Medium Voltage Solution Reduces Installation Costs Ninefold

Relocating a debutanizer process to a new site near a city center presented HF Sinclair with a significant challenge: how to meet stringent emissions regulations without compromising the efficiency of its thermal oil heating system. The solution needed to deliver high performance, ensure environmental compliance, and align with the company’s broader sustainability goals.

HF Sinclair, a diversified energy company headquartered in Dallas, Texas, operates across the U.S. and internationally, specializing in traditional and renewable fuels, lubricants, and industrial products. With over 5,000 employees, seven complex refineries, and exports to more than 80 countries, the company is a major player in the global energy landscape.

To address the heating challenge, HF Sinclair began evaluating electric heating technologies. We proposed a 4160V medium voltage solution, which significantly reduced amperage to 334 amps and cut installation costs by a factor of nine. Our team provided comprehensive total cost of ownership comparisons between low voltage and medium voltage systems, validated by an engineering firm. HF Sinclair’s engineering team also visited our Ogden, Utah facility to assess the technology firsthand.

Importantly, HF Sinclair’s decision was driven not only by regulatory compliance but also by its commitment to sustainability. The company has set a target to reduce net greenhouse gas emissions intensity by 25% by 2030 and continues to invest in renewable energy and innovative technologies. After evaluation, HF Sinclair selected Chromalox to deliver a tailored medium voltage electric heating solution that meets both environmental and operational demands.

The Solution: Medium Voltage Electric Heating System

Chromalox engineered a custom DirectConnect™ MV heating system tailored to the refinery’s process and site requirements. The system included:

• 2400 kW electric heater operating at 4160V, 3-phase power
• Design pressure: 175 PSIG (12 BARG)
• Design temperature: 650°F (343°C)
• Remote-mounted thyristor control panel for precise temperature regulation
• Compact heater skid: 211”L x 60”W x 120”H

This configuration ensured efficient heat transfer, reduced installation footprint, and compliance with urban environmental standards.

The Benefits: Cleaner Operation and Lower Costs

By choosing a medium voltage electric heating system, the refinery achieved:

• Lower installation and operational costs compared to 480V alternatives
• Reduced emissions, supporting compliance with city-center pollution restrictions
• Improved energy efficiency and simplified electrical infrastructure
• Reliable, high-performance heating for continuous debutanizer operation

Chromalox’s expertise in electric process heating and system integration ensured a smooth transition and long-term operational reliability