feedstock blend for the new H-Oil-RC™ ebullated bed · feedstock blend for the new ... and the...
Transcript of feedstock blend for the new H-Oil-RC™ ebullated bed · feedstock blend for the new ... and the...
Optimization of the
feedstock blend for the new
H-Oil-RC™ ebullated bed
resid upgrading unit
at LukOil Neftochim Burgas,
to maximize the conversion
and yields of the on-site FCC
unit
Presented by:
Dr. Dicho Stratiev LukOil - Burgas
Wessel IJlstra Criterion - Amsterdam
Co-authors:
Dr. Ilshat Sharafutdinov LukOil - Burgas
Dr. Georgi Argirov LukOil – Burgas
Dr. Magdalena Mitkova Burgas University
Radoslava Nikolova Burgas University
Dr. David E. Sherwood Jr. Criterion - Houston
Burgas University
Disclaimer
Criterion, LukOil, and Burgas University are the trade names of independent entities. Where
an entitity is identified by its trade name, the reference is used for convenience, or may be
used where no useful purpose is served in referring to the entity by name. The services and
products of these entities may not be available in certain countries or political subdivisions
thereof.
The information contained in this presentation is provided for general information purposes
only and must not be relied on as specific advice in connection with any decisions you may
make. No representations or warranties, express or implied, are made by the entity or
entities presenting these materials, or their affiliates, concerning the applicability, suitability,
accuracy or completeness of the information contained herein and these entities do not
accept any responsibility whatsoever for the use of this information. The entities presenting
these materials, and their affiliates, are not liable for any action you may take as a result of
you relying on such material or for any loss or damage suffered by you as a result of you
taking this action. Furthermore, these materials do not in any way constitute an offer to
provide specific services.
Copyright ©2015 Shell Oil Company. All rights reserved. No part of this publication may be
reproduced or transmitted in any form or by any means, electronic or mechanical including
by photocopy, recording or information storage and retrieval system, without permission in
writing from Shell Oil Company or Criterion Catalysts & Technologies L.P.
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Program
- Introduction to LukOil Neftochim, refinery Burgas
and the new H-Oil-RC™ unit licensed by Axens
- Study objectives for this presentation
- Introduction to ebullated bed pilot plant testing
- Pilot plant test plan
- Pilot plant test results
- Experimental and theoretical estimates FCC yields
- Refinery scheduling
- Conclusions
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Process Diagram of LUKOIL Neftohim
Burgas
Crude oil
6.5 MM t/y
+ 1.5 MM t/y
Atm. Residue
B L E N D I N G
FCC
Pre-
treate
r
Bitumen unit
LPG
Naphtha
Premium
gasoline
(A-95H)
Super
Gasoline
(А-98Н)
Jet A-1
Euro diesel
Road
Bitumen
Fuel oil
S<1%
Sulphur - New units
- Gasoline
- Kerosene
- VGO
- Diesel fuel - C1-C4 gas - Н2S
- Heavy residue
- Existing units
- Fuel oil
Fuel gas
AVD-1
AD-4
VDU-2
HDS-1
HDS-2
HDS-3
Reformer
AGFU CGFU
Naphtha
Hydrotreater
SRU-3
Prime-G
VBU
SMR
HDS-5 1 700
хил.т./г
MTBE
Alkylatio
n
FCCU
n-С4
Isomerization
SRU-4
2015
2015
H-Oil residue
hydrocracking
- Units out of operation
SMR
«ЛУКОЙЛ Нефтохим Бургас» АД
18
SRU-2
2015
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Program
Problem definition: • Commissioning of the new H-Oil-RC™ unit at LukOil Burgas will
allow for rescheduling of the refinery to optimize product yields.
• At start-up, not enough vacuum resid will be available to fully utilize
the capacity of the new unit, but alternative heavy feed components
(AR, VGO) can be rerouted to H-Oil-RC™ unit.
Study objectives:
Screen possible feed blends for the H-Oil-RC™ unit.
• Use yields- and product quality results from H-Oil pilot-plant study
to estimate/test FCC unit performance.
• Use conclusions in site scheduling program to optimize refinery
margins.
