bbtc 2011 dubrovnik ( th international bottom of the barrel technology conference

1616 ConfidentialConfidential 11

Update on Latest Technology Update on Latest Technology Developments for Specialized Developments for Specialized

Equipment Used in Thermal Processes to Equipment Used in Thermal Processes to Promote Efficiency and Plant safetyPromote Efficiency and Plant safety

Dr. Amarjit BakshiDr. Amarjit BakshiPresidentPresident

Refining Hydrocarbon TechnologiesRefining Hydrocarbon TechnologiesTexas, USA.Texas, USA.

www.rhtgulfcoast.comwww.rhtgulfcoast.comPresented atPresented at

BBTCBBTC9 th International Bottom of the barrel9 th International Bottom of the barrel

Technology ConferenceTechnology Conference15 & 16 June, 201115 & 16 June, 2011

Rixos Libertas, Dubrovnik, CroatiaRixos Libertas, Dubrovnik, Croatia1 RHT

http://www.rhtgulfcoast.com/


Residue Upgrading TechnologiesResidue Upgrading TechnologiesCatalytic optionsCatalytic options

• RFCC unitRFCC unit• Ebullated Bed Hydrocrackers Ebullated Bed Hydrocrackers • UOP Uniflex ProcessUOP Uniflex Process• SDA/UniflexSDA/Uniflex• Hydrotreating/Hydrocracking Hydrotreating/Hydrocracking • Hydrotreat/FCC/HydrocrackingHydrotreat/FCC/Hydrocracking

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Residue Upgrading Residue Upgrading Catalytic Options-Catalytic Options-OverviewOverview

• All catalytic processes mentioned have All catalytic processes mentioned have been in operation except Uniflex, and been in operation except Uniflex, and provide upgrading which enhances the provide upgrading which enhances the economics. But most have high Capex economics. But most have high Capex and Opex, due to catalyst, complex and Opex, due to catalyst, complex design, maintenance, feed metals and design, maintenance, feed metals and upgrading requirements. upgrading requirements.

• But in last 10 to 15 years with the Crude But in last 10 to 15 years with the Crude price quadrupling these technologies have price quadrupling these technologies have become viable, and are used more and become viable, and are used more and more due to upgrading. more due to upgrading.

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Residue Upgrading TechnologiesResidue Upgrading TechnologiesThermal ProcessThermal Process

• VisbreakerVisbreaker

• Delayed CokerDelayed Coker

• SDA/CokerSDA/Coker

• FlexicokerFlexicoker

• Hydrogen Donor VisbreakingHydrogen Donor Visbreaking

• New Concept Rotary Kiln option New Concept Rotary Kiln option RHT


Thermal Upgrading ProcessesThermal Upgrading Processes VisbreakerVisbreaker• Provides low conversions so does not provide Provides low conversions so does not provide the complete solution for residue destruction.the complete solution for residue destruction.

Delayed CokerDelayed Coker• Delayed Coker is widely used residue upgrading Delayed Coker is widely used residue upgrading and has been used more and more in last 10 and has been used more and more in last 10 years all over the world especially due to years all over the world especially due to Syncrude applications. Delayed Coker has been Syncrude applications. Delayed Coker has been used by North American refiners for long time to used by North American refiners for long time to improve the refinery economics.improve the refinery economics.

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Thermal Upgrading ProcessesThermal Upgrading Processes Delayed CokerDelayed Coker

• Delayed Coker provides good economics Delayed Coker provides good economics for residue destruction at high Capex. It is for residue destruction at high Capex. It is cumbersome to operate the Coke drums/ cumbersome to operate the Coke drums/ cutting rotator head with water jets at high cutting rotator head with water jets at high pressure, removing of coke from drums in pressure, removing of coke from drums in cyclic operation. Process has safety issues, cyclic operation. Process has safety issues, and OSHA document on hazards of DCU and OSHA document on hazards of DCU provides guide for operators.provides guide for operators.

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• SDA/DCUSDA/DCUSDA provides DAO which can be sent to FCC. SDA provides DAO which can be sent to FCC. SDA/DCU economics is enhanced compared to SDA/DCU economics is enhanced compared to Delayed Coker only by reducing the size of unit. Delayed Coker only by reducing the size of unit.

FlexicokerFlexicokerFlexicoker with low BTU gas product at high Flexicoker with low BTU gas product at high Capex, has marginal economics. Exxon refineries Capex, has marginal economics. Exxon refineries have used at few locations. Two units have been have used at few locations. Two units have been licensed outside Exxon to other refiners, last one licensed outside Exxon to other refiners, last one being to Hellenic in 2008. being to Hellenic in 2008.

