UOP 7804-0 © 2017 UOP LLC. A Honeywell Company All rights reserved.

13-17 March 2017 ARA Week 2017 Cape Town

Solutions for Diesel Specification ChangesDerek BultitudeRegional Sales Manager

Honeywell International Inc.

UOP’s 65 Years of Hydroprocessing Innovations

340+ Unionfining Units & 220+ Unicracking Units Licensed

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0

40,000

80,000

120,000

160,000

200,000

1950 1955 1960 1965 1970 1975 1980 1985 1990 1995 2000 2005 2010 2015 2020

Lic

en

se

d C

ap

ac

ity,

BP

SD

Award Year

UOP Hydroprocessing Experience

Unionfining Units

Unicracking Units

1952

1st Unionfining™

Unit

1960

1st Unicracking™

Unit

2008

E2S

Process

2016

Unity

Hydroprocessing Catalysts

TM

2012

UniflowTM

Reactor

Internals5th Generation

1990s/2006

HPNA

Management

2011

Lubes & Fuels

Alliance

AFRI & EURO Diesel Specifications

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Die

se

l

Property AFRI-4 AFRI-5 EURO-4 EURO-5

Sulphur content, % mass, max. 0.005 0.005 0.005 0.001

Density at 15ºC, kg/m3 max 880 880 845 845

Cetane Number, min. - 49 51 51

PAH, mass-%, max. - 11 11 8

ASTM D86 Distillation 95% recovery, ºC, max.

- - 360 360

1. In cases of dispute ASTM D3244 / EN ISO 4259 shall be used.

UOP 7959-2

Solutions to Meet Diesel Specifications

Optimum solution by modifying existing equipment

Sulfur

Reduced cycle length on DHT

Catalyst selection

Lower LHSV

Improved Reactor

Internals

Higher H2 purity

T95

Increased fuel oil production at the expense of Diesel

Hydrocracking for

End-point correction

Tightening

Specification

Impact of

Doing nothing

UOP Solution

Cetane Number

Restricted Crude selection

Catalyst selection

H2 availability

Cetane improver

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Hydrotreating Process Variables

Several important variables influence product quality

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Liquid Feed Gas

Process

Conditions

Products

H2 Content

H2S Content

Impurities

Reactor Pressure

ppH2

Treat Gas Rate

Treat Gas Purity

Space Velocity

Temperature

Sulfur

Nitrogen

Density

Distillation

Contaminants

Aromatics

Bromine Number

Catalyst selection

Reactor internals

Grading

CatalystUtilisation

UOP Unity Increasing Performance of Your Hydrotreating Unit

UOP offers an extensive range of Hydrotreating Catalysts

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HYT-4118

State-of-the-art, high activity catalyst provides excellent

desulfurization, denitrogenation, and hydrogenation

• Designed for challenging feedstocks including distillates, VGO,

heavy coker gas oils, DAO, & more

• Enhanced dispersion of metals results in high activity & increased stability

• Achieves longer operating cycles & improves sulfur and nitrogen reduction

• Rejuvenation demonstrated up to 95% of fresh catalyst activity

High Activity Distillate Hydrotreating Catalysts

HYT

6219

HYT

4118

Enhances unit performance through superior desulfurization

and low hydrogen consumption

• Designed for low to medium pressure ultra low sulfur diesel production

• High activity and stability for longer cycle lengths

• Manage hydrogen consumption

• Compatible with range of feedstocks including straight run diesel, light

cycle oil, light coker gas oil, & other cracked feedstocks

UOP 7959-6

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Uniflow™ Hydroprocessing Reactor Internals

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• Novel vapor-liquid distribution tray offers step change in performance

– Faster installation & easier turnaround maintenance

– Lower radial delta T

– Improved range-ability (vapor-liquid rates) allow flexible operation

•Commercially proven– 100+ Uniflow trays sold into

21 units since 2013

•Currently 8 units operating

UOP 7959-7

Uniflow Reactor Internals – Improved Radial Spread

• Installed in 5-Bed hydrocracking reactor in November 2014

• Unit operating with 32% higher feed rate compared to previous cycle

Reactor Bed

Uniflow InternalsRadial Spread (deg. C)

New Cycle

Old InternalsRadial Spread (deg. C)