CATALYST/ LIQUID/GAS
LIQUID/GAS
HYDROGEN and FEED OIL
FRESH CATALYST
EXPANDED CATALYST LEVEL
RECYCLE OIL
USED CATALYST
LIQUID
EBULLATION PUMP
GRID PLATE WITH MULTIPLE DISTRIBUTION CAPS
PRODUCT LIQUID/GAS
SETTLED
CATALYST
LEVEL
Level instrument Example of a commercial Ebullated Bed Reactor Defining characteristics: * Back-mixing of liquid and catalyst - Little temperature and concentration gradient - Uniform catalyst activity * Continues catalyst replacement - Stable performance of catalyst inventory
Introduction ebullated bed pilot plant testing
Criterion uses autoclave reactors equipped with Robinson-Mahoney type
internals. Back-mixed (CSTR) kinetics are assumed
to evaluate Ebullated Bed Catalyst Performance
• Fixed annular catalyst basket
with baffles inside and outside the basket
to prevent vortexing.
• Rotating shaft with agitator, creating flow
through the basket to the reactor wall for
upward and downward deflection.
• Liquid level controlled by overflow tube
• Gas hold-up controlled by mixer speed
• Multi-phase gradientless reactor.
From: http://www.autoclave-france.fr/english/cata.html
Introduction to Ebullated Bed pilot plant testing
Two of the four Criterion CSTR Pilot Plants
located in the Houston R&D laboratory
Test plan
• Three independent tests were done in the same Criterion pilot-
plant at Shell Technology Center, Houston (STCH) to simulate
the new H-Oil-RC™ unit at LukOil Burgas.
• Each test used one of 3 feed blends as specified and supplied by
LukOil:
A. 100% VR
B. 75% VR + 25% heavy VGO
C. 50% VR + 50% heavy AR
(All feed blends were additionally blended with FCCUHCO +
FCCU Slurry Oil [diluents], as specified and supplied by LukOil)
• Each test was done at equal conditions. The feed rates were kept
constant, but, to allow for interpolation to the target conversion
level, the evaluations were done at 2 different conversion levels.
Test plan --- Feed Blends A, B and C (after diluent addition)
Analysis Unit
VR
100%
(+diluents)
VR/VGO
75%/25%
(+diluents)
VR/AR
50%/50%
(+diluents)
Density kg/l 1.010 0.984 0.978
Sulphur wt-% 2.73 2.38 2.03
Nitrogen wt-% 0.4964 0.4051 0.3679
Carbon residue, MCR wt-% 16.0 11.0 11.0
Ni ppm 82 53 48
V ppm 258 175 143
SimDis
538 oC+ wt-% 82.1 65.5 58.6
565 oC+ wt-% 75.2 55.5 52.1
Test Results
• For each test, 2 (or 4) test-periods were selected for
complete analysis (fractionation + product quality
analysis).
• All samples of the VGO and VR products were shipped to
LukOil Burgas for further evaluation by LukOil and Burgas
University.
Test Results
Test Results
• Net 540°C+ conversion appears higher for vacuum resid
only feed, compared to the lighter blends.
35.0
40.0
45.0
50.0
55.0
60.0
65.0
70.0
75.0
80.0
406 408 410 412 414 416 418 420
Net
54
0°C
co
nve
rsio
n [
wt%
]
Operating temperature [°C]
Target Conversion
Test Results
• For each of the feed blends the yield pattern was
determined.
• This example is for the100% VR feed.
2.0
7.0
12.0
17.0
22.0
27.0
32.0
37.0
50 52 54 56 58 60 62 64 66 68 70 72 74 76 78 80
Pro
du
ct y
ield
s [w
t%]
Net 540°C+ conversion [wt%]
Target Conversion
VGO
Test Results
• The yield patterns can be directly compared for the
different feed blends.
• Lighter feed blends, containing more VGO, give higher
VGO yields at equal 540°C+ conversion.
12.0
17.0
22.0
27.0
32.0
37.0
42.0
47.0
50 52 54 56 58 60 62 64 66 68 70 72 74 76 78 80
VG
O y
ield
s [w
t%]
Net 540°C+ conversion [wt%]
Target Conversion
75/25 VR/VGO
100% VR
Test Results
• Lighter feed blends, containing more diesel, result in
higher diesel yields at equal 540°C+ conversion.
2.0
7.0
12.0
17.0
22.0
27.0
32.0
37.0
50 52 54 56 58 60 62 64 66 68 70 72 74 76 78 80
Die
sel y
ield
s [w
t%]
Net 540°C+ conversion [wt%]
Target Conversion
Test Results
• Hydrogenation performance and product quality data were
interpolated to the target 540°C+ conversion level.
