Course Overview
What is the hydrotreating process in a petroleum refinery? Crude oil refining essentially consists of separation stages that produce valuable products. Consequently, the main challenge during crude oil refining is to manage the multicomponent feed and product streams. What is the purpose of hydrotreating? Generally, the crude oil is refined, consists of gases, light/heavy naphtha, kerosene, light gas oil, heavy gas oil, and residue. This complex mixture ultimately gets separated and broken down into valuable product streams like fuel gas, liquefied petroleum gas, gasoline, jet fuel, kerosene, auto diesel, lubricants, etc.
This Zoe training course will give you comprehensive Hydrotreating & Hydrocracking Process Technology training. The course is developed to cover the basic knowledge, as well as, the advanced concepts of hydrotreating and hydrocracking. The course will also include an overview of the latest literature related to the material, energy balance, and design of hydro processors.
Why This Course Is Required?
Hydrotreating and hydrocracking are foundational refinery processes used worldwide to meet increasingly stringent fuel quality and emission standards where real-world deployments show these hydrogen-based processes are essential for removing sulfur, nitrogen, metals, and aromatics enabling compliance with Euro 5/6 and other global regulations for clean fuels. The complexity of modern refinery operations requires specialized knowledge in advanced catalyst management and process optimization where refineries using advanced hydrotreating catalysts and flexible hydrocracking configurations realize improved yields, stable operations, and major reductions in operational costs and environmental impact while ensuring competitive positioning through systematic implementation of cutting-edge technologies and robust process control systems.
The essential need for comprehensive training in hydrotreating and hydrocracking is underscored by its critical role in yield and profit maximization where proper understanding of advanced hydrocracker designs and revamped units is crucial for increasing flexibility for feedstocks, boosting middle distillate output, and optimizing both product slate and profitability. Hydroprocessing professionals must master the principles of regulatory compliance and reliability, understand technology and safety improvements frameworks, and apply proper process management methodologies to ensure organizations achieve ultra-low sulfur requirements, optimized catalyst selection, and competitive advantage through robust safety, reduced deactivation, and effective catalyst regeneration systems that save millions on hydrogen costs while minimizing shutdowns.
Research demonstrates that hydrotreating and hydrocracking are foundational refinery processes used worldwide to meet increasingly stringent fuel quality and emission standards, with real-world deployments showing these hydrogen-based processes are essential for removing sulfur, nitrogen, metals, and aromatics enabling compliance with global regulations, while refineries using advanced catalysts and flexible configurations realize improved yields, stable operations, and major reductions in operational costs and environmental impact.
Course Objectives
The main objectives of this course are as follows:
- Grasp the essence of hydrotreatment processes
- Develop a deep understanding of mass/hydrogen/energy balance in refining processes
- Gain in-depth knowledge of the state-of-the-art of material and energy integration in hydroprocessing
- Evaluate various flow schemes for both, hydrotreating & hydrocracking
- Adjust operational and design parameters to achieve enhanced hydrogen conversion
- Enhance knowledge of the underlying chemistry, reaction kinetics, catalysis, green production, and ecological challenges of hydro processes
- Analyse optimization of hydrotreatment units and their operation
- Detect potential deficiencies by troubleshooting
- Advanced competency in flexible hydrocracking configurations and dual-service reactor designs
- Expertise in advanced catalyst selection and regeneration technologies
- Enhanced understanding of process integration with upstream vacuum distillation units
- Skills in hydrogen balance optimization and steam/methane reforming integration
- Proficiency in troubleshooting deactivation issues and implementing safety improvements
Master hydrotreating and hydrocracking excellence and drive refining success. Enroll today to become an expert in Hydrotreating and Hydrocracking Petroleum Refining Process!
Training Methodology
This collaborative Hydrotreating and Hydrocracking Petroleum Refining Process program will comprise the following training methods:
The training framework includes:
- Expert-led lectures delivered by industry professionals with extensive hydroprocessing experience
- Interactive seminars and presentations that foster collaborative learning and process understanding
- Group discussions and assignments that reinforce hydroprocessing concepts and optimization strategies
- Case studies and functional exercises that simulate real-world refinery operational scenarios
- Hands-on training with process simulation tools and reactor design methodologies
This immersive approach fosters practical skill development and real-world application of hydroprocessing principles through comprehensive coverage of catalyst management, process optimization, and advanced troubleshooting techniques.
