteed for the service selected by the manufacturing vendor, but these guidelines will
greatly reduce the amount of up front engineering hours that are required to develop the final design. The guidelines
are a training tool for young engineers or a resource for engineers with experience.
This document is entrusted to the recipient personally, but the copyright remains with us. It must not be copied,
reproduced or in any way communicated or made accessible to third parties without our written consent.

KLM Technology
Group

HYDROTREATING

Practical Engineering
Guidelines for Processing Plant
Solutions

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vi. Olefin saturation

Hydrogenation of olefins is necessary to prevent fouling or coke deposits in
downstream units. Olefins can polymerize at the Catalytic Reforming Unit combined
feed exchanger and thus cause fouling. These olefins will also polymerize upstream of
the naphtha hydrotreating reactor and cause heat transfer problems. a Naphtha
Hydrotreating Unit must be approached with care because of the high exothermic heat
of reaction. The olefin reaction is detailed below.

a.

(Linear olefin)

b.

(Cyclic olefin)

C-C-C-C = C-C + H2

C-C-C-C-C-C (and isomers)

As a guide in the selection of the method of treating to be used, the following

characteristics of each are given:
A. Regenerated Caustic
The regenerated caustic method of removing methyl and ethyl mercaptans from LP-gas
or butane employs countercurrent contacting of the liquid with 10% sodium hydroxide
solution in a packed column. The caustic is regenerated in a stripping column by the
addition of open steam or by steam internally generated by a column heating element.
A condenser may be used to condense water vapors that go overhead with the liberated
mercaptan vapors. The condensate is returned to the stripping column to maintain
caustic concentration. An LP-gas stream containing 0.03% mercaptan sulfur can be
treated doctor sweet with volume ratios of hydrocarbon to caustic as high as 33 to 1.
These design guideline are believed to be as accurate as possible, but are very general and not for specific design
cases. They were designed for engineers to do preliminary designs and process specification sheets. The final
design must always be guaranteed for the service selected by the manufacturing vendor, but these guidelines will
greatly reduce the amount of up front engineering hours that are required to develop the final design. The guidelines
are a training tool for young engineers or a resource for engineers with experience.
This document is entrusted to the recipient personally, but the copyright remains with us. It must not be copied,
reproduced or in any way communicated or made accessible to third parties without our written consent.

KLM Technology
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Approximately six pounds of process steam per gallon of caustic are required for
regeneration at this hydrocarbon/ caustic volume ratio.
The diameter of the extractor is based upon the hydrocarbon throughput. A typical
design uses flow rates of 10-15 GPM/ft2 of cross-sectional area for a column packed
with 1-1/4 in. raschig rings. Other tower packing may be used and, if so, the above
throughput would be changed. The packed height is normally about 30 feet in two or
three packed sections to optimize dispersion of the hydrocarbon phase. An additional 8
- 10 feet of column height is required for distribution and settling areas.
1. Can handle large volumes of hydrocarbon.
2. Primarily for removing methyl and ethyl mercaptans.
3. Capable of producing a doctor-sweet product.
4. Reduces the total sulfur content of treated product.

Filter
Hydrocarbon
feed

Coalescer
Treated
product

Mixer

Interface

Caustic pump

Figure 6: Non regenerative caustic

These design guideline are believed to be as accurate as possible, but are very general and not for specific design
cases. They were designed for engineers to do preliminary designs and process specification sheets. The final
design must always be guaranteed for the service selected by the manufacturing vendor, but these guidelines will
greatly reduce the amount of up front engineering hours that are required to develop the final design. The guidelines
are a training tool for young engineers or a resource for engineers with experience.
This document is entrusted to the recipient personally, but the copyright remains with us. It must not be copied,
reproduced or in any way communicated or made accessible to third parties without our written consent.

KLM Technology
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B. Solid Copper Chloride