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Thermal Upgrading Thermal Upgrading ProcessesProcesses

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• Hydrogen Donor VisbreakingHydrogen Donor VisbreakingExxon and Gulf have patents but the process has Exxon and Gulf have patents but the process has not been commercialized. The process is an not been commercialized. The process is an extension of visbreaking, where some of gas oil is extension of visbreaking, where some of gas oil is hydrogenated and is recycled back to visbreaker hydrogenated and is recycled back to visbreaker and one can essentially go to destruction of and one can essentially go to destruction of residue. But did not show that much of promise residue. But did not show that much of promise even though pilot work was done until about 1985 even though pilot work was done until about 1985 by Gulf Canada so as to apply it for syncrude by Gulf Canada so as to apply it for syncrude applications.applications.

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New Concept Rotary Kiln OptionNew Concept Rotary Kiln Option• Refining Hydrocarbon Technologies LLCRefining Hydrocarbon Technologies LLChas developed a new concept where Coker has developed a new concept where Coker drums are replaced by a rotary kiln after the drums are replaced by a rotary kiln after the furnace which provides the coke in pellets/ furnace which provides the coke in pellets/ Chunks, and the gas product is fed to the Chunks, and the gas product is fed to the existing fractionator, same as in a Coker. existing fractionator, same as in a Coker. • The option provides easy coke handling The option provides easy coke handling solution, coke comes out of the kiln as small solution, coke comes out of the kiln as small pallets/ balls/chunks, with same liquid pallets/ balls/chunks, with same liquid yields. yields.

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NEW CONCEPT ROTARY KILN OPTIONNEW CONCEPT ROTARY KILN OPTION• The rotary kiln is capable of upgrading the The rotary kiln is capable of upgrading the product by removing the metals and also product by removing the metals and also desulfurizing simple sulfur species by desulfurizing simple sulfur species by hydrogenation catalyst.hydrogenation catalyst.

The concept is explained in Figures 1 to 3 The concept is explained in Figures 1 to 3 and provides better economics. It is much and provides better economics. It is much easier and safer to operate compared to easier and safer to operate compared to classical Delayed Coker operation.classical Delayed Coker operation.

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New Concept Rotary Kiln OptionNew Concept Rotary Kiln Option• Process can be applied to residue, Shale, Oil Process can be applied to residue, Shale, Oil Sands and biomass with much better economics Sands and biomass with much better economics than any of the onsite above ground processes than any of the onsite above ground processes being used is patented for applications.being used is patented for applications.• Process does not use any water hence no Process does not use any water hence no waste water producedwaste water produced. .

• Rotary Kiln operates under moderate positive Rotary Kiln operates under moderate positive pressure to meet the process requirements, so pressure to meet the process requirements, so gas produced is fed to the fractionator. Additional gas produced is fed to the fractionator. Additional information can be provided under NDA. information can be provided under NDA.

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FIGURE 1FIGURE 1 Resid UPGRADERResid UPGRADER

FURNACE

Heavy Crude/Resid

KILN

To Fractionator for separation of liquid fractions

COKE Pellets/ oil to Storage

Binding Agent

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FIGURE 2FIGURE 2 Resid UpgradingResid Upgrading

FURNACE

Heavy Crude/Resid

1

KILN

To Fractionator for separation of fractions

COKE Pellets/ oil To storage

Catalyst recycle

Hydrogen

Catalyst removal screen

Binding Agent

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Catalyst recycle/removalCatalyst Addition

Catalyst Removal


FIGURE 3FIGURE 3 SHALE/OIL SANDS/BIOMASSSHALE/OIL SANDS/BIOMASS

on purpose on siteon purpose on site

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KILN To Fractionator for separation of fractions

Residual Shale, Sand waste or Biomass To Disposal

Fuel gas

Syncrude to Storage or to Figure 2 for upgrading

Residual Shale/Sand Seperator Screen

1

Shale/Oil sandOr Biomass

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RHT-Rotary Kiln ProcessRHT-Rotary Kiln Process For Resid upgrading For Resid upgrading

• Thermal processes in general have lower Thermal processes in general have lower Capex and Opex than Catalytic processes for Capex and Opex than Catalytic processes for Resid upgrading.Resid upgrading.

• Rotary Kiln Process provides Paradigm shift,Rotary Kiln Process provides Paradigm shift, coke pellets or chunks as productcoke pellets or chunks as product• Similar liquid yields as Delayed Coker or Similar liquid yields as Delayed Coker or

better.better.• Capable of upgrading the productsCapable of upgrading the products• Safer operation, cost effective, no mechanical Safer operation, cost effective, no mechanical

or hydraulic equipment required for coke or hydraulic equipment required for coke cutting.cutting.

