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Changing Refinery Configuration Changing Refinery Configuration for Heavy and Synthetic Crude for Heavy and Synthetic Crude
ProcessingProcessingGary BrierleyGary Brierley
UOP LLCUOP LLC
© 2006 UOP LLC. All rights reserved.©© 2006 UOP LLC. All rights reserved.2006 UOP LLC. All rights reserved. UOP 4525A-01
Why Should I Even Think About Why Should I Even Think About Running Synthetics?Running Synthetics?
Oil sands deposits in Western Canada are hugeOil sands deposits in Western Canada are huge–– 1.7 trillion barrels total oil in place1.7 trillion barrels total oil in place–– 174 billion barrels of recoverable oil with 174 billion barrels of recoverable oil with
existing technologyexisting technology–– Cumulative production since 1967 Cumulative production since 1967
only 4 billion barrelsonly 4 billion barrels
Recoverable reserves could Recoverable reserves could increase dramatically with increase dramatically with improved technologyimproved technology
UOP 4525A-02
BitumenBitumen--derived Crudes Replacing derived Crudes Replacing Declining Conventional CrudesDeclining Conventional Crudes
from Western Canadafrom Western Canada4,0004,0003,5003,5003,0003,0002,5002,5002,0002,0001,5001,5001,0001,000
5005000019901990 19951995 20052005 20102010 20152015 20202020
Upgraded Bitumen/SCOUpgraded Bitumen/SCONonNon--Upgraded BitumenUpgraded BitumenConventional HeavyConventional HeavyConventional LightConventional Light
Tho
usan
ds o
f Bar
rels
per
Day
Tho
usan
ds o
f Bar
rels
per
Day
20002000
UOP 4525A-04
Source: Source: PurvinPurvin & & GertzGertz, 2005, 2005
Synthetic Crudes and BitumenSynthetic Crudes and BitumenBlends Available in MarketBlends Available in Market
BitumenBitumenProductionProduction
UpgradingUpgrading
HeavyHeavyCrudeCrude
RefineriesRefineries
MediumMediumCrudeCrude
RefineriesRefineries
LightLightCrudeCrude
RefineriesRefineries
LightLightSCOSCO
SynDilBitSynDilBitHeavyHeavySCOSCO
LightLightSyntheticSyntheticCrude OilCrude Oil
(SCO)(SCO)
CondensateCondensateRefiningRefining
DilBitDilBit
SynBitSynBit
(Mining or In(Mining or In--Situ)Situ)
Source: Source: PurvinPurvin & & GertzGertz, 2004, 2004
UOP 4525A-05
Diluent Shortages will Make Diluent Shortages will Make SynBitsSynBitsthe Dominant Heavy Crude from the Dominant Heavy Crude from
Western CanadaWestern Canada2,5002,500
2,0002,000
1,5001,500
1,0001,000
500500
0019951995
Tho
usan
ds o
f Bar
rels
per
Day
Tho
usan
ds o
f Bar
rels
per
Day
20002000
20012001
20022002
20032003
20042004
20052005
20062006
20072007
20082008
20092009
20102010
20152015
20202020
SynBitSynBitDilBitDilBitConventional HeavyConventional Heavy
UOP 4525A-06
Source: Source: PurvinPurvin & & GertzGertz, 2005, 2005
Western Canadian Select (WCS)Western Canadian Select (WCS)Will Become a New Benchmark CrudeWill Become a New Benchmark Crude
Became available in January 2005Became available in January 2005–– Currently at 350 KBPDCurrently at 350 KBPD–– Expected to reach 500 KBPD by 2008Expected to reach 500 KBPD by 2008
Each batch contains:Each batch contains:–– CondensateCondensate–– Hydrotreated synthetic crudeHydrotreated synthetic crude–– Heavy conventional crudeHeavy conventional crude–– Medium conventional crudeMedium conventional crude–– Cold Lake bitumenCold Lake bitumen–– Athabasca bitumenAthabasca bitumen
UOP 4525A-07
BitumenBitumen--derived Crude Composition derived Crude Composition Different from Conventional CrudesDifferent from Conventional Crudes
0%
20%
40%
60%
80%
100%
WTI ArabLight
ANS LloydBlend
BowRiver
DilBit WCS SCO
Resid Vacuum Gas Oil Distillate Naphtha/LPG
0%
20%
40%
60%
80%
100%
WTI ArabLight
ANS LloydBlend
BowRiver
DilBit WCS SCO
Resid Vacuum Gas Oil Distillate Naphtha/LPG
vol-%
UOP 4525A-08
Processing BitumenProcessing Bitumen--derived Crudesderived CrudesAffects All Areas of the RefineryAffects All Areas of the Refinery
Bitumen BlendsBitumen BlendsHigh resid contentHigh resid content
–– Coking or SDA Coking or SDA requiredrequired
High contaminant High contaminant levellevel
–– HighHigh--severity severity hydrotreatinghydrotreating
High VGO content High VGO content after resid conversionafter resid conversion
Synthetic CrudesSynthetic CrudesNo resid contentNo resid content
–– Blending with other Blending with other heavy crudesheavy crudes
LowLow--quality distillatequality distillate–– HighHigh--severity severity
hydrotreatinghydrotreating
Large volume of lowLarge volume of low--quality VGOquality VGO
–– FCC feed FCC feed pretreatmentpretreatment
UOP 4525A-09
Processing BitumenProcessing Bitumen--derived Crudesderived CrudesAffects All Areas of the RefineryAffects All Areas of the Refinery
Bitumen BlendsBitumen BlendsHigh resid contentHigh resid content
–– Coking or SDA Coking or SDA requiredrequired
High contaminant High contaminant levellevel
–– HighHigh--severity severity hydrotreatinghydrotreating
High VGO content High VGO content after resid conversionafter resid conversion
Synthetic CrudesSynthetic CrudesNo resid contentNo resid content
–– Blending with other Blending with other heavy crudesheavy crudes
LowLow--quality distillatequality distillate–– HighHigh--severity severity
hydrotreatinghydrotreating
Large volume of lowLarge volume of low--quality VGOquality VGO
–– FCC feed FCC feed pretreatmentpretreatment
UOP 4525A-09
Additional VGO Conversion Required!