The copper chloride sweetening process can be used to sweeten natural gasoline. It is
a continuous process in which the mercaptan sulfur in the gasoline is converted to
disulfides in a reaction with copper chloride. To maintain the reactivity of the bed, water
should be added by injecting a small quantity of steam into the gasoline feed stream to
the treater, or bubbling a sidestream of gasoline through a small pot containing water
and returning it to the main stream.
Any hydrogen sulfide in the gasoline must be removed by a caustic wash before contact
with the bed. The "standard" bed depth is 7 feet with a maximum of 9 feet and a
minimum of 4 feet.
Air is added to the sour charge by means of a diffusing disc at the rate of 1 cu ft of air
(STP)/bbl of charge for each 0.01% mercaptan sulfur. If the mercaptan content of the
gasoline is high, the operating pressure must be increased to hold the additional air in
solution. The rate of air injection should be maintained as near to this figure as practical
since insufficient air will prevent complete reactivation of the reagent and excess air
may result in air binding of the treater vessel an extremely hazardous condition.
1. Can treat gasoline streams with relatively high mercaptan content.
2. Suited for small flow rate.
3. Sulfur content not reduced.
4. Water content must be only that of saturation.
5. Hydrogen sulfide must be removed ahead of contact with bed.
6. Excess regeneration oxygen may cause corrosion downstream of bed. Gasoline
with components that may be affected by oxygen, such as olefins, should not be
treated with this process.
7. Capable of producing doctor-sweet product.

These design guideline are believed to be as accurate as possible, but are very general and not for specific design
cases. They were designed for engineers to do preliminary designs and process specification sheets. The final
design must always be guaranteed for the service selected by the manufacturing vendor, but these guidelines will
greatly reduce the amount of up front engineering hours that are required to develop the final design. The guidelines
are a training tool for young engineers or a resource for engineers with experience.
This document is entrusted to the recipient personally, but the copyright remains with us. It must not be copied,
reproduced or in any way communicated or made accessible to third parties without our written consent.

KLM Technology
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HYDROTREATING

Practical Engineering
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Table 2: Standard solid copper reagent towers

Charge rate

Tower size

Bed volume

Reagent

Bbl/day

ft

Ft3

lb

187

2 x 10

21.9

1090

424

3 x 10

49.5

2475

752

4 x 10

88

4400

1177

5 x 10

137.5

6870

1500

5 x 12

176.5

8830

C. Batch Caustic Wash

Caustic wash can be used to remove hydrogen sulfide and/or lighter mercaptans from
LP-gas and gasoline. Liquid hydrocarbon and recirculated caustic (Ratio 1:0.5) are
mixed by means of a pump or static mixer and discharged to a settling tank where the
liquids separate. The size of the tank required is based on the retention time necessary
for complete separation of the gasolinecaustic emulsion. The retention time varies from
1-1/2 hours for heavy gasolines to 30 minutes or less for propane. A coalescing element
on the settling tank inlet can reduce the required retention time.
1. Can use a single wash.
2. Best suited for streams with low mercaptan content (if mercaptan removal is
important).
3. Primarily for removing trace amounts of hydrogen sulfide and methyl and ethyl
mercaptans.
4. Disposing of spent caustic can be a major consideration.
5. Relatively high caustic consumption per gallon of product.

These design guideline are believed to be as accurate as possible, but are very general and not for specific design
cases. They were designed for engineers to do preliminary designs and process specification sheets. The final
design must always be guaranteed for the service selected by the manufacturing vendor, but these guidelines will
greatly reduce the amount of up front engineering hours that are required to develop the final design. The guidelines
are a training tool for young engineers or a resource for engineers with experience.
This document is entrusted to the recipient personally, but the copyright remains with us. It must not be copied,
reproduced or in any way communicated or made accessible to third parties without our written consent.

KLM Technology
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Solutions

HYDROTREATING

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D. Solid Potassium Hydroxide

1. Low installation and operation costs.
2. Acts as a desiccant as well as removing the sulfur compounds.
3. Suitable for removing trace amounts of H2S.
E. Molecular Sieve
1. Can handle large or small streams.
2. Reduces total sulfur content by removing hydrogen sulfide, mercaptans, and
partially removing organic sulfur in the same adsorber vessel.
3. Will produce 1A copper-strip, doctor-sweet product.
4. Will dry in the same step with additional equipment.
5. Requires that the regeneration gas be made slightly sour by use of this stream to
strip sulfur compounds from the molecular sieve.
F. Merox
Sour product is treated with caustic containing Merox catalyst to extract the mercaptans.
The Merox solution is regenerated by mixing with air and oxidizing. Disulfides and
excess air are removed overhead. Existing extraction equipment with steam
regeneration can be adapted to the Merox process. The Merox solution gives a very
high degree of removal of mercaptans in a liquid stream. If more complete removal is
desired, Merox also provides a fixed-bed catalytic conversion of mercaptans to
disulfides.
1. Can handle large or small streams.
2. Eliminates problem of disposal of spent caustic.
3. Product is sweet when it leaves unit; no holding period is required.
4. Adds problems of sulfur compounds in regeneration air leaving the regenerator.
5. Low operating cost and investment requirement.
6. Ease of operation
These design guideline are believed to be as accurate as possible, but are very general and not for specific design
cases. They were designed for engineers to do preliminary designs and process specification sheets. The final
design must always be guaranteed for the service selected by the manufacturing vendor, but these guidelines will
greatly reduce the amount of up front engineering hours that are required to develop the final design. The guidelines
are a training tool for young engineers or a resource for engineers with experience.
This document is entrusted to the recipient personally, but the copyright remains with us. It must not be copied,
reproduced or in any way communicated or made accessible to third parties without our written consent.