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Catalytic Reactor TypesCatalytic Reactor TypesAdvantages and DisadvantagesAdvantages and Disadvantages

• CSTRCSTR• Fixed Bed down flow or Fixed Bed down flow or

Expanded bed up flow reactorsExpanded bed up flow reactors• FCCUFCCU• Slurry ReactorsSlurry Reactors• Ebullated bed ReactorsEbullated bed Reactors

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• Reactive Distillation (RD) Reactive Distillation (RD)

• Channel ReactorsChannel Reactors

• Ceramic membrane reactorsCeramic membrane reactors

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Catalytic Reactor Catalytic Reactor Advantages & disadvantagesAdvantages & disadvantages

CSTRCSTR

• CSTR are used in petrochemical, CSTR are used in petrochemical, pharmaceutical and refining industry. pharmaceutical and refining industry. Classical example is Sulfuric Acid Classical example is Sulfuric Acid alkylation process. It is effective, in alkylation process. It is effective, in Alkylation it uses lot of power, Alkylation it uses lot of power, requires maintenance but this is due requires maintenance but this is due to nature of the process design. to nature of the process design.

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CSTRCSTR

• CSTR application are common CSTR application are common in batch processes and had its in batch processes and had its advantages with homogeneous advantages with homogeneous catalysts.catalysts.

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FIXED BED REACTORSFIXED BED REACTORS

• Fixed bed down flow reactors are used Fixed bed down flow reactors are used

commonly in refinery/petrochemical plants. commonly in refinery/petrochemical plants. If designed properly one can avoid If designed properly one can avoid channeling and have good catalyst channeling and have good catalyst life/utilization.life/utilization.

• Fixed Bed reactors are economical and Fixed Bed reactors are economical and may need standard internals, some may need standard internals, some licensors provide proprietary distributorslicensors provide proprietary distributors..

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RHT FIXED BED SMARTRHT FIXED BED SMARTTMTM Configuration Configuration

• RHT Fixed bed are conventional reactors, RHT Fixed bed are conventional reactors, and may be a side reactor to a fractionator and may be a side reactor to a fractionator based on process requirement. Smart based on process requirement. Smart configuration, uses multiple draw off from configuration, uses multiple draw off from column, reactor effluent is returned to the column, reactor effluent is returned to the column. Smart configuration provides column. Smart configuration provides multiple stages of reaction and separation multiple stages of reaction and separation without increasing the column size, without increasing the column size, provides multiple stages at low cost. provides multiple stages at low cost.

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RHT FIXED BED SMARTRHT FIXED BED SMARTTMTM Configuration Configuration

• Smart Configuration emulates multiple reaction Smart Configuration emulates multiple reaction and separation stages in series, providing and separation stages in series, providing maximum conversion/yield, selectivity and maximum conversion/yield, selectivity and removes the equilibrium constraints with out removes the equilibrium constraints with out increasing the column, reboiler or condenser increasing the column, reboiler or condenser size. For close or wide boiling products in the size. For close or wide boiling products in the column it still works. Major process efficiency is column it still works. Major process efficiency is realized with proper selection of multiple draw realized with proper selection of multiple draw off and reactor effluent returning to the column.off and reactor effluent returning to the column. RHT


Catalytic Reactor Catalytic Reactor Advantages & disadvantagesAdvantages & disadvantagesReactive Distillation (RD)Reactive Distillation (RD)

• Reactive distillation verses Fixed Bed reactors Reactive distillation verses Fixed Bed reactors articles published to date have stated the articles published to date have stated the advantages of RD over Fixed bed reactors in all advantages of RD over Fixed bed reactors in all technologies, like Ethers, all hydrogenation technologies, like Ethers, all hydrogenation and HDS, dimerization, isomerization, Benzene and HDS, dimerization, isomerization, Benzene saturation applications in following areas:saturation applications in following areas:

Lower Capex, Opex, longer catalyst life, higher Lower Capex, Opex, longer catalyst life, higher conversion and overcoming equilibrium conversion and overcoming equilibrium constrains, but Chemical engineering unit constrains, but Chemical engineering unit operation and kinetic principles do not prove it. operation and kinetic principles do not prove it.

