Hydrocrackers & Hydroprocessing Units — Asbestos Exposure Crosswalk
What This Equipment Is
Hydroprocessing is the family of refinery units that contact a hydrocarbon feedstock with hydrogen over a catalyst at high pressure and high temperature to remove sulfur, nitrogen, and metals (hydrotreating) and to crack heavy molecules into lighter ones (hydrocracking). Hydroprocessing units include:
- Naphtha hydrotreaters — feed prep for catalytic reforming
- Distillate hydrotreaters — diesel and jet-fuel desulfurization
- Resid hydrotreaters — heavy-feed upgrading
- Hydrocrackers — heavy-distillate / vacuum-gas-oil cracking
- Isomerization units — light-naphtha octane improvement
- Hydrogen plants — supplying hydrogen feedstock
These units operate at hydrogen partial pressures of 500–3,000 psig and temperatures of 600–800°F. Reactor vessels are thick-walled forged steel; charge heaters are large fired furnaces (see Fired Heaters); recycle compressors run continuously; the hydrogen-rich gas streams require extensive flange-sealing and insulation.
Asbestos Products Historically Used Around Hydroprocessing
| Product Category | Where on the Unit | Notes |
|---|---|---|
| Reactor insulation | High-pressure reactor exteriors | Block insulation, calcium silicate, magnesia |
| Charge-heater refractory | Fired-heater interior | See Fired Heaters, Refractory Brick |
| Pipe covering | Hydrogen recycle, feed/effluent, hot piping | Magnesia, calcium silicate |
| High-pressure gaskets | All reactor-loop flanges | Spiral-wound asbestos-filled, ring-joint |
| Valve packing | Hydrogen-loop and process valves | Braided asbestos rope packing |
| Recycle compressor components | Hydrogen-recycle compressor seals and gaskets | See Compressors |
| Heat-exchanger gaskets and tubes | Feed/effluent exchangers, charge heaters | See Heat Exchangers |
Why Hydroprocessing Work Was a Heavy-Exposure Activity
Hydrogen service is unforgiving — leaks at flanged joints are safety-critical, gasket integrity is paramount, and routine maintenance is intense. Turnarounds open every reactor, exchanger, and major flange in the unit for inspection, gasket renewal, and catalyst change-out. The combination of asbestos-bearing high-pressure gaskets, hot-piping insulation, and large fired-heater refractory work means turnaround crews handle multiple asbestos product families across a compressed multi-week window.
Manufacturers Named in Hydroprocessing Litigation
- Chevron Lummus Global — hydrocracker licensor
- UOP (Universal Oil Products) — hydrocracker and hydrotreater licensor
- Haldor Topsoe — hydroprocessing technology
- Axens — hydroprocessing licensor
- A.P. Green Refractories — charge-heater refractory
- Harbison-Walker Refractories — refractory
- Johns-Manville — insulation, pipe covering
- Owens-Corning / Fibreboard — insulation
- Garlock Sealing Technologies — gaskets
- Flexitallic — spiral-wound gaskets
- A.W. Chesterton — packing
Documented Product References
Images sourced from publicly available product-identification reference materials. Inclusion does not constitute a finding of liability against any company.
Trust Funds That May Apply
- A.P. Green Industries Asbestos PI Settlement Trust
- Harbison-Walker Refractories / RHI Asbestos PI Trust
- Manville Personal Injury Settlement Trust
- Owens-Corning / Fibreboard Asbestos PI Trust
- Garlock Sealing Technologies LLC Asbestos PI Trust
- Flexitallic Group Asbestos PI Trust (where applicable)
Trades Most Exposed at Hydroprocessing Work
Pipefitters (the heaviest exposed trade given the gasketing intensity), insulators (Heat & Frost), boilermakers, refractory masons, refinery turnaround contract crews, plant operators.
Cross-References
- See companion pages: Fired Heaters, Cat Cracker, Coker Units, Reformer Units, Distillation Towers, Compressors, Heat Exchangers, Gaskets
Compiled from publicly filed asbestos litigation, EPA / state-DNR records, and industry-publication histories on petroleum-refining exposure. Product and company references reflect what has been alleged or documented in publicly filed litigation. This page does not constitute a finding of liability against any company. Not legal advice; consult a licensed attorney about your specific situation.