KLM Technology
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HYDROTREATING

Page 18 of 70

(ENGINEERING DESIGN GUIDELINES) Rev: 02

July 2013

7. Limited Mercaptan treating not less than 5ppm

G. Other Processes
Others offer several processes for the removal of Na2S and/or mercaptans from light
hydrocarbon liquids. In all of these the key technology is use of a patented Fiber Film
bundle to achieve intimate contact between the hydrocarbon feed and the caustic
solution. The bundle is comprised of long continuous small diameter fibers placed in a
pipe. The caustic solution preferentially wets the fibers, creating a large interfacial area
for contact with the hydrocarbon liquid. The fiber bundles can be installed easily into
existing systems.
1. Can handle large or small streams of light hydrocarbon liquids.
2. Removes mercaptans and organic acids.
3. Uses a bundle of fibers to increase interfacial area between caustic and
hydrocarbon.
4. Sulfur compounds are present in regeneration air
The gas treating process can affect the design of the entire gas processing facility
including methods chosen for acid gas disposal and sulfur recovery, dehydration, liquids
recovery, liquids fractionation and liquid product treating. Some of the factors to be
considered in making a gas treating process selection are:
1. Air pollution regulations regarding sulfur compound disposal and/or Tail Gas
Clean Up (TGCU) requirements.
2. Type and concentration of impurities in the sour gas.
3. Specifications for the residue gas.
4. Specifications for the acid gas.
5. Temperature and pressure at which the sour gas is available and at which the
sweet gas must be delivered.
6. Volume of gas to be processed.
7. Hydrocarbon composition of the gas.
These design guideline are believed to be as accurate as possible, but are very general and not for specific design
cases. They were designed for engineers to do preliminary designs and process specification sheets. The final
design must always be guaranteed for the service selected by the manufacturing vendor, but these guidelines will
greatly reduce the amount of up front engineering hours that are required to develop the final design. The guidelines
are a training tool for young engineers or a resource for engineers with experience.
This document is entrusted to the recipient personally, but the copyright remains with us. It must not be copied,
reproduced or in any way communicated or made accessible to third parties without our written consent.

KLM Technology
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HYDROTREATING

Page 19 of 70

(ENGINEERING DESIGN GUIDELINES) Rev: 02

July 2013

8. Selectivity required for acid gas removal.

9. Capital cost and operating cost.
10. Royalty cost for process.
11. Liquid product specifications.
12. Disposal of byproducts considered hazardous chemicals.
A. Naphtha hydrotreating
Naphtha hydrotreating process is catalytic refining process employing a selected
catalyst and a hydrogen-rich gas stream. It decomposes organic sulfur, oxygen and
nitrogen compounds contained in hydrocarbon fractions. In addition, hydrotreating
removes organometallic compounds and saturates olefinic compounds.
The feed stream and the hydrogen gas stream are pre-heated by exchange with the hot
reactor effluent stream. The feed then enters the fired heater which brings it up to the
reactor temperatures (about 450F) and leaves the heater to enter the reactor which
operates at about 400450 psig. Sulfur is removed from the hydrocarbon as hydrogen
sulfide in this reactor and the reactor effluent is cooled to about 100F by heat exchange
with the feed. The cooled effluent is collected in a flash drum where the light hydrogen
rich gas is flashed off. This gas enters the suction side of the booster compressor which
delivers it to other hydrotreaters. The liquid phase from the drum is pumped to a
reboiled stabilizer. The overhead vapor stream from the stabilizer is routed to fuel while
the bottom product, cat reformer feed, is pumped to the cat reformer.
1. Naphtha hydrotreated primarily for sulfural removal. Mostly mercaptans (R-SH) and
sulfides (R-S-R), some disulfides (R-S-S-R) and thiophenes.
2. Cobalt molybdenum on alumina most common catalyst
3. Chemical hydrogen consumption typically 50 250 scf/bbl. For desulfurization
containing up to 1 wt% sulfur typically 70 100 scf/bbl. For significant nitrogen and
sulfur removal typically 250 scf/bbl.