This training format was conceptualised by Zoe Talent Solutions and is used for all its courses. It is called the Do–Review–Learn–Apply Model, creating a structured learning journey that transforms hydroprocessing knowledge into operational excellence through systematic practice and implementation.
Who Should Attend?
This Hydrotreating and Hydrocracking Petroleum Refining Process course is designed for:
- Process and development engineers
- Plant managers
- Operational engineers / control engineers
- Technicians from the refining industry
- Refining Industry – designers & researchers
- The personnel from other walks of life who are eager to gain information about the hydro-conversion processes
- The course is equally suitable for both experts and beginners
- Catalyst specialists and reactor design engineers
- Process optimization specialists and troubleshooting experts
- Environmental compliance and sustainability professionals
Organisational Benefits
Considering the importance of this course for organisations, their delegates can benefit in the following ways:
- Able to identify the areas of improvement in the hydroprocessing units
- Equip themselves with the state of the art knowledge of hydroprocessing
- Understand the underlying kinetics and chemistry of the hydrocracking and hydro-treatment methods enabling the implementation of the best practices, optimization of existing methods, and troubleshooting any issues
- Conduct risk assessment and address challenges faced by the internees or newly hired staff to prevent loss of organisational resources
- Get knowledge of the advanced tools that can enhance the operation and maintenance of hydro-treatment and hydrocracking units of a petroleum refining plant
- Develop an understanding of the maintenance and safe handling during the operation of hydro-treatment and hydro-cracking in day-to-day activities
- Develop the ability to guide others on the operational aspects and troubleshooting of the hydro-processing units
- Significantly enhanced yield and profit maximization through companies leveraging new hydrocracker designs and revamped units that increase flexibility for feedstocks and boost middle distillate output
- Better regulatory compliance and reliability through refineries with advanced hydroprocessing that meet ultra-low sulfur and winter-grade requirements through optimized catalyst selection
- Improved technology and safety improvements through pioneering hydroprocessing technologies that have evolved for robust safety and reduced deactivation
- Strengthened competitive positioning through enhanced product quality, profitability optimization, and effective catalyst regeneration at scale while saving millions on hydrogen costs and minimizing shutdowns
Studies show that organizations implementing comprehensive hydrotreating and hydrocracking training achieve significantly enhanced yield and profit maximization as companies like Shell, Hyundai Oilbank, and Grupa LOTOS have leveraged new hydrocracker designs and revamped units to increase flexibility for feedstocks, boost middle distillate output, and optimize both product slate and profitability, better regulatory compliance and reliability through refineries with advanced hydroprocessing meeting ultra-low sulfur and winter-grade requirements through optimized catalyst selection and reactor configurations saving millions on hydrogen costs, and improved technology and safety improvements as companies like Chevron Lummus Global have pioneered hydroprocessing technologies for clean fuels with systems evolved for robust safety, reduced deactivation, and effective catalyst regeneration.
Empower your organization with hydrotreating and hydrocracking expertise. Enroll your team today and see the transformation in refining performance and operational efficiency!