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• The Ethers and hydrogenation reactions are The Ethers and hydrogenation reactions are conducted at 40 to 60 C, coke cannot form conducted at 40 to 60 C, coke cannot form based on unit operation principles. Problem based on unit operation principles. Problem due to poison in Fixed bed recycle is less due to poison in Fixed bed recycle is less pronounced compared to Reactive pronounced compared to Reactive distillation, as reflux will bring the poison distillation, as reflux will bring the poison back. Reflux washes the catalyst provides back. Reflux washes the catalyst provides longer life does not meet the engineering longer life does not meet the engineering scrutiny in any application.scrutiny in any application.

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RDRD



RDRD

• Gasoline HDS published articles suggest CDHydro Gasoline HDS published articles suggest CDHydro and CDHDS will meet 10 to 15 wppm sulfur. But MCN and CDHDS will meet 10 to 15 wppm sulfur. But MCN has maximum olefins/ H2S from CDHDS hence has maximum olefins/ H2S from CDHDS hence mercaptan will form, and spec will not be met. To mercaptan will form, and spec will not be met. To meet the spec, it needs another stage of HDS making meet the spec, it needs another stage of HDS making three stages, increasing the Capex by 20 to 30 three stages, increasing the Capex by 20 to 30 percent compared to fixed beds gasoline HDS. percent compared to fixed beds gasoline HDS.

• Gasoline HDS reflux cannot enhance catalyst life. If Gasoline HDS reflux cannot enhance catalyst life. If MCN olefins get to severe conditions, below feed and MCN olefins get to severe conditions, below feed and come in contact with additional catalyst volume, come in contact with additional catalyst volume, octane loss will increase per unit operation principles.octane loss will increase per unit operation principles.

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RDRD • RD Benzene Saturation based on kinetics RD Benzene Saturation based on kinetics

needs, will operate at higher pressure, that needs, will operate at higher pressure, that requires high level heat source. Fixed bed can requires high level heat source. Fixed bed can operate at optimum distillation conditions at operate at optimum distillation conditions at lower pressure. As the feed is clean both Fixed lower pressure. As the feed is clean both Fixed bed and Reactive Distillation catalyst should bed and Reactive Distillation catalyst should have similar life, but Reactive distillation column have similar life, but Reactive distillation column and condenser will be much larger due to heat and condenser will be much larger due to heat of reaction vapor generation. Need for high of reaction vapor generation. Need for high level heat requires Furnace/HPS increasing level heat requires Furnace/HPS increasing Capex/Opex.Capex/Opex.

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RDRD

• Isomerization of feeds, like 1-butene to 2-Isomerization of feeds, like 1-butene to 2-butene or vice versa, needs huge catalyst. butene or vice versa, needs huge catalyst. In finite catalyst system, components are In finite catalyst system, components are in equilibrium, before those could be in equilibrium, before those could be separated. RHT multiple side draw off separated. RHT multiple side draw off concept from column, side reactors, concept from column, side reactors, provides best yield, less catalyst volume, provides best yield, less catalyst volume, smaller column and Opex.smaller column and Opex.

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• Reactive distillation for additional Reactive distillation for additional capacity, will need another train. Fixed capacity, will need another train. Fixed bed capacity expansion is easy by bed capacity expansion is easy by installing additional reactor(s), revamping installing additional reactor(s), revamping the stripper/stabilizer capacity to 50 the stripper/stabilizer capacity to 50 percent with high efficiency trays, which percent with high efficiency trays, which will be lower than new train for reactive will be lower than new train for reactive distillationdistillation

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RD RD


RHT PortfolioRHT Portfolio• Please see website Please see website www.rhtgulfcoast.comwww.rhtgulfcoast.com

and linkedin for other details and presentations and linkedin for other details and presentations attached to profile. attached to profile.

• RHT LLC provides technology for Oil and gas RHT LLC provides technology for Oil and gas production from Shale Frac/Oil Sands/ Biomass production from Shale Frac/Oil Sands/ Biomass and heavy oil production by new concept which and heavy oil production by new concept which does not produce any liquid or gases waste and does not produce any liquid or gases waste and has better economics than available options.has better economics than available options.

• Please contact us and look up the Patents/IP.Please contact us and look up the Patents/IP.

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http://www.rhtgulfcoast.com/

4242 ConfidentialConfidential 4242RHT

Thank You Refining Hydrocarbon Technologies LLC

20130 Chateau Bend DriveKaty ( Houston Suburb),

Texas 77450USA

Dr. Amarjit BakshiPhone 281-398-8408/281-235-7780E-mail:[email protected]

www.rhtgulfcoast.com

bbtc 2011 dubrovnik ( th international bottom of the barrel technology conference

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