These design guideline are believed to be as accurate as possible, but are very general and not for specific design
cases. They were designed for engineers to do preliminary designs and process specification sheets. The final
design must always be guaranteed for the service selected by the manufacturing vendor, but these guidelines will
greatly reduce the amount of up front engineering hours that are required to develop the final design. The guidelines
are a training tool for young engineers or a resource for engineers with experience.
This document is entrusted to the recipient personally, but the copyright remains with us. It must not be copied,
reproduced or in any way communicated or made accessible to third parties without our written consent.

KLM Technology
Group

Page 20 of 70

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(ENGINEERING DESIGN GUIDELINES) Rev: 02

July 2013

Naphtha Hydrotreating Process

1. Reactor typically at 200 psig and 700 F. Temperature increases to compensate for
decrease in catalyst activity.
2. Hydrogen recycle typically 2000 scf/bbl
3. Acid gas removal may not be directly incorporated into recycle gas loop. Overhead
vapor from fractionators to saturates gas plant to recover light hydrocarbons and
remove H2S.
4. Product fractionation: pentane/hexane overhead either to blending or isomerization,
bottoms to reformer.

Table 3: Catalysts for naphtha hydrotreating

Designator

Base

Form

Size
(in)

ABD
lb/ft3

Metals

Regeneration

S-6

Alumina

Sphere

1/16

36

Ni/Mo/Co

Steam/Air

S-9

Alumina

Sphere

1/16

38

Mo/Co

Steam/Air

S-12

Alumina

Extrudate

1/16

45

Mo/Co

Inert Gas

S-15

Alumina

Extrudate

1/16

45

Ni/Mo

Inert Gas

S-16

Alumina

Extrudate

1/16

45

NVMo

Inert Gas

S-18

Alumina

Sphere

1/16

45

Mo/Co

Inert Gas

S-19

Alumina

Extrudate

1/18 1/16

41-45

Ni/Mo

Inert Gas

S-120

Alumina

Cylinder

1/16

47

Mo/Co

Inert Gas

N-108

Alumina

Quadlobe

40

Mo/Co

Inert Gas

N-204

Alumina

Extrudate

1/20

46

Ni/Mo

Inert Gas

HC-K

Alumina

Quadlobe

1/20

57

Ni/Mo

Inert Gas

These design guideline are believed to be as accurate as possible, but are very general and not for specific design
cases. They were designed for engineers to do preliminary designs and process specification sheets. The final
design must always be guaranteed for the service selected by the manufacturing vendor, but these guidelines will
greatly reduce the amount of up front engineering hours that are required to develop the final design. The guidelines
are a training tool for young engineers or a resource for engineers with experience.
This document is entrusted to the recipient personally, but the copyright remains with us. It must not be copied,
reproduced or in any way communicated or made accessible to third parties without our written consent.

KLM Technology
Group
Practical Engineering
Guidelines for Processing Plant
Solutions

Page 21 of 70

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(ENGINEERING DESIGN GUIDELINES) Rev: 02

July 2013

Fresh feed

Makeup
hydrogen

Lights end
H2, C1 C3

Reactor

Recycle gas
compressor

Stripper

C3 C4

Separator
Product
Heater

C5 C12
Sour water

Figure 7: Naphtha hydrotreater

These design guideline are believed to be as accurate as possible, but are very general and not for specific design
cases. They were designed for engineers to do preliminary designs and process specification sheets. The final
design must always be guaranteed for the service selected by the manufacturing vendor, but these guidelines will
greatly reduce the amount of up front engineering hours that are required to develop the final design. The guidelines
are a training tool for young engineers or a resource for engineers with experience.
This document is entrusted to the recipient personally, but the copyright remains with us. It must not be copied,
reproduced or in any way communicated or made accessible to third parties without our written consent.

