05 bottom of barrel

8/12/2019 05 Bottom of Barrel

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BottomofBarrelProcessingChapters5,6,&8


2/15

Light Naphtha

CrudeOil

Desalter

AtmosphericDistillation

VacuumDistillation

GasSeparation &

Stabilizer

SolventDeasphal-

ting

Coking

Visbreaking

FluidizedCatalyticCracking

Hydro-cracking

NaphthaReforming

Isom-erization

Sat GasPlant

Polymer-ization

Alkylation

NaphthaHydro-treating

Treating &Blending

Coke

Fuel Gas

LPG

AviationGasoline

AutomotiveGasoline

Solvents

Jet Fuels

Kerosene

Solvents

Heating Oils

Diesel

ResidualFuel Oils

Lubricant

Greases

Waxes

Asphalts

HeavyNaphtha

Kerosene

Distillate

AGO

LVGO

HVGO

VacuumResiduum

CatDistillates

Gas OilHydro-treating

DAO

Isomerate

Gas

AlkylFeed

Alkylate

PolymerizationNaphtha

Gases

Butanes

LPG

Reformate

Naphtha

Fuel Oil

Bottoms

Distillates

DistillateHydro-treating

CatNaphtha

Cycle Oils

SDABottoms

CokerNaphtha

Heavy

CokerGasOil

Light CokerGas Oil

SulfurPlant

Sulfur

Naphtha

Fuel Oil

SolventDewaxing

Lube Oil

Waxes

2


3/15

NeedForHeavyEndsProcessing Worldcrudeslatehasbecomeheavier thiswillcontinue

Concentrationofsulfur&othercontaminantshasbeenincreasing thiswillcontinue

Sulfurspecificationsbecomingmorestringent

Forenvironmentalprotection

DemandforNo.6FuelOildeclining

Forenvironmental

protection

Costoflightcruderelativetoheavycrudeisincreasing

Producersareincreasingthesaleofheavycrudestoprolongthelifeoflightcrude

fields

3


4/15

ProcessingOptionsPhysicalseparations

Vacuumdistillation

Volatility

SolventDeasphalting

Solubility

Chemicalreactions(inorderofincreasingseverity)

Visbreaking

Catalyticcracking

Coking

Delayedcoking

Fluidizedbedcoking

Hydrocracking

LubeOilProcessing

Requiresspecializedfeedstocks

4


5/15

U.S.RefineryImplementation

5

CORPORATION State Site

AtmosphericCrudeDistillationCapacity(barrelsperstreamday)

VacuumDistillation

DownstreamChargeCapacity,

CurrentYear(barrelsperstreamday)

ThermCracking,Visbreaking

DownstreamChargeCapacity,


ThermCracking,Other(IncldngGasOil)DownstreamChargeCapacity,


FuelsSolventDeasphaltingDownstream

ChargeCapacity,CurrentYear(barrelsperstreamday)

CONOCOPHILLIPS Louisiana WESTLAKE 252,000 132,000 0 10,600 0

CHEVRONCORP California RICHMOND 257,200 123,456 0 0 66,000EXXONMOBILCORP Texas BAYTOWN 584,000 297,000 0 0 47,000MARATHONPETROLEUMCORP Louisiana GARYVILLE 518,000 268,000 0 0 34,500VALEROENERGYCORP Texas TEXASCITY 233,000 142,500 0 0 33,500TESOROCORP Washington ANACORTES 125,000 47,000 0 0 24,300VALEROENERGYCORP Louisiana MERAUX 140,000 60,000 0 0 22,000CONOCOPHILLIPS NewJersey LINDEN 251,000 75,000 0 0 20,000VALEROENERGYCORP Texas HOUSTON 90,000 38,000 0 0 18,000BPPLC Texas TEXASCITY 475,000 237,000 0 0 17,000TOTALSA Texas PORTARTHUR 245,000 114,000 0 0 15,500VALEROENERGYCORP Texas SUNRAY 160,000 50,000 0 0 14,500MARATHONPETROLEUMCORP Kentucky CATLETTSBURG 253,000 119,000 0 0 13,000PLACIDOILCO Louisiana PORTALLEN 59,000 27,000 0 0 11,000VALEROENERGYCORP Texas THREERIVERS 95,000 35,000 0 0 10,000ALONISRAELOILCOMPANYLTD Texas BIGSPRING 70,000 24,000 0 0 10,000DELEKGROUPLTD Arkansas ELDORADO 85,000 45,000 0 0 7,400HOLLYFRONTIERCORP Utah WOODSCROSS 26,400 0 0 0 6,000CVRENERGY Oklahoma WYNNEWOOD 75,000 30,000 0 0 4,850HOVENSALLC VirginIslands KINGSHILL 525,000 225,000 40,000 0 0TESOROCORP Hawaii EWABEACH 95,000 40,000 11,000 0 0SANJOAQUINREFININGCOINC California BAKERSFIELD 25,000 14,300 5,000 0 0


6/15

SolventDeasphalting Purpose

Removeasphaltsfromlubeplantfeeds

Increasegasoilyieldfromcrude

Makecommercial

asphalts

from

asphalticcrudeunitbottoms

Characteristics

Physicalrecoveryusinglighthydrocarbonsolvent(C3,C4,C5)

Dissolvesaturated

components

Leavebehind/precipitateasphaltenes

Resinssplitbetweenphases

Products

Deasphalted Oil(DAO)

Resins

Bottoms/pitch asphaltenes

6

HandbookofPetroleumRefiningProcessesRobertMeyers

McGrawHill,Inc,1986


7/15

CharacteristicsofProducts DAOresemblesgasoilbutisofdrasticallydifferentboilingpointrange

