Cost-effective solutions are the mantra of the capital projects group at ALON Big Springs Refinery, and the ULSD revamp project proved no exception. The refinery explored many options and exhausted all technological alternatives in converting their only DHT to ULSD service. This was particularly challenging given that its low operating pressure and feed difficulty (25% LCO), but creative technical solutions and close collaboration between refinery and technology suppliers yielded a solution with a capital cost of ~$850/B, much lower than the industry average cost. This paper will describe the trials and tribulations experienced along the road to the final solution, and the key decisions that lead to the successful startup in May 2005. The refinery will also describe how they have moved on the next phase of ULSD; getting the most out of the unit in an ever-changing economic environment.

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