Feed blend VR VR/VGO VR/AR
Blending ratio 100 75/25 50/50
540°C+ Conversion Base Same Same
Sulfur in unconverted resid wt% Base -0.2 -0.2
HDS wt% Base +4 +4
HDN wt% Base +5 Same
HDMCR wt% Base +5 +6
HDMetals wt% Base +4 +2
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H-Oil-RC™ products from 3 different feed blends
were separated and analyzed for product quality
100% VR
75/25 VR/VGO
50/50 VR/AR
Diesel VGO VR
Feed blends
H-Oil-RC(TM) Product Density
100% VR
75/25 VR/VGO
50/50 VR/AR
Diesel VGO VR
Feed blends
H-Oil-RC(TM) Product Sulfur
100% VR
75/25 VR/VGO
50/50 VR/AR
Diesel VGO
Feed blends
H-Oil-RC(TM) ProductNitrogen
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FCC feed specific properties for VGO product
100% VR
75/25 VR/VGO
50/50 VR/AR
Kw Saturates light middle heavy ResinsAromatics
Feed blends
100% VR
75/25 VR/VGO
50/50 VR/AR
Kw Saturates Aromatics Resins Asphaltenes
Feed blends
Specific properties for the unconverted product
Specific properties of the H-Oil-RC™ products, needed for
predicting the FCC unit performance were analyzed in the
LukOil laboratory
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H-Oil-RC™ pilot-plant products were used as feed
for Micro Laboratory FCC pilot units
FCC yield patterns simulated at max gasoline yield, when
using H-Oil-RC™ VGO products neat from different feed
blends
100% VR
75/25 VR/HVGO
50/50 VR/AR
drygas LPG gasoline LCO HCO Coke conversion
VGO product
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In addition, Micro Laboratory FCC simulations were performed
for blends of H-Oil-RC™ products with straight-run HVGO
FCC yield patterns simulated at max gasoline yield, when using
blends of SR HVGO and H-Oil-RC™ VGO products
Compared to the blend 50%/50% blend with VGO product from
100% VR run, the 50%/50% blend with VGO product from the
75%/25% VR/VGO run gave ~+4% gasoline + LPG at the
expense of ~-4% cycle oils.
100% SR HVGO
50% SR HVGO + 50% H-OilVGO (100% VR)
50% SR HVGO + 50% H-OilVGO (75/25 VR/HVGO)
drygas LPG gasoline LCO HCO Coke conversion
VGO blends
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Simulated LUKOIL Neftohim Burgas Constrained FCCU yields
Product Yields, wt.%
90%/10% HTVGO/
VGO
50%/50% HTVGO/
H-Oil-RC™ VGO
(100%VR)
50%/50% HTVGO/
H-Oil-RC™ VGO (75%/25% VR/HVGO)
dry gas 2.5 3.30 2.8
PPF 8.7 7.48 8.1
BBF 13.4 11.80 12.4
Cracked Naphtha 52.4 49.00 51.0
LCO 9.9 11.48 10.9
HCO 5.3 6.70 5.5
Slurry 3.9 5.85 5.2
Coke 4.0 4.40 4.1
Conversion 81.0 76.0 78.4
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Yield- and product property data were used in the
refinery’s LP-model to evaluate the profitability
When the H-Oil-RC™ unit capacity is not fully
utilized, processing SR HVGO in the unit appears
very favorable for overall refinery profitability
100% VR 75/25VR/HVGO
50/50 VR/AR
BaseBase + 5%
Base + 7.5%
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Conclusions
• LukOil, Burgas is starting up it’s new H-Oil-RC™ unit. Initially, not enough
VR will be available to fully utilize the unit capacity.
• Criterion’s pilot-plants were used to simulate the new H-Oil-RC™ unit of
LukOil Burgas, processing 3 different feed blends.
• Products of the pilot-plant studies were analyzed and used for FCC
simulations and micro FCC conversion tests.
• The FCC laboratory yields, simulated on the basis of LukOil derived
correlations and properties of VGO products from H-Oil-RC™ pilot-plant
tests, revealed an opportunity for an FCC conversion increase between
about 5 and 10%.
• Applying predicted commercial yields and product property data in the
refinery’s LP model showed a clear profitability advantage to use the
remaining unit capacity for co-processing of SR HVGO.
Burgas University
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Thanks for your attention
Burgas University