KLM Technology
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Guidelines for Processing Plant
Solutions

HYDROTREATING

Page 22 of 70

(ENGINEERING DESIGN GUIDELINES) Rev: 02

July 2013

B. Distillate Hydrotreating
1. All liquid distillate streams contain sulfur compounds that must be removed
2. Saturate olefins inn diesel to improve the cetane number
3. Hydrogenation at the high pressure produces small amounts of naphtha from
hydrocracking. It required to get at the embedded sulfur
4. Diesel hydrotreater stabilizer will have an upper sidestream draw producing the
naphtha which is recycled to motor gasoline processing.
Distillate Hydrotreating Process
1. Reactor typically at 800 F
2. Hydrogen recycle starts at 2000 scf/bbl, consumption 100 to 400 scf/bbl
3. Condition highly dependent upon feedstock.
4. Distillate (jet fuel and diesel) with 85% - 95% sulfur removal typically pressure about
300 psig, hydrogen consumption 200 300 scf/bbl.
5. Saturation of diesel for cetane number improvement has over 800 scf/bbl hydrogen
with pressure up to 1000 psig

These design guideline are believed to be as accurate as possible, but are very general and not for specific design
cases. They were designed for engineers to do preliminary designs and process specification sheets. The final
design must always be guaranteed for the service selected by the manufacturing vendor, but these guidelines will
greatly reduce the amount of up front engineering hours that are required to develop the final design. The guidelines
are a training tool for young engineers or a resource for engineers with experience.
This document is entrusted to the recipient personally, but the copyright remains with us. It must not be copied,
reproduced or in any way communicated or made accessible to third parties without our written consent.

KLM Technology
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Guidelines for Processing Plant
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HYDROTREATING

Page 23 of 70

(ENGINEERING DESIGN GUIDELINES) Rev: 02

July 2013

Recycle gas
compressor

Makeup
hydrogen

Absorber

Furnace

Lean amine

Reactor
Rich amine
High pressure
separator

H2 rich gas

Fresh feed
Product to
fractionation
Low pressure
separator

Figure 8: Distillate hydrotreater

These design guideline are believed to be as accurate as possible, but are very general and not for specific design
cases. They were designed for engineers to do preliminary designs and process specification sheets. The final
design must always be guaranteed for the service selected by the manufacturing vendor, but these guidelines will
greatly reduce the amount of up front engineering hours that are required to develop the final design. The guidelines
are a training tool for young engineers or a resource for engineers with experience.
This document is entrusted to the recipient personally, but the copyright remains with us. It must not be copied,
reproduced or in any way communicated or made accessible to third parties without our written consent.

KLM Technology
Group
Practical Engineering
Guidelines for Processing Plant
Solutions

HYDROTREATING

Page 24 of 70

(ENGINEERING DESIGN GUIDELINES) Rev: 02

July 2013

C. Gas Oil Hydrotreating

This process uses a recycled hydrogen stream to desulphurise a gas oil feed. A
hydrogen rich stream is introduced at the coil outlet prior to the mixed streams entering
the reactor. The reactor contains a bed of cobalt molybdenum on alumina catalyst and
desulfurization takes place over the catalyst with 7075% of the total sulfur in the oil
being converted to H2S.
The reactor effluent is cooled by the cold feed stream,water or air. This cooled effluent
enters a flash drum where the gas phase and liquid phase are separated. The gas
phase rich in H2S and hydrogen enters the recycle compressor. The gas stream then
enters an amine contactor where the H2S is absorbed into the amine and removed from
the system.
1. Catalytic cracker feedstocks (atmospheric gas oil, light vacuum gas oil, solvent
deasphalting gas oil) hydrotreated severely sulfur removal, opening of aromatic
rings, and removal of heavy metals
2. Desulfurization of gas oil can be achieved with a relatively modest decomposition of
structures
3. Gas oil can be contaminated with resins and asphaltenes. They deposited in
hydrotreater. Thus require catalyst replacement with a shorter run length than
determined by deactivation.
4. Guard chamber may be installed to prolong bed life
5. Nickel molybdenum catalyst system for severe hydrotreating
6. Gas oil units more expensive beause of more intensive hydrogenation, and required
more equipment such as quench, multi stage flash and more complex strippers.
Gas Oil Hydrotreating Process
1. Normally two reactor beds, so the temperature is rise
2. Hydrogen partial pressure requirements related to ring saturation and amount of
sulfur and other heteroatoms
a. For low ring saturation 300 psig may be sufficient
These design guideline are believed to be as accurate as possible, but are very general and not for specific design
cases. They were designed for engineers to do preliminary designs and process specification sheets. The final
design must always be guaranteed for the service selected by the manufacturing vendor, but these guidelines will
greatly reduce the amount of up front engineering hours that are required to develop the final design. The guidelines
are a training tool for young engineers or a resource for engineers with experience.
This document is entrusted to the recipient personally, but the copyright remains with us. It must not be copied,
reproduced or in any way communicated or made accessible to third parties without our written consent.

