HH--Oil technology descriptionOil technology …...6 Vacuum Residue (VR) Feedstock • 40 - 85% VR...
Transcript of HH--Oil technology descriptionOil technology …...6 Vacuum Residue (VR) Feedstock • 40 - 85% VR...
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Delphine LE BARS
H-Oil technology description H-Oil technology description
Alexandre Javidi Jean-Philippe Toupance
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Oil Refining
CLAUS ACID GAS REMOVAL TGT SULFUR
SULFUR RECOVERY S
FOSSIL &
RENEWABLE
FEEDSTOCKS CDU
VDU
TOP OF
THE
BARREL
BOTTOM
OF THE
BARREL
FCC post-
treatment
VGO/Res.
conversion
REFINERY GASES
LPG
NAPHTHA
GASOLINE
JET FUEL / KEROSENE
DIESEL / GASOIL
HEATING OILS
FUEL OILS
LUBE OILS
ASPHALT
SYNCRUDE
SULFUR
Lube Oils
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Bottom of the Barrel Axens Offer
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Axens Residue HydroCracking Offer
Objective: Conversion of Vacuum Residue (VR)
Feedstock into Valuable Products
High Flexibility
Fixed Bed Technology
• Limited conversion level
Ebullated Bed Technology
• Deep conversion level possible
Deep Conversion
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Axens H-Oil®RC Residue HydroCracking Feedstock
Vacuum Residue (VR) Feedstock
Conversion into valuable products
› Naphtha, Diesel, VGO
Unconverted Residue (UCO)
› Low Sulfur & Stable Fuel Oil
› Feed for Coker, SDA, Boilers or Gasification
High Value Products
UCO is a Liquid Fuel
Various Options for UCO Outlet
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Vacuum Residue (VR) Feedstock
• 40 - 85% VR conversion
Unconverted residue application
• Low sulfur (up to S< 1%) & stable fuel oil
• Feed for coker, SDA or gasification units
On-line Addition/Withdrawal of
catalyst
• Fully Automated System
• Constant product quality
• APC from Axens used to control catalyst
bed expansion
Availability > 96%
• 2 to 6 years cycle
• No shutdown for catalyst required
Settled Catalyst Level
Expanded Catalyst
Level
Distributor
Grid
Plate
Hydrogen and
Feed Slurry Feed
Catalyst Addition
Recycle Cup
Ebullated Bed
Ebullating Pump
Gas / Liquid
Separator
Recycle Oil Catalyst Withdrawal
Axens H-Oil RC – Residue HydroCracking
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Axens H-Oil Process - Flexibility
Feedstock of Motiva Refinery
Design Feedstock of Motiva unit • 70% Arabian Light
• 30% Arabian Medium
• Arabian Light
• Arabian Medium
• Arabian Heavy
• Basrah
• Bonny Light, Brass River
• Brent, Ekofish and Escravos
• Iranian Light
• Kirkuk
• Maya
• Alaskan North Slope
• Eugene Island
• …
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Axens H-Oil®RC – Simplified scheme overview
Make-Up
H2
Resid Feed
Heater
Heater
HP HT
Separator
Inter-Stage
Separator
MP HT
Separator
MP LT
