jsc siberian technological company “zeosit” - sec “zeosit” pr. lavrentieva, 6, novosibirsk...

JSC Siberian Technological Company “Zeosit” - SEC “Zeosit” Pr. Lavrentieva, 6, Novosibirsk 630090, Russia Tel. /Fax: (383) 330-05-96, 335-62-51

E-mail: [email protected] URL: http://www.zeosit.nsc.ru

Small modular catalytic units for production of high-octane unblended gasolines through the process of Zeoforming

The process of Zeoforming, an effective method for production of high-octane unblended gasolines

(Based on the results of industrial operation of a Zeoforming-40 installation)

Zeoforming is a technology for catalytic conversion of low-octane gasoline fractions (straight-run gasoline fractions of oils and gas condensates) into high-octane unblended gasolines proved at pilot to industrial levels.

Zeoforming is a technology for catalytic conversion of low-octane gasoline fractions (straight-run gasoline fractions of oils and gas condensates) into high-octane unblended gasolines proved at pilot to industrial levels.

Zeoforming has been adjusted:

Pilot level:

Pilot level:

At the Urengoy Gas Condensate Processing Plant, Nizhnevartovsk Gas Processing Plant, Luginetskoe Oil Field (Tomsk Region), Volgograd Refinery, Orenburg Gas Processing Plant.



Industrial level:Industrial level:

Demonstrational level:Demonstrational level:

A 5,000-ton/year Zeoforming installation for unblended gasoline production from stable gas gasoline has been in operation at Nizhnevartovsk Gas Processing Plant since September 1992.

An industrial Zeoforming installation of 40,000 ton/year capacity with respect to straight-run gasoline fraction (“Zeoforming-40”) began to operate in Poland in February, 1997. Lurgi Company (Germany) was the general contractor and designer. The commercial products of the installation are unblended Eurosuper-95 gasoline and liquefied gas. All the guarantee parameters presented by "Zeosit" are fully met: the octane number of the gasoline is 95 RON and total yield of both commercial products not less than 92-95%. During the start-and-adjustment works, new additional possibilities of the process and the catalyst were tested which may allow a still higher efficiency in future installations (i.e., an increased yield of the commercial products, octane number of the gasoline, and catalyst lifetime) without making the investments or running costs higher.



Process parameters:

Advantages:

Temperature, оC 320-450

Pressure, MPa 0.5-1.5

WHSV of the feedstock, ton/ton of cat. per hour 1-4

Temperature, оC 320-450

Pressure, MPa 0.5-1.5

WHSV of the feedstock, ton/ton of cat. per hour 1-4

which decreases the capital and running costs.

which decreases the capital and running costs.

In contrast to Reforming, the process of Zeoforming does not require:In contrast to Reforming, the process of Zeoforming does not require:

The catalysts are based on an environment-friendly system.

The catalysts are based on an environment-friendly system.The installations can operate autonomously.

The installations can operate autonomously.

► a hydrofining stage to remove sulphur and nitrogen-containing compounds

from the raw material

► either hydrogen or any related compressor equipment

► expensive catalysts based on noble metals ,

► a hydrofining stage to remove sulphur and nitrogen-containing compounds

from the raw material

► either hydrogen or any related compressor equipment

► expensive catalysts based on noble metals ,



Being autonomous, these mini-plants are useful in remote regions or regions difficult of access where oil, gas condensate, or other hydrocarbon raw material are produced. They are expedient in meeting the demand in motor fuels of the local population as well as geologists and oilmen.

Depending on the type of the raw material and the chosen production mode, RON-80 or RON-91 - 93 gasolines can be produced at one and the same installation.

The gasoline yields are: when RON-80 gasoline is produced – 80-92%, when RON-91 - 93 gasoline is produced – 65-85%.



Expenditure rates of the main and auxiliary materials

№ Units, Apparatus, Production StagesMaterials,

Measure units

Approximate expenditure rate per

1 ton of the feedstock

1 Reactors Catalyst, kg/ton 0.06-0.10

2 Regeneration and purging Nitrogen, nm3/ton ~ 3

3 Catalyst regeneration Air, nm3/ton ~ 18

4 Cooling down the technological flowsRecycled cooling water

(t=25°C), ton/ton0-12*

5 Providing for the rectification process Water vapour, ton/ton 0-0.15*

6 Furnace section Fuel gas, nm3/ton 15-25*

7 Pumps, compressors, fans ABO Electric power, KWt·hour/ton 15-25**

* - depends on the chosen process flow-sheet

** - depends on the chosen process flow-sheet and the capacities of the chosen electrical receivers



Diagram of conversion of oil fractions or gas condensate into motor fuels through different processes:

Gas

olin

e fr

acti

on

26%

iso-

para

ffin

s8.