KLM Technology
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Guidelines for Processing Plant
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(ENGINEERING DESIGN GUIDELINES) Rev: 02

July 2013

b. 1200 psig will convert 25% ring saturation and somewhat less than 95% sulfur
removal.
c. Pressure as high as 1500 psig can achieve saturation of 30% of aromatic rings.
3. Hydrogen absorption of 300 scf/bbl could give about 80% sulfur removal and only
require 300 psig.

Makeup
hydrogen

Fresh feed

Lights end

Stripper

Reactor

Recycle gas
compressor

Steam

Separator
Product
Heater
Sour water

Figure 9: Oil hydrotreater

These design guideline are believed to be as accurate as possible, but are very general and not for specific design
cases. They were designed for engineers to do preliminary designs and process specification sheets. The final
design must always be guaranteed for the service selected by the manufacturing vendor, but these guidelines will
greatly reduce the amount of up front engineering hours that are required to develop the final design. The guidelines
are a training tool for young engineers or a resource for engineers with experience.
This document is entrusted to the recipient personally, but the copyright remains with us. It must not be copied,
reproduced or in any way communicated or made accessible to third parties without our written consent.

KLM Technology
Group

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(ENGINEERING DESIGN GUIDELINES) Rev: 02

July 2013

Table 4: Process condition of hydrotreating

Feedstock

Boiling
range
F

Temperature Hydrogen
pressure
F
psig

Hydrogen
rate
Scf/bbl

LHSV

Catalyst life
Month Bbl/lb

Naphtha

160

570

100

250

36

500

Kerosene

320

625

150

500

36

300

Gas Oil

465

645

150

1000

36

200

Vacuum gas
oil

660

680

450

1000

36

50

650

700

750

1500

0.5

12

Residue

Below is design guideline for hydrotreating

1. Hydrotreating reactions are carried out at temperatures of 290 to 430oC and
pressures ranging from 7 barg for naphtha to 140 barg for gas oils.
2. Two catalysts can be used on alumina; Co/Mo is more effective for S removal,
Ni/Mo is More effective for N removal and aromatics saturation
3. When hydrotreating heavier fractions a guard reactor is required
4. Metals (particularly nickel and vanadium) are generally bound in large molecules
requires catalyst with large pores.
5. Removed nickel and vanadium are bound up with sulphur and remain on the
catalyst surface
6. Guard reactors have layers of catalyst starting with large pore size and decreasing
pore size through the reactor
7. The hydrogen consumption increases depending on the severity and feedstock.
Table 1 show the hydrogen consumption for typical feedstock

These design guideline are believed to be as accurate as possible, but are very general and not for specific design
cases. They were designed for engineers to do preliminary designs and process specification sheets. The final
design must always be guaranteed for the service selected by the manufacturing vendor, but these guidelines will
greatly reduce the amount of up front engineering hours that are required to develop the final design. The guidelines
are a training tool for young engineers or a resource for engineers with experience.
This document is entrusted to the recipient personally, but the copyright remains with us. It must not be copied,
reproduced or in any way communicated or made accessible to third parties without our written consent.

KLM Technology
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Solutions

HYDROTREATING

Page 27 of 70

(ENGINEERING DESIGN GUIDELINES) Rev: 02

July 2013

Table 5: Hydrogen consumption for typical feedstock

Application
Desulphurization of SR naphtha

Typical H2 use
(Nm3/bbl)
1.5 4

Desulphurization of cracked naphtha

39

Desulphurization of kerosene

8 11

Light desulphurization of diesel

8 11

Deep desulphurization of diesel

9 18

Desulphurization of heavy gas oil

14 28

These design guideline are believed to be as accurate as possible, but are very general and not for specific design
cases. They were designed for engineers to do preliminary designs and process specification sheets. The final
design must always be guaranteed for the service selected by the manufacturing vendor, but these guidelines will
greatly reduce the amount of up front engineering hours that are required to develop the final design. The guidelines
are a training tool for young engineers or a resource for engineers with experience.
This document is entrusted to the recipient personally, but the copyright remains with us. It must not be copied,
reproduced or in any way communicated or made accessible to third parties without our written consent.