Personal Benefits
Through this course, participants can benefit in a variety of ways, including but not limited to the following:
- Develop a basic understanding of the hydroprocessing
- Acknowledge the significance and methodology of impurities removal in petroleum refining
- Enhance knowledge of the latest catalysts being used in the hydroprocessing
- Develop expertise to assess current hydroprocessing units, assuring proper management, and development of appropriate handling guidelines
- Improve awareness concerning the existing documentation on hydrocracking and hydro-treating to ensure its adherence to the required standards
- Obtain insight into potential hazards that might compromise the hydro-process units’ capacity and operational capability
- Able to train others on key operations and troubleshooting requirements of hydrotreating and hydrocracking units of petroleum refining
- Advanced expertise in hydroprocessing technology and catalyst management
- Enhanced career prospects and marketability in refining and petrochemical sectors
- Improved ability to lead hydroprocessing teams and manage complex refinery operations
- Greater competency in regulatory compliance and environmental stewardship
- Increased capability to mentor and develop other hydroprocessing professionals
- Enhanced understanding of emerging hydroprocessing technologies and sustainability practices
Course Outline
The course content has been organised as follows:
Module 1: Introduction
- Impurities in petroleum cuts and products
- Impact of petroleum impurities on health, environment and on other refining processes
- Recent regulations and future trends
- Quality standards of refining product stream in terms of permissible impurities
- Sulfur, nitrogen, oxygen, and metal impurities in petroleum feedstocks
- Environmental impact and emission control requirements for clean fuel regulations
- Ultra-low sulfur diesel (ULSD) specifications with less than 10 ppm sulfur content
- Impact of impurities on downstream catalyst performance and equipment corrosion
Module 2: The Basics
- Basics of material, energy interaction, and hydrogen balance in refining processes
- State-of-the-Art of Material and Energy Integration
- Basics of crude refining processes
- Products’ Specifications and Characteristics
- Process Design/Optimization and Heat Integration Schemes
- Environmental and Economic Issues
- Heat exchange network design for energy efficiency and cost optimization
- Hydrogen consumption and balance calculations for hydroprocessing operations
- Material balance fundamentals for reactor and separation design
- Economic considerations including capital and operating cost optimization
Module 3: Hydrotreatment – Fundamentals and Principles
- Basics of hydroconversion processes and hydrogen generation
- Process Flow Schemes
- Process Chemistry and Kinetics
- Catalysis
- Operating Conditions, Principles, and Design Considerations
- Hydrogen Requirements for Hydrotreatment
- Catalytic reaction mechanisms for sulfur removal through hydrodesulfurization (HDS)
- Cobalt-molybdenum and nickel-molybdenum catalyst systems on alumina support
- Operating conditions: 290-430°C temperature and 7-180 bar pressure
- Hydrogen consumption rates and makeup hydrogen requirements
Module 4: Hydrotreatment – Advanced Processing
- Reactors Design
- Atmospheric Residue Desulphurization
- Saturation of Benzene in Gasoline
- Possible process optimization for cost-saving in terms of raw material and energy utilization
- Fixed-bed reactor design with downflow trickle-bed operation
- Reactor internals and catalyst loading configurations
- Benzene saturation for gasoline quality improvement and environmental compliance
- Heat integration and energy recovery from reactor effluent streams
Module 5: Hydrocracking – Fundamentals and Principles
- Feed Stocks and Products
- Process Chemistry/Kinetics
- Catalysts/Deactivation and Regeneration
- Quality of product stream and conversion
- Process layout, catalysis, process parameters
- Reactors Technology for Hydrocracking
- Single Stage Hydrocracking Process Technology
- Bifunctional catalysts combining acid function (zeolites) and metal function (noble metals)
- Heavy feedstock conversion to lighter products: diesel, jet fuel, and gasoline
- Operating conditions: 400-450°C temperature and up to 200 bar pressure
- Single-stage process for moderate conversion with simplified operation
Module 6: Hydrocracking – Advanced Processing
- Two-Stage Hydrocracking Process Technology
- Process Design Features
- Hydrogen Balance and Consumption
- Scope for Process Integration Improvements
- Hydrogen Balance/Integration and Management
- Steam/Methane Reforming
- Two-stage configuration with hydrotreating followed by hydrocracking
- Higher conversion rates (60-85%) with improved product selectivity
- Hydrogen recycle systems and makeup hydrogen integration
- Steam methane reforming for hydrogen production and supply
Module 7: Commercial Considerations In Hydroprocessing
- Classification and characteristics
- Catalyst presulfiding
- Catalyst deactivation and regeneration