5%

Gasoline fraction 35%

Hydrogen-containing gas

High-octane

component 22%

C5-C6

9%

Fuel oil 30%

Diesel fuel 35%

Feedstock

Blending unit

Fractioning installation

Hydrofining installation

Reforming installation

Unit of gas desulphurisation

Hydro-isomerisation installation

Hydrogen-containing gas

H2

Diagram 1. Conventional scheme (Reforming and isomerisation)



Feed-stock

Liquefied gas

6-9%

High-octane gasoline

25-28%Zeoforming installation

Fractioning installation

Fuel oil

30%

Fuel gas

1%

Gasoline

fraction 35%

Diesel fuel 35%

Diagram 2. Zeoforming technology (Verkh-Tarskoe oil is taken as an example)



Dynamics of costs and profits depending on the capacity of a Zeoforming installation

(the data concern the production of gasolines of 92 to 95 RON)

0 5 10 15 20 25 30 35 40 45 50 55 60number of months

Co

sts,

rel

. u

nit

s

Pro

fits

, re

l. u

nit

s

80 thou. ton/ year40 thou. ton/ yearТочечная 3

Starting the installation



Comparative analysis of the net present value (NPV) for the installations of high-octane gasoline production

via Zeoforming and Reforming

-4

-2

0

2

4

6

8

10

0 20 40 60 80 100

Capacity of installation with respect to the gasoline produced, thou. ton/year

NP

V, m

illio

n U

SD

Zeoforming

Reforming



Range of the benzene content in Zeoforming gasolines (1) and Reforming gasolines (2)

depending on the octane number of the gasoline

70 75 80 85 900

2

4

6

8

10

12

Reforming gasolines

Zeoforming gasolines

Be

nze

ne

co

nte

nt,

%w

t.

MON of the gasoline

1

2



Range of the aromatic content in Zeoforming gasolines (1) and Reforming gasolines (2)

depending on the octane number of the gasoline

65 70 75 80 85 90

10

20

30

40

50

60

70

80

Reforming gasolines

Zeoforming gasolines

Aro

mat

ic c

onte

nt,

%w

t.

MON of the gasoline

1

2



Parameter Zeoforming ReformingAdditionally required

for Reforming

The reaction temperature, оC 320-450 480-520

Pressure, atm. 5-15 3-35

Hydrogen equipment Is not required Is required Hydrogen equipment

Raw material hydrofining Is not required Is required Desulphurisation Unit

Raw materialHydrocarbon fractions C5 –

240оC; olefin-containing gases; oxygen-containing compounds

Hydrocarbon fractions C6

–180оC (naphthenes)

Catalyst Contains no noble metals;

ecologically safe

Contains Pt, Pd; may contain other heavy

metals

Final product

High-octane gasoline ready for use, with benzene content 1-3% vol. The second desired product

is liquefied gas The second desired product is liquefied gas,

a fuel both for domestic purposes and for automobiles

High-octane aromatic component of gasoline which needs blending, with benzene content

5-15% vol.

Blending Unit

Zeoforming vs. Reforming: key parameters



Parameter Zeoforming ReformingAdditionally required for Reforming

Gasoline yield : Motor gasoline :

Depend on blending conditions Blending Unit

RON-80 RON-92 «Euro-super-95»

- for fraction 35-160оС 80-90% 65-75% 60-67%

- for fraction 70-180оС 85-92% 70-85% 65-75%

Permissible sulphur content in the raw material

is not limited less than 0.0004 % wt. Desulphurisation Unit

Sulphur content in the gasoline produced

depends on the sulphur content in the raw material but does not exceed 0.05% wt.

no more than 0.0004% wt.

Catalyst lifetimeproved to be at least 20 000 hours at the industrial installation Zeoforming-40 in

Poland

Costs of the catalyst: Zeoforming –

$ 18 000-20 000 /ton; Reforming –

$ 67 000-90 000 /ton

Economic characteristics

For capacities 80-600 thousand tons/ year, the investments are repaid in less

than 1.5 – 2.5 years

Is profitable for capacities above 600-

800 thousand tons/year

Continuation

Zeoforming vs. Reforming: key parameters

jsc siberian technological company “zeosit” - sec “zeosit” pr. lavrentieva, 6, novosibirsk...

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