Increasing Distillate DemandIncreasing Distillate DemandWill Change Refinery Product SlateWill Change Refinery Product Slate
Distillate demand growing Distillate demand growing faster than gasoline demandfaster than gasoline demandIncreased dieselization of Increased dieselization of U.S. vehicle fleetU.S. vehicle fleetVGO conversion will shift VGO conversion will shift from FCC to hydrocracking from FCC to hydrocracking for distillate productionfor distillate production
2.402.40
2.002.00
1.601.60
1.201.20Rat
io (V
olum
etri
c B
asis
)R
atio
(Vol
umet
ric
Bas
is)
20002000 20022002 20042004 20062006 20082008 20102010 20122012 20142014YearYear
USA G:D Ratio ForecastUSA G:D Ratio Forecast
Source: Source: PurvinPurvin and and GertzGertz 2005 GPMO2005 GPMO
UOP 4525A-03
Adding 25% Synthetic VGOAdding 25% Synthetic VGOReduces FCC YieldsReduces FCC Yields
0%
10%
20%
30%
40%
50%
60%
70%
80%
Brent Brent + Sweet Blend Brent + Sour Blend
Crude Blend
LPG Gasoline LCO CSO
0%
10%
20%
30%
40%
50%
60%
70%
80%
Brent Brent + Sweet Blend Brent + Sour Blend
Crude Blend
LPG Gasoline LCO CSO
UOP 4525A-10
BitumenBitumen--derived derived VGOsVGOs are Hydrogen are Hydrogen Lean and Contaminant RichLean and Contaminant Rich
Lt. Arabian Lt. Arabian Cold Lake Cold Lake Athabasca Athabasca CokerCokerPropertyProperty VGO VGO VGOVGO VGOVGO HGOHGO
Gravity, Gravity, °°APIAPI 22.722.7 16.316.3 14.214.2 11.411.4Sulfur, wtSulfur, wt--%% 2.102.10 3.103.10 3.773.77 4.994.99Nitrogen, wppmNitrogen, wppm 820820 13801380 18541854 40324032Hydrogen, wtHydrogen, wt--%% 12.4712.47 11.3811.38 10.8010.80 10.4310.43Total Aromatics, Total Aromatics, volvol--%% 5858 6060 6969 7676
UOP 4525A-13
Integration of Hydroprocessing and Integration of Hydroprocessing and FCC Operation is the Key to FCC Operation is the Key to
Processing BitumenProcessing Bitumen--derived Crudesderived Crudes
DieselDiesel
GasolineGasoline
FCC Feed Hydrogen Content Must be OptimizedFCC Feed Hydrogen Content Must be Optimized
HDSHDS FCCFCC
UOP 4525A-11
What is the Right HydrogenWhat is the Right HydrogenContent for FCC Feed?Content for FCC Feed?
11.411.4 11.611.6 11.811.8 1212 12.212.2 12.412.4 12.612.6 12.812.8 1313 13.213.2 13.413.4 13.613.6 13.813.8
Hydrogen Content, WtHydrogen Content, Wt--%%
4848
5252
5656
6060
6464
6868
7272
Gas
olin
e Y
ield
, G
asol
ine
Yie
ld, V
olV
ol-- %%
EbullatedEbullated--bedbedGas OilGas Oil
CokerCokerGas OilGas Oil
HydrocrackerHydrocrackerBottomsBottoms
VacuumVacuumGas OilGas Oil
UOP 4525A-12
Tougher Feeds
Tougher Feeds -- Higher N
PV
Higher NPV
FCC Feed FCC Feed PretreatPretreat Economics Economics Improve as Feed Quality WorsensImprove as Feed Quality Worsens
700700
200200
00BrentBrent Brent +Brent +
Sweet Sweet SynSyn..Blend Blend
Brent +Brent +Sour Sour SynSyn..