KLM Technology
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July 2013

DEFINITIONS
Absorption: A separation process involving the transfer of a substance from a gaseous
phase to a liquid phase through the phase boundary.
Acid Gases: Impurities in a gas stream usually consisting of CO2, H2S, COS, RSH,
and SO2. Most common in natural gas are CO2, H2S and COS.
Adsorption: The process by which gaseous components adhere to solids because of
their molecular attraction to the solid surface.
Alkanolamine: An organic nitrogen bearing compound related to ammonia having at
least one, if not two or three of its hydrogen atoms substituted with at least one, if not
two or three linear or branched alkanol groups where only one or two could also be
substituted with a linear or branched alkyl group ( i.e. methyldiethanolamine MDEA ).
The number of hydrogen atoms substituted by alkanol or alkyl groups at the amino site
determine whether the alkanolamine is primary, secondary or tertiary.
Antifoam: A substance, usually a silicone or a long-chain alcohol, added to the treating
system to reduce the tendency to foam.
Aromatic molecules - Any of a large class of organic compounds whose molecular
structure includes one or more planar rings of atoms, usually but not always six carbon
atoms. The ring's carbon-carbon bonds (bonding) are neither single nor double but a
type characteristic of these compounds, in which electrons are shared equally with all
the atoms around the ring in an electron cloud.
Catalyst - A substance, usually used in small amounts relative to the reactants, that
modifies and increases the rate of a reaction without being consumed in the process.
Catalytic - Causing a chemical reaction to happen more quickly
Cetane number - The performance rating of a diesel fuel, corresponding to the
percentage of cetane in a cetane-methylnaphthalene mixture with the same ignition
performance. A higher cetane number indicates greater fuel efficiency. Also called
cetane rating.

These design guideline are believed to be as accurate as possible, but are very general and not for specific design
cases. They were designed for engineers to do preliminary designs and process specification sheets. The final
design must always be guaranteed for the service selected by the manufacturing vendor, but these guidelines will
greatly reduce the amount of up front engineering hours that are required to develop the final design. The guidelines
are a training tool for young engineers or a resource for engineers with experience.
This document is entrusted to the recipient personally, but the copyright remains with us. It must not be copied,
reproduced or in any way communicated or made accessible to third parties without our written consent.

KLM Technology
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July 2013

Chelate: An organic molecule in which a central metallic ion is held in a coordination

compound.
Claus Process: The process in which one third of the H2S is burned to SO2 which is
then reacted with the remaining H2S to produce elemental sulfur.
Deasphalting - The process of removing asphalt from petroleum fractions.
Degradation Products: Impurities in a treating solution that are formed from both
reversible and irreversible side reactions.
Denitrogenation - Removal of nitrogen dissolved in the bloodstream and body tissues
by breathing 100% oxygen for an extended period.
Desulfurization - The process of removing sulfur from a substance, such as flue gas or
crude.
Furans - One of a group of colorless, volatile, heterocyclic organic compounds
containing a ring of four carbon atoms and one oxygen atom, obtained from wood oils
and used in the synthesis of furfural and other organic compounds.
Grain: A unit of mass where one pound is equivalent to 7,000 grains and a specification
of 0.25 grain of H2S per 100 SCF is equivalent to an H2S concentration of 4.0 ppmv.
Hydrotreating - Oil refinery catalytic process in which hydrogen is contacted with
petroleum intermediate or product streams to remove impurities, such as oxygen, sulfur,
nitrogen, or unsaturated hydrocarbons.
LHSV (Liquid hourly space velocity) - Usually feed flow rate divided by catalyst mass
or volume in heterogeneous catalysis
Maldistribution - Non-uniform liquid/gas flow leads to poor catalyst utilization, resulting
in lower than expected activity and cycle length.
Mercaptans - A group of sulfur-containing organic chemical substances. They smell like
rotting cabbage, and are, for the most part, what make pulp mills smell like pulp mills. If
mercaptans are in the air, even at low concentrations, they are very noticeable.
These design guideline are believed to be as accurate as possible, but are very general and not for specific design
cases. They were designed for engineers to do preliminary designs and process specification sheets. The final
design must always be guaranteed for the service selected by the manufacturing vendor, but these guidelines will
greatly reduce the amount of up front engineering hours that are required to develop the final design. The guidelines
are a training tool for young engineers or a resource for engineers with experience.
This document is entrusted to the recipient personally, but the copyright remains with us. It must not be copied,
reproduced or in any way communicated or made accessible to third parties without our written consent.