7

0.0000

0.0005

0.0010

0.0015

0.0020

0.0025

500 600 700 800 900 1000 1100 1200 1300 1400 1500

Boiling Point (F)

MassYieldD

istribution(1/F)

Feed

DAO

Bottoms

Recombined (51.1wt% Lift)


8/15

Provider Features

FosterWheelerKBR

LighthydrocarbonsolventwithDAO/solventseparationatsupercriticalconditions

SDATechnologyProviders

8

HydrocarbonProcessings2008RefiningProcessesHandbook

Foster Wheeler KBR ROSE


9/15

IntegrationofSDAintoRefinery

9

HandbookofPetroleumRefiningProcessesRobertMeyers

McGrawHill,Inc,1986

Atm ResidVacuum

DistilationGas Oil HDS FCC

SDAVac Bottoms

SDA Bottoms

DAO

Cycle Oil

Slurry

Fuel Gas

C3/C

4

Naphtha

Distillate

H2

Base With SDA Base With SDA

Atm Resid Feed bpsd 50,000 50,000 Feed to FCC bpsd 27,340 40,651

API 15.1 15.1 API 24.0

wt% S 4.02 4.02 HDS Fuel Gas Mscfd 4,200 6,310

ppmw metals 69 69 FCC Fuel Gas Mscfd 4,430 6,582

Vac Resid bpsd 20,000 20,000 Total Fuel Gas Mscfd 8,630 12,892

API 5.6 5.6 HDS C3/C4 bpsd 190 289

wt% S 5.55 5.55 FCC C3/C4 bpsd 5,220 7,765

ppmw metals 160 160 Total C3/C4 bpsd 5,410 8,054SDA Bottoms bpsd 5,400 HDS Naphtha bpsd 260 388

API -12.6 FCC Naphtha bpsd 15,420 22,927

wt% S 7.15 Total Naphtha bpsd 15,680 23,315

ppmw metals 475 API 54.5 54.5

SDA DAO bpsd 14,600 FCC Cycle Oil bpsd 7,108 10,569

API 11.4 API 25.5 25.5

wt% S 4.84 FCC Slurry bpsd 1,367 2,033

ppmw metals 20 API 0.9 0.9

Gas Oil bpsd 30,000 30,000 HDS Distillate bpsd 2,750 4,090

API 22.3 22.3 API 32.5 32.5

wt% S 3.04 3.04

Feed to HDS bpsd 30,000 44,600

API 22.3 18.5

wt% S 3 3.66

ppmw metals 7


10/15

Visbreaking

Purpose

Cutviscosityinoffeed(specsfor

heavyfueloil)

Reduces"cutter

stock

Reducesheavyfueloilamount

Characteristics

Relativelymildthermalcracking

operation

Flexibleonfeedstockquality

Typicallyhighresincrudeoils

Lowcapitalcostforprocess

Products

About20%feedcrackedtolightends,naphtha,gasoil&sometimesdistillate.

Low

yield

of

valuable

naphtha Productscontainalotofolefins

Olefinic C3s&C4softenrecovered

Naphtha&distillateoftenhydrotreatedbecauseofolefins&sulfur

Gasoil

high

in

aromatics

more

appropriateforhydrocrackingthancatcracking

Largevolumesofheavyfueloilwithhighsulfurcontent

Bottoms(visbreaker tar)

sent

directly

to

heavyfueloil

10


11/15

TypicalCoilVisbreaker

11

http://www.fwc.com/industries/pdf/Residue_upgrading_English_10th_Sept.pdf?DIRNAME=%23dirName%23


12/15

VisbreakingTechnologyProviders

12

HydrocarbonProcessings2008RefiningProcessesHandbookFosterWheeler ShellGlobalSolutions

Provider Features

FosterWheelerShellGlobalSolutions Visbreakerheater&downstreamcoil


13/15

CatalyticCracking Purpose

Makegasoline&distillates

(diesel/heatingoil)

Tryto

minimize

heavy

fuel

oil

Characteristics

Mediumseveritycrackingprocess

Gasoilsaretypicalfeedstocks

Notnormallyusedonwhole

atmosphericorvacuumresids

PNAstendtocondense,leadingto

coking

Catalystssensitive

to

poisoning

by

sulfur&metalspresentinPNAs

Products

Lightgases

Olefins

Light&HeavyNaphtha

Light&HeavyCycleOils

Slurry

13


14/15

Hydrocracking

Purpose

Minimizeheavyfueloil

Characteristics

Severecrackingprocess

Combinescracking&hydrogenation

Cokingbetterforresids

Highpressures&largeamountsof

hydrogenrequired

Products

Produceshighyieldsofliquids

Hydrogensuppressescokeformation

Liquidslowinsulfur&olefins

14


15/15

Coking

Purpose

Createlightgases&distillates

Carbonrejection

Characteristics

Severethermalcrackingprocess

Canprocessawidevarietyof

feedstocks

Highmetals(nickelandvanadium),

sulfur,resins&asphaltenes withPNAs

SeparatesthermallystablePNAcores

fromtheirsidechains

PNAscontain

majority

of

the

heteroatoms(sulfur,nitrogen,metals)

ConcentrateinthecokeasPNAs

condense

Products

Produceslightgases,distillates

(naphthas &gasoils)forcatalytic

upgrading Lowyieldsofliquidsrelativeto

hydrocracking

Liquidscontainlargeamountsofsulfur

&olefinsbutlittlearomatics

Coke

Containslargeamountsofmetals&

sulfur.

Cokeusedependsuponquality

- May

pose

a

disposal

problem

15

05 bottom of barrel

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