Hydrocracking is a critical component of modern refining, enabling the conversion of heavier feedstocks into lighter, more valuable products like diesel, jet fuel, and gasoline. As the refining industry continues to face challenges related to processing heavier and more complex feedstocks (often opportunity crudes or blends with high variability), the role of advanced filtration technologies has become increasingly important. In this article, we explore the latest developments in filtration media and how they are helping refineries optimize their hydrocracking units for better performance, increased efficiency, and reduced operational costs.

The Challenges of Hydrocracking

Hydrocracking units operate under high temperatures and pressures, using hydrogen to remove impurities such as sulfur, nitrogen, and metals from crude oil and other feedstocks. The process also involves breaking down larger, more complex molecules into simpler ones, making the feedstock more suitable for producing high-value fuels.

However, the efficiency of hydrocracking units can be significantly impacted by contaminants in the feedstock. These contaminants, which often include asphaltenes, gums (as a result of oxidative polymerization), and metals, can lead to fouling, catalyst deactivation, and increased pressure drops, all of which reduce the efficiency of the process and increase operational costs. As refineries process a wider variety of feedstocks, including opportunity crudes and renewable materials, the need for robust and adaptable filtration solutions has never been greater.

Advanced Filtration Media: Meeting the Demands of Modern Hydrocracking 

To address the challenges of hydrocracking, Jonell Systems has developed a range of advanced filtration media designed to provide superior contaminant removal while maintaining high efficiency and reliability. These media are specifically engineered to handle the extreme conditions of hydrocracking units and the complex nature of modern feedstocks.

By reducing the risk of contaminants like asphaltenes entering the reactor, these technologies help minimize the potential for coke deposition on the active catalyst sites. This, in turn, reduces the need for additional hydrogen (often used as an inhibition mechanism against coke deposition), allowing the refinery to better control its hydrogen demand- a key factor in the decarbonization process. As Leonid Pankratov and Jeff Pro from Shell Catalysts & Technologies point out, maintaining operational flexibility in hydrocracking is crucial as refineries navigate the ongoing energy transition (Pankratov & Pro, 2024). 

High-Temperature Lofted Media: A Breakthrough in Depth Filtration

One of the most exciting developments in filtration technology is the introduction of high-temperature lofted media. This innovative media is designed to provide enhanced depth filtration, making it particularly effective for capturing semi-deformable contaminants such as asphaltenes, gums, and waxes. Using proprietary synthetic technology capable of sustaining temperatures of up to 450°F and withstanding aggressive aromatic components in the feed, this technology is engineered with flexibility in mind (e.g., media construction, hybrid depth-pleat design, flow pattern, multi-layered configuration). With over 100 installations worldwide, Jonell recognizes that adaptability in design is key to addressing refinery-specific challenges. 

The lofted structure of the media creates a high-void volume, allowing for greater contaminant capture without significantly increasing pressure drop. This is particularly important in hydroprocessing units, where maintaining stable pressure and flow rates is critical for efficient operation. By effectively capturing contaminants before they reach the catalyst, lofted media helps to extend catalyst life, reduce fouling, and minimize the need for frequent maintenance. In cases where a backwash filter is installed, the technology aims to increase backwash cycles by removing semi-deformable contaminants, which are often the main cause of short backwash cycles in metallic filter systems. 

Fiberglass Depth Filters: Superior Performance in High-Temperature Applications

Jonell Systems’ High Temperature Fiberglass Depth Filters are another key innovation designed to meet the demands of hydroprocessing units. These filters are constructed from high-temperature-resistant fiberglass media, making them ideal for use in the extreme conditions typical of hydrocracking and hydrotreating processes.  

The depth filtration design of these filters allows for the efficient capture of a wide range of contaminants, including asphaltenes, particulates, and metals. This not only helps protect the catalyst from deactivation (e.g. coke deposition) but also reduces the risk of fouling in downstream equipment. The result is more stable operation, improved efficiency, and lower overall operational costs. 

TriShield™ Filters: Multi-Layered Filtration for Comprehensive Protection of Recycled Hydrogen Compressors

The TriShield™ liquid-gas coalescers from Jonell Systems provide a multi-layered approach to removing submicron aerosols and solid contaminants that can enter the recycled hydrogen loop, offering comprehensive protection for compressor units (recycle, boost). Each layer of the filter media is designed to capture specific types of contaminants, ensuring that even the most challenging feedstocks can be processed efficiently.  

In an environment where hydrogen demand is a major factor in energy transition efforts, ensuring the purity of hydrogen and protecting downstream equipment is critical for unit reliability. João da Silva, in his analysis of hydrocracking technologies, emphasizes the importance of managing impurities in the recycled hydrogen loop to optimize refinery operations and support decarbonization (da Silva, 2024). 

For a detailed discussion on the TriShield technology, consult our dedicated page.  

Case Study: Advanced Filtration in Action

A large refinery on the U.S. Gulf Coast was facing significant challenges with its hydrocracking unit, which was processing a mix of heavy crude and opportunity crudes. The unit was experiencing frequent shutdowns due to fouling and catalyst deactivation, leading to increased operational costs and reduced throughput.  

After implementing Jonell Systems’ high-temperature lofted media and Fiberglass Depth Filters, the refinery saw a significant improvement in the performance of its hydrocracking unit. The advanced filtration media effectively captured contaminants, reducing the frequency of shutdowns and extending the life of the catalyst. The refinery also reported improved flow rates and more stable operations, demonstrating the value of advanced filtration technologies in optimizing hydroprocessing units.  

Looking Ahead: The Future of Filtration in Hydroprocessing

As the refining industry continues to evolve, the demand for advanced filtration solutions that can handle increasingly complex feedstocks will only grow. Jonell Systems is committed to staying at the forefront of this field, developing innovative filtration media that address the unique challenges of modern hydroprocessing.  

Future developments are likely to focus on enhancing the efficiency of filtration media while maintaining high contaminant capture rates. This includes the continued refinement of lofted media, as well as the exploration of new materials and filtration technologies that can offer even greater performance in demanding applications.  

Conclusion

Optimizing hydroprocessing units requires a comprehensive approach that includes the use of advanced filtration media capable of handling the challenges posed by modern feedstocks. Jonell Systems’ high-temperature lofted media, Fiberglass Depth Filters, and TriShield™ filters provide refineries with the tools they need to improve efficiency, reduce operational costs, and extend the life of their hydroprocessing units. As the industry continues to face new challenges, Jonell Systems remains committed to delivering innovative filtration solutions that help refineries stay ahead of the curve.

Interested in hearing more about Jonell Systems’ innovative filtration technology? Talk to an engineer today. 

References: 

• Pankratov, Leonid, and Jeff Pro. “Leveraging Hydrocracker Flexibility to Navigate the Energy Transition.” Shell Catalysts & Technologies, January 2024. 

• Da Silva, João. “The Role of Hydrocracking Technologies in the Future of Downstream.” LinkedIn Pulse. https://www.linkedin.com/pulse/role-hydrocracking-technologies-future-downstream-da-silva-mba–szocf/.