maximizing bottom-of-the barrel conversion with...

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Jacinthe Frécon

Maximizing Bottom-of-the Barrel Conversion with Commercially Proven

Technologies

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Conversion Mapping

H-Oil®RC: Ebullated Bed Residue Hydrocracking

Case Study: Diesel maximization with H-Oil® & Coker

Summary

Agenda

Refining India, 12-13 October 2015, New Delhi

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Conversion Mapping



Summary

Agenda


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RFCC

Conversion Mapping

AR

VR Fixed bed Residue HDT

Ebullated Bed Resid

HCK

Slurry HCK

VGO

VGO HDT /

MHC

SDA EB Distillate

HCK

FCC

HCK

Visbreaker

Delayed

Coker


VDU

LPG

Naphtha

Jet/Kero

Diesel

Fuel

Oil

DAO

Pitch

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Conversion Mapping



Summary

Agenda


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Axens H-Oil® Process

Nearly isothermal

Low and constant pressure drop

Daily addition of fresh catalyst

No cycle length

Flexibility

Ebullated-Bed Reactor


First unit started in 1968

10 units in operation today

7 units in design/construction

4 awards in 2013/2014

1 award in 2015

Total capacity ~865,000 BPSD

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Availability of H-Oil® Units (2001-2010/2013)

Superior Reliability

Avg. 96.6%


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Conversion Mapping


Case Study: Diesel Maximization with H-Oil® & Coker

Summary

Agenda


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Context: Expansion Study for an Asian refinery

Maximize Diesel Euro V production

Minimize revamping cost for DCU (if any)

Case Study - Overview


Delayed

Coker

3.6 MTA

Existing

Distillation

Trains

New

Distillation

Train

New resid

Hydro-

conversion

Unit

VR1

VR2

2.2 MTA

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Feedstock: Vacuum Residue 550°C+

Case Study – Description

VR 550°C+

API 7.1

Sulphur, wt% 2.5

Nitrogen, wppm 4900

Viscosity @ 100°C, cSt 9300

Vanadium, wppm 315

Nickel, wppm 110

South America

West Africa

Middle East

Others

2 technology options to achieve high residue conversion

• Ebullated-bed Technology

• Slurry Technology


Crude oil slate

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VR2

UCO

Products

(540°C-)

VR1

H-Oil®RC

3.4 MTA

(1 train)

3.6

MTA

1.2 MTA

2.2

MTA

1.2

MTA

2.4 MTA

Case Study – Ebullated-bed Technology H-Oil®RC

Anode

Grade Coke

Delayed

Coker 3.6 MTA

Liquid

& Gas

Products

Overall Conversion:

(100-Coke) = 79.5 wt%

VR2 Conversion: 87 wt%

Proven High Conversion Scheme

Coke Upgraded as Anode Grade


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VR2

UCO

Products

VR1

Liquid

& Gas

Products

Coke

Delayed

Coker

3.6 MTA

3.6

MTA

2.2

MTA

Case Study – Slurry Technology

Slurry

2.2 MTA

UCO to be Solidified

(catalyst, ashes, coke)

Overall Conversion:

(100-Coke) = 78.1wt%

VR2 Conversion: 92 wt%

Slurry: Little Commercial Experience & only

Short Term Operation

Very Limited Outlet for Slurry UCO Disposal

Coke from Coker cannot be Upgraded

Poorer Quality Products


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VGO HyK and Diesel HDT are included for Diesel

production

Case Study – Diesel Production Comparison


VR 2

Unconverted

VR

Diesel

VR 1

Coke

150°C-

VGO

Diesel

150°C-

VGO

2% diesel

loss in HDT

65% of H-Oil® VGO

& Coker VGO

converted to Diesel

Potential

Diesel

Euro V

Slurry

H-Oil®RC

Delayed

Coker

Diesel

HDT

HyK

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Conversion

• Proven High Conversion with Combination of H-Oil® & Coker

VGO/Diesel Product quality

• Slurry products: heavier, high nitrogen & low hydrogen content

• H-Oil® products: better quality allows boosting downstream unit performance

UCO Disposal

• H-Oil® & Coker: Coke can be marketed as anode grade for Al production

• Slurry & Coker: Coke from coker cannot be upgraded. Slurry UCO has very

poor quality, needs to be solidified and very limited outlets for disposal

Product yield

• Slurry: Highest gas and naphtha yield

• H-Oil® & Coker: Highest potential diesel Euro V production

Case Study – Conclusions


H-Oil® & Coker Option

Higher Profitability

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Conversion Mapping


Case Study: Diesel Maximization with H-Oil® & Coker

Summary

Agenda


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H-Oil® is a proven technology allowing high conversion of

residue

Design & Catalyst improvements redefine existing H-Oil®RC

limits

H-Oil®RC and Coker association

• Highest Diesel production (20% more than slurry technology)

• Better VGO/Diesel quality: benefit for downstream units and maximizing

diesel product

• Possible Anode Grade Coke production

Summary


Axens has an extensive experience in

Resid upgrading and continues to

improve technologies to reach higher

conversion with better operability

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