The project originally included a pre-treatment unit (PTU) to process the UCO before entering the hydrotreater. However, due to difficulty in sourcing feedstock for the PTU and economics, it was decided to outsource the pretreatment process and import pretreated feedstock to the refinery.

UCO Pre-treatment Unit Concept Study

• Optioneering study to identify existing equipment that could be repurposed.
• Development of the process flow scheme, heat & mass balance, and plot plan.
• Preparation of safety, environmental, and operating philosophies.
• Identification of pre-treatment vendor scope and interfaces.
• Civil & structural calculations and assessment for the pre-treatment unit.
• Provision of a HAZID chairperson and technical experts to review the project basis.
• Comprehensive class 5 Cost Estimate of several options, to assist the client in the phase gate approval.

UCO Pre-treatment Unit FEED and Detailed Design

• Design of the facilities outside of the pre-treatment unit, including tank refurbishment, new pump, pipework design, electrical supply, and control system integration.
• Civil design for the pre-treatment unit, including new tankage/silos and access routes.
• Mechanical design support for the pre-treatment unit.
• Provision of project management support at the client site and Vendor management for the pre-treatment unit.

UCO Co-processing Concept Study

• Identification of suitable tie-in points and existing equipment that could be repurposed.
• Preliminary design of the truck and rail unloading facilities.
• Review of filtration and heating requirements.
• Investigation of water wash options to minimise corrosion.
• Preparation of process simulations to enable a heat & mass balance to be prepared and to review possible options for improved heat integration.
• Updates to P&IDs and attendance at HAZOP.
• Preparation of +/-30% cost estimate.

Corrosion Mitigation Overview

• Addressed HCl corrosion by implementing water-wash injection facilities to dilute the acid and bring the pH back into a less corrosive range.
• Conducted calculations of salt sublimation temperature to determine locations where NH4Cl salts could form and implemented water wash facilities at these points.

• Corrosion
  Specialised refinery experience was essential in identifying and mitigating corrosion issues.
• Uncertainty of UCO feedstock chlorine content
  The project found a balance between feedstock variability and Capex.
  
• Reuse and refurbishment of equipment
  Site experience was crucial in identifying existing equipment that could be reused and refurbished.