Previous Cycle

Bed 1Top: 1

Bottom: 1

Top: 2

Bottom: 10

Bed 2Top: 2

Bottom: 2

Top: 1

Bottom: 3

Bed 3Top: 2

Bottom: 1

Top: 3

Bottom: 3

Bed 4Top: 2

Bottom: 2

Top: 7

Bottom: 20

Bed 5Top: 2

Bottom: 2

Top: 6

Bottom: 25

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“We would never have been able to operate this unit where it

is today without these new internals. This is a step change for UOP”

CustomerFeedback

UOP 7959-8

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Hydrogen Management

• More severe operation increases chemical hydrogen demand

• Higher make-up purity increases partial pressure in the reactor

– Increasing catalyst cycle length

– Allowing higher throughput

Integrated and recycle schemes to maximize H2 and LPG recovery

• As product specifications tighten, Hydrogen Management is critical to

maintaining plant profitability

Hydrogen recovery solutions can be tailored to meet specific refinery needs

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Comparing H2 Purification Technologies

Polybed™ PSA Polysep™ Membrane

H2 Purity 98.9 – 99.999% up to 98%

H2 Recovery 60 – 95% 85 – 95%

Feed Pressure 90 – 580 psi g 200 – 2,500 psi g

Product Pressure 70 – 565 psi g 70 – 1,250 psi g

UOP offers both PSA and Membrane as skid mounted packaged equipment

Impact of LHSV on Product Sulphur

Adding catalyst volume can recover cycle-length lost at higher severity

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LHSV = FLOWRATE

CATALYST VOLUME

Catalyst

temperature

Time

Reducing LHSV

EOR

SOR

Hydrotreating Revamp - Case Study

Action required on catalyst, hydrogen, internals and LHSV

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Existing Unit Design - 300 ppm Product Sulfur

Feedstock: Straight Run Gas Oil

Low Recycle Gas Purity: 80% hydrogen

Process Conditions: 40 bar, 4.4 hr-1 LHSV

Revamp Objectives: 10 ppm Product Sulfur

Product Specification: Produce Euro V diesel

UOP Solution

Change Catalyst

Increase Hydrogen Purity

Increase Catalyst Volume

Upgrade Reactor Internals:

Customer met their objective in a cost effective way

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Hydrotreating Revamp - Case Study Continued

CATALYST - upgraded to higher activity option

INTERNALS - state-of-the-art distributor installed

HYDROGEN – purity increased to > 90%

Situation before revamp UOP Solution

LHSV – additional reactor increased catalyst volume

300 ppm S 10 ppm S

Meeting T95 through fractionation can cost $0.5/bbl crude

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Euro V – the Cost of Meeting T95

• The low investment solution to meeting a Euro V T95 distillation specification is to drop the heavy end of the diesel to gasoil or fuel oil

• Consider the economics for a 100,000 bpd refinery with a 34,000 bpd diesel Hydrotreater:

– Assume 16% of Hydrotreater feed downgraded • ~ 2 million barrels per year

– Assume a 10ppm diesel crack spread of $10/bbl.

– The cost of the downgrade to fuel oil will cost $20 million/year or $0.5 on every barrel of crude processed.

– If the refinery is able to segregate the heavy diesel cut and market as a low sulphur fuel oil grade or blend to gasoil, the cost of the downgrade would be lower but still significant.

Hydrotreating Revamp Case StudyT95 reduction enables upgrade of fuel oil

Total product value 5% higher with 3 month payback

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Existing Solution

Fractionation

16% of feed lost to

fuel oil

Configuration

Main hydrotreating reactor.

Smaller dewaxing reactor

with bypass

Revamp Objectives

Process Heavier Feedstock

Recover feed lost to fuel oil

Meet Euro V specification

UOP Solution

Optimize Catalyst Volume

Replace dewaxing catalyst

with hydrocracking catalyst

Increase Hydrogen Consumption

>90% hydrogen

Meets all Euro V specs

Dewaxing

Reactor

Refiners Need to Address a Range of Issues to Meet Tighter Diesel Specifications

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UOP has the Solutions to help Refiners meet the transition

to AFRI 4/5 or EURO 4/5 Diesel Specifications

Specification Challenges UOP Solutions

Sulfur reduction

Unity hydroprocessing catalyst, Uniflow internals, PolybedTM PSA or PolysepTM membrane. Revamp or new modular DHT

Cetane and T95 controlFractionation and UnicrackingTM

Endpoint correction using UnicrackingTM catalyst

UOP 7959-16