SPECIAL TOPIC : OIL & GAS
Valve Innovations Enhance Residue Hydrocracking Performance
Explore how new valve technologies are improving residue hydrocracking processes , enhancing safety , efficiency and reactor performance in refinery operations .
By Duke Tran , P . Eng MBA and Luc Vernhes , P . Eng ., Ph . D – Velan
Recent advancements in valve design and materials have led to substantial improvements in residue hydrocracking reactors ( RHRs ) operations . These innovations address key issues such as thermal shock , corrosion and the need for precise control in these critical processes . For example , thermal sleeves utilizing advanced materials and manufacturing techniques , like ceramic coatings and 3D printing , have emerged as effective solutions for protecting valves from rapid temperature fluctuations . These designs minimize heat transfer through conduction , convection and radiation , significantly extending valve lifespan and reducing maintenance requirements .
Gasket technology has also evolved to meet the demands of RHR environments . High-performance gaskets , including those employing noble metal plating , offer enhanced corrosion resistance , thermal stability and durability . These advancements ensure better sealing performance and reduced risk of leakage , which is crucial for both safety and efficiency in hydrocracking operations .
Furthermore , the integration of automationmsystems , such as Programmable Logic Controllers ( PLCs ) and advanced control panels , has revolutionized valve management in RHRs . These systems enable precise control , efficient purging , optimal heating cycles and enhanced safety protocols . The combination of robust hardware and sophisticated software allows for real-time monitoring and adjustment , minimizing human error and maximizing process efficiency .
Thermal Shock Protection in Valve Design
Thermal shock poses a significant challenge in residue hydrocracking operations , where valves undergo rapid temperature fluctuations . During a typical process cycle , catalyst valves may experience numerous thermal cycles ranging from ambient temperature to over 800 ° F ( 427 ° C ).
These sudden changes cause different parts of the valve body to expand or contract at varying rates , potentially leading to severe mechanical stresses , cracking or complete valve failure .
To address this critical issue , valve manufacturers like Velan have developed advanced thermal protection solutions . One notable innovation in this field is the implementation of Hexashield™ ceramic-coated , 3D-printed thermal sleeves .
These sleeves provide a robust thermal barrier that effectively absorbs and dissipates rapid temperature changes , thereby protecting the integrity of the valve body .
The effectiveness of these thermal sleeves lies in their ability to mitigate all three mechanisms of heat transfer : 1 . Conduction : Traditional solid metal sleeves readily conduct heat . In contrast , modern 3D-printed doublewalled thermal sleeves create an insulating space between the walls , significantly reducing heat conduction . This design principle is similar to that used in vacuum-insulated containers .
2 . Convection : The double-wall design also minimizes convective heat transfer . By preventing direct contact between the high-temperature process fluid and critical areas inside the valve body , these sleeves effectively eliminate a major pathway for heat movement .
3 . Radiation : Advanced thermal sleeves often incorporate ceramic coatings on
Velan high performance ANSI-2500 isolation valves for residue hydrocracking
their inner surface . These coatings are designed to reflect radiant heat back towards the process fluid , further minimizing heat transfer to the valve body .
The combination of 3D printing technology and ceramic coating in thermal sleeve design offers several advantages :
• Precision manufacturing : 3D printing allows for the creation of complex , double-walled structures with precise specifications , optimizing thermal protection .
• Enhanced thermal resistance : Ceramic coatings provide an additional layer of thermal insulation , improving overall heat management .
• Corrosion and fouling resistance : Many ceramic coatings also offer excellent resistance to corrosion and fouling , enhancing the durability and longevity of the sleeve in harsh process environments .
These innovations in thermal protection technology enable valves to withstand the extreme conditions typical in residue hydrocracking processes , significantly improving reliability and reducing maintenance requirements .
Advanced Gasket Technology in Severe Service Applications
In residue hydrocracking processes , where extreme temperatures , high pressures , corrosive substances and significant mechanical stress are commonplace , the reliability and durability of gaskets are paramount . Recent advancements in gasket technology , such as Velan ’ s Securaring™ gold-plated gaskets , have emerged as critical components in these demanding environments , offering exceptional performance and longevity .
Gold-plated gaskets represent a significant leap forward in sealing technology for severe service applications . Their unique properties address several key challenges in hydrocracking processes : gases , makes these gaskets ideal for environments where standard materials rapidly degrade . This resistance ensures long-term seal integrity in the presence of corrosive process fluids . 2 . Thermal stability : Gold maintains its properties across a wide temperature range , from cryogenic conditions to extreme heat . This stability is crucial in hydrocracking processes , where temperatures can fluctuate dramatically , ensuring consistent sealing performance under varying thermal conditions .
3 . Chemical inertness : The non-reactive nature of gold provides a robust barrier against chemical attacks that could compromise the seal . This inertness is particularly valuable in processes involving complex hydrocarbon mixtures and catalysts .
4 . Electrical conductivity : In highly combustible environments , the electrical conductivity of gold offers an additional safety benefit . By facilitating the dissipation of static electricity , these gaskets help prevent spark generation , reducing the risk of fires or explosions .
5 . Durability : Gold-plated gaskets exhibit excellent wear resistance , crucial for maintaining seal integrity in high pressure and high-stress environments . This durability translates to extended service life and reduced maintenance frequency .
1 . Corrosion resistance : Gold ’ s inherent resistance to corrosion , even when exposed to aggressive chemicals and
Velan purge control panel
4 Valve World Americas | February 2025 • www . valve-world-americas . net