KLM Technology
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(ENGINEERING DESIGN GUIDELINES) Rev: 02

July 2013

Naphtha - Normally refers to a number of flammable liquid mixtures of hydrocarbons,

i.e., a component of natural gas condensate or a distillation product from petroleum,
coal tar or peat boiling in a certain range and containing certain hydrocarbons.
Physical Solvent: A liquid capable of absorbing selected gas components by solubility
alone without associated chemical reactions.
Polythionic acid - an oxoacid which has a straight chain of sulfur atoms and has the
chemical formula H2SnO6
ppmv: A volume concentration of a species in a bulk fluid measured in parts per million.
Residence Time: The time period for which a fluid will be contained within a specified
volume.
Selective Treating: Preferential removal of one acid gas component, leaving at least
some of the other acid gas components in the treated stream.
Sour Gas: Gas containing undesirable quantities of hydrogen sulfide, mercaptans
and/or carbon dioxide.
Space velocity - The relationship between feed rate and reactor volume in a flow
process; defined as the volume or weight of feed (measured at standard conditions) per
unit time per unit volume of reactor (or per unit weight of catalyst).
Threshold Limit Value: The amount of a contaminant to which a person can have
repeated exposure for an eight hour day without adverse effects.

These design guideline are believed to be as accurate as possible, but are very general and not for specific design
cases. They were designed for engineers to do preliminary designs and process specification sheets. The final
design must always be guaranteed for the service selected by the manufacturing vendor, but these guidelines will
greatly reduce the amount of up front engineering hours that are required to develop the final design. The guidelines
are a training tool for young engineers or a resource for engineers with experience.
This document is entrusted to the recipient personally, but the copyright remains with us. It must not be copied,
reproduced or in any way communicated or made accessible to third parties without our written consent.

KLM Technology
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NOMENCLATURE

A
Abed
AC
AC/VS
D0S
dc
dR
Ds
Eff
F
FH2
GH2
H2cons
H2purity
H2S
Lbed
LR
%N
MF
MH2
Mmix
MW
MW avg
P
P
Purity
Recycle
%S
SCV
SCL
t
T
Tc
Vbed

Deactivation rate, F/bpp

cross sectional of bed, m
Catalyst area, cm
Outer surface / unit volume solid, cm/cm
Initial desulfurization activity
Diameter of catalyst, cm
diameter, m
Desulfurization activity
% S & N removes, %
Feed rate, bbl/day
H2 rate, scf/bbl
Feed rate H2, scf/hr
H2 Consumption, kg/hr
Mole fraction of hydrogen purity
H2S formed, kg moles/hr
length bed, m
reactor length, m
%wt nitrogen in feed, %
Molar weight feed rate, kg moles/hr
Molar feed rate H2, Kg moles/hr
Molar mix feed rate, kg moles/hr
Feed Molecular weight of Feed, kg/kg moles
Avg molecular weight H2 in stream, kg/kg moles
Reactor operating pressure, atm
Pressure drop reactor, bar
H2 purity,%
Recycle gas to reactor, Nm3/hr
%wt sulfur in feed, %
Space velocity at standard condition (gas feed)/LHSV, hr -1.
Space velocity at standard condition (liquid feed)/GHSV, hr -1.
residence time, min
Temperature, K
Catalyst life, bpp
Bed volume, m

These design guideline are believed to be as accurate as possible, but are very general and not for specific design
cases. They were designed for engineers to do preliminary designs and process specification sheets. The final
design must always be guaranteed for the service selected by the manufacturing vendor, but these guidelines will
greatly reduce the amount of up front engineering hours that are required to develop the final design. The guidelines
are a training tool for young engineers or a resource for engineers with experience.
This document is entrusted to the recipient personally, but the copyright remains with us. It must not be copied,
reproduced or in any way communicated or made accessible to third parties without our written consent.

KLM Technology
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VF
vS
VVS
WC
WF
WH2
Wmix

HYDROTREATING

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(ENGINEERING DESIGN GUIDELINES) Rev: 02

July 2013

Volume feed rate, m/hr

Superficial velocity, m/s
Volumeric flow rate at standard condition, m/hr
catalyst mass, kg
Weight of feed, kg/hr
Weight of H2, Kg/hr
Weight of combination feed, kg

Greek letters
Feed
G

Density of Feed, kg/m3

Molar gas density, kg moles/m

These design guideline are believed to be as accurate as possible, but are very general and not for specific design
cases. They were designed for engineers to do preliminary designs and process specification sheets. The final
design must always be guaranteed for the service selected by the manufacturing vendor, but these guidelines will
greatly reduce the amount of up front engineering hours that are required to develop the final design. The guidelines
are a training tool for young engineers or a resource for engineers with experience.
This document is entrusted to the recipient personally, but the copyright remains with us. It must not be copied,
reproduced or in any way communicated or made accessible to third parties without our written consent.