BlendBlend
Arab LightArab Light Arab +Arab +Sweet Sweet SynSyn..
BlendBlend
Arab +Arab +Sour Sour SynSyn..
Blend Blend
100100
300300
400400
500500
600600Inc Op Costs, $MM/yrInc Op Costs, $MM/yr ISBL Costs, $MMISBL Costs, $MM NPV, $MMNPV, $MM
UOP 4525A-14
FCC Feed PretreatingFCC Feed Pretreatingis Not Always the Right Solutionis Not Always the Right Solution
FCC capacity still limited by high VGO FCC capacity still limited by high VGO content of bitumencontent of bitumen--derived crudesderived crudesHighHigh--quality distillate fuels quality distillate fuels cannot be produced in an cannot be produced in an FCC unitFCC unit
UOP 4525A-15
Hydrocracking Required to Convert Hydrocracking Required to Convert Incremental VGO and ProduceIncremental VGO and Produce
Right Product MixRight Product MixDieselDiesel
GasolineGasolineUnionfiningUnionfining™™ FCCFCC
DieselDiesel
GasolineGasoline
UnicrackingUnicracking™™
FCCFCC GasolineGasoline
UOP 4525A-16
Is the OnceIs the Once--throughthroughUnicracking Process the Right Choice?Unicracking Process the Right Choice?
Higher yields of naphtha and distillateHigher yields of naphtha and distillate
Higher quality FCC feedstockHigher quality FCC feedstock
Flexibility to adjust conversion Flexibility to adjust conversion for seasonal demandfor seasonal demand
UOP 4525A-17
OnceOnce--through Unicracking Process Produces through Unicracking Process Produces FCC Feed with High Hydrogen ContentFCC Feed with High Hydrogen Content
RR--11RR--22 NaphthaNaphtha
KeroseneKerosene
Heavy DieselHeavy Diesel
FCC FeedFCC Feed
6060
6464
55
1212
1717
3030
61.561.5
16 mm Smoke Point16 mm Smoke Point
45 Cetane No.45 Cetane No.
UOP 4525A-18
HH22
FeedFeed
00
3030
Conversion, wtConversion, wt--%%
Cetane IndexCetane Index
Smoke Point
Smoke Point2525
2020
1515
1010
55
002020 4040 100100
8080
7070
6060
5050
4040
3030
Conventional VGO FeedConventional VGO Feed
Ker
osen
e Sm
oke
Poin
t, m
mK
eros
ene
Smok
e Po
int,
mm
6060 8080
Die
sel C
etan
e In
dex
Die
sel C
etan
e In
dex
Increased Conversion Produces Increased Conversion Produces HigherHigher--quality Fuelsquality Fuels
UOP 4525A-19
SeparateSeparate--hydrotreat Configurationhydrotreat ConfigurationProvides FlexibilityProvides Flexibility
RR--11
RR--22 NaphthaNaphtha
KeroseneKerosene
Heavy DieselHeavy Diesel
FCC FeedFCC Feed
6060
9595
1111
1616
88
3030
3030
23 mm Smoke Point23 mm Smoke Point
57 Cetane No.57 Cetane No.
3030
Independent Control of Distillate Independent Control of Distillate and FCC Feed Qualitiesand FCC Feed Qualities
UOP 4525A-20
HH22
FeedFeed
ULSDULSD
CoCo--feedfeedHH22
VGOVGOFeedFeed
HTRx
HCRx
EHS
FractionationFractionationAMINE
SEP
PTRx
FCC FeedFCC Feed
Enhanced HotEnhanced HotSeparatorSeparator
Advanced PartialAdvanced Partial--conversion Unicracking conversion Unicracking (APCU) Integrates FCC Feed (APCU) Integrates FCC Feed
Pretreatment with ULSD ProductionPretreatment with ULSD Production
UOP 4525A-21
Unicracking Process is the Right Unicracking Process is the Right Choice for Converting Choice for Converting
Incremental VGOIncremental VGOOptimizes FCC feed hydrogen contentOptimizes FCC feed hydrogen contentProduces highProduces high--quality distillate fuels to meet quality distillate fuels to meet growing demandgrowing demandDiesel produced can meet all ULSD specsDiesel produced can meet all ULSD specsProduct slate can be seasonally adjustedProduct slate can be seasonally adjustedSmall incremental capital cost to upgrade from Small incremental capital cost to upgrade from FCC feed pretreating to Unicracking processFCC feed pretreating to Unicracking process
UOP 4525A-22
SummarySummary
BitumenBitumen--derived crudes will be an increasing derived crudes will be an increasing crude component for northern US refinercrude component for northern US refinerSignificant processing implications will Significant processing implications will prompt both resid and VGO prompt both resid and VGO hydroprocessing conversionhydroprocessing conversion‘‘IntelligentIntelligent’’ hydroprocessing hydroprocessing solutions will be required to solutions will be required to cost effectively accomplish the cost effectively accomplish the upgrading of synthetic crudes. upgrading of synthetic crudes.
UOP 4525A-23
UOP 4525A-24