KALVERAENERGY TECHNOLOGIES Commercial inquiries

Refinery residual processing · For refiners

More value from the bottom of the barrel.

Beyond extra-heavy crude, the KHU process can turn selected refinery residual streams into higher-value products, such as base-oil precursors. Compact, modular units sit within an existing site and tie into the units you already run.

Discuss a residual stream See where it fits
For
Refiners
Feed
Selected residual streams
Products
Higher value, e.g. base-oil precursors
Delivery
Modular, within existing sites
Fig. 1 — The bottom of the barrelConcept
A distillation column with lighter cuts drawn off at the top and residue at the bottom routed to a KHU module for higher-value products FEED LIGHTER CUTS DISTILLATES GAS OILS RESIDUE KHU HIGHER VALUE
Conceptual. The heaviest fraction of a refinery’s crude leaves the bottom of distillation as residue.
02Block flow diagramDetail B · Fig. 2

Where KHU sits in a refinery.

Residue from the vacuum unit is often sent to fuel oil or a coker. A KHU module gives selected streams another route: on to higher-value products.

Which streams qualify, and what they can yield, is confirmed by characterization and evaluation. See the feasibility path below.

Fig. 2 — Refinery block flow · residue routingSimplified
Refinery block flow with a KHU module on the residue stream Crude enters the crude unit. Distillates go to existing units. Atmospheric residue goes to the vacuum unit, whose gas oils also go to existing units. Vacuum residue, a selected residual stream, goes to the highlighted KHU module, which makes higher-value products such as base-oil precursors. The conventional fate of the residue, fuel oil or a coker, is shown dashed as the alternative. DISTILLATES & GAS OILS · TO EXISTING UNITS CRUDE U-100 CRUDE UNIT ATMOSPHERIC ATM. RESIDUE U-200 VACUUM UNIT VACUUM DISTILLATION VACUUM RESIDUE KHU-300 SELECTED STREAMS KHU MODULE HIGHER-VALUE PRODUCTS E.G. BASE-OIL PRECURSORS FUEL OIL / COKER CONVENTIONAL FATE CONVENTIONAL ALTERNATIVE LOWER-VALUE OUTLETS 1 2 3 4
Illustrative. Units and stream routing vary by refinery; suitable residual streams and products are confirmed case by case.
03What it means for refinersDetail C

A better outlet for a difficult stream.

Photo 1 — Residue units at dawnRepresentative
Refinery distillation columns and drums seen from ground level at dawn, backlit by a low sun, with steam rising from the units.
Representative refinery residue units. A KHU module is sized to the stream and sits beside units like these.

Residue is the stream with the fewest good outlets. KHU gives selected residual streams another route, in a unit sized to the stream and built beside the units that make it.

C-1Value

Value uplift

Selected residual streams become higher-value products, such as base-oil precursors, instead of going to lower-value outlets.

C-2Footprint

Compact footprint

Units sized to the stream, not to a large centralized complex, so they can fit into the plot space a site already has.

C-3Integration

Modular integration

Modules are manufactured, assembled and tested in the USA, then tied into existing units at defined interfaces.

04IntegrationDetail D · Fig. 3

A compact train beside the units you already run.

Fig. 3 — Tie-in plan · typicalPlot plan · NTS
Typical tie-in plan for a KHU train within an existing refinery Plan view. An existing vacuum unit, utilities and tankage sit beside an existing pipe rack. One KHU train, Module 01 Conditioning and Module 02 Conversion, occupies plot space inside a dashed integration boundary. Three tie-in points on the boundary connect the residue feed from the vacuum unit, product to existing storage, and utilities. PLOT PLAN · SCHEMATIC · NTS N VACUUM UNITEXISTING UTILITIESEXISTING TANKAGEEXISTING EXISTING PIPE RACK INTEGRATION BOUNDARY M01 · CONDITIONINGM02 · CONVERSION KHU TRAIN · MODULE 01 + 02 TP-1 TP-2 TP-3 RESIDUE PRODUCT TO STORAGE UTILITIES
Typical arrangement only. Actual tie-ins, plot space and interfaces are defined in the engineering study for each site.

KHU modules arrive tested and ready to connect. Integration comes down to a small number of defined tie-in points at the boundary of our scope.

TP-1 · Feed
Residue from the existing unit, routed along the pipe rack.
TP-2 · Product
Upgraded product to existing storage or blending.
TP-3 · Utilities
Connected to the site’s existing systems.
Boundary
The KHU scope: modules plus tie-ins, defined in the engineering study.
05Feasibility pathDetail E · Fig. 4

From sample to module, one gate at a time.

Each stage answers one question before the next one starts, so you only commit as far as the evidence supports.

  1. 1

    Stream characterization

    Share data on the residual streams you would like to upgrade. We assess whether they suit the KHU process.

    Gate · Worth testing?

  2. 2

    Lab / pilot evaluation

    Representative samples are evaluated to confirm what the stream can yield in practice.

    Gate · Results confirmed?

  3. 3

    Engineering study

    Capacity, layout, tie-ins and project economics are defined for your site.

    Gate · Investment decision

  4. 4

    Modular delivery

    Modules are manufactured, assembled and tested in the USA, then installed and tied in on site.

    Gate · Start-up

Every stage runs under NDA. Your stream data stays confidential.

06General notesDetail F · Notes

Questions refiners ask.

General notes · Select a note to expand
Which residual streams can KHU process?

Selected residual streams. Whether a stream suits the process depends on its properties, which is why every evaluation starts with characterization. Share what you have and we will tell you whether it is worth testing.

What products can it make?

Higher-value products, such as base-oil precursors. The achievable products depend on the feed and the application, and are defined during evaluation.

Does it need hydrogen?

It depends on the application. Process requirements, including utilities, are discussed under NDA once we understand your stream.

How does it fit into an existing refinery?

As modules placed beside existing units, connected at a small number of defined tie-in points. Plot space, tie-ins and interfaces are set out in the engineering study.

Is the technology proven?

The KHU process has been deployed in a large-scale industrial environment. How it applies to a specific residual stream is confirmed through characterization and evaluation.

What do you need from us to start?

Whatever stream data you have, an idea of the volumes involved, and where the stream goes today. We can put an NDA in place before you share anything.

What stays confidential?

On our side, catalyst formulations and reactor design. On yours, your stream data and project information, which are protected under NDA. See the disclosure schedule.

07Commercial inquiries · RefinersForm KAL-INQ

Tell us about your residue.

Share the stream, where it goes today and what you would like it to become. Our engineering team will outline whether KHU is worth evaluating. All discussions are under NDA.

All discussions are under NDA

Discuss a residual stream Next sheet · Modular Solutions