- Process design/mechanical design features
- Catalyst presulfiding procedures using hydrogen sulfide or sulfur compounds
- Deactivation mechanisms including coke formation and metal poisoning
- Regeneration procedures and catalyst lifecycle management
- Economic evaluation of catalyst replacement versus regeneration
Module 8: Commercial Hydrocracking
- GC sampling
- Hydrocracking feedstock
- Pre-treatment considerations
- Review of hydrocracking reactions/heats of reaction
- Hydrocracking process configurations
- Reactor design
- Process variables and catalysts
- Catalyst deactivation and regeneration
- Hydrocracking yields and product properties
- Gas chromatography analysis for product quality monitoring
- Feedstock preparation including hydrotreating for impurity removal
- Reaction kinetics and thermodynamics of cracking and hydrogenation
- Product yield optimization and selectivity control
Module 9: Hydroprocessing Mechanical Considerations & Troubleshooting
- Design principles
- Common problem areas
- Safety issues
- High-pressure vessel design and materials of construction
- Corrosion prevention and hydrogen embrittlement considerations
- Catalyst loading and unloading procedures
- Troubleshooting temperature runaway and pressure drop issues
Module 10: Hydroprocessing Mechanical Considerations & Troubleshooting
- Design principles
- Common problem areas
- Safety issues
- Emergency shutdown systems and safety instrumented systems (SIS)
- Hydrogen safety considerations including leak detection and ventilation
- Process control and optimization strategies
- Maintenance best practices for extended run lengths
- Troubleshooting catalyst performance and reactor fouling issues
- Advanced process control and model predictive control applications
Real World Examples
The impact of Hydrotreating and Hydrocracking training is evident in leading implementations:
- Shell Pernis (Netherlands) & Hyundai Oilbank (South Korea)
Implementation: Revamps at Shell Pernis introduced comprehensive new reactor internals, improved effluent exchangers, and integration with upstream vacuum distillation while Hyundai Oilbank’s Daesan refinery adopted these approaches to produce more high-value Group II base oils and increase VGO yields through systematic hydrocracker flexibility implementation.
Results: The implementation achieved production of more high-value Group II base oils and increased VGO yields through systematic revamp introduction of new reactor internals and comprehensive effluent exchanger improvements, demonstrated hydrocracker flexibility delivering both product quality and profitability through comprehensive upstream vacuum distillation integration and systematic process optimization, and established industry leadership through systematic approach adoption and comprehensive yield enhancement strategies, demonstrating how comprehensive hydrotreating training enables exceptional refinery performance optimization and product quality enhancement. - Grupa LOTOS (Gdańsk Refinery, Poland)
Implementation: Started comprehensive new 45,000-bbl/d DAO hydrocracker at the Gdańsk refinery through systematic implementation that boosted conversion from 60% to 85% in its first cycle to maximize jet fuel and Euro 5 diesel production while utilizing flexible hydrocracking configurations that enabled adaptation to changing product demand.
Results: The implementation achieved boosted conversion from 60% to 85% in first cycle through systematic 45,000-bbl/d DAO hydrocracker deployment and comprehensive production optimization, maximized jet fuel and Euro 5 diesel production through systematic conversion enhancement and comprehensive product slate optimization, and enabled adaptation to changing product demand through flexible hydrocracking configurations and systematic process flexibility implementation, showcasing how systematic hydrocracking training enables superior refinery conversion efficiency and product optimization. - Valero (USA) & CNOOC (China)
Implementation: Deployed comprehensive Shell’s dual-service hydrocracking at Valero’s St Charles and Port Arthur refineries (each 50,000-bbl/d) and at CNOOC’s huge 80,000-bbl/d facility in Guangzhou through systematic unified, two-stage design that allowed tailored outputs, higher conversion, and synergy with other downstream assets.
Results: The implementation achieved tailored outputs and higher conversion through systematic dual-service hydrocracking deployment and comprehensive two-stage design optimization, delivered synergy with other downstream assets through systematic unified design approach and comprehensive facility integration, and established large-scale hydrocracking excellence through systematic implementation at multiple major facilities with comprehensive performance optimization, demonstrating how comprehensive hydrocracking training enables exceptional multi-facility performance and operational synergy.
Be inspired by industry-leading hydrotreating and hydrocracking achievements. Register now to build the skills your organization needs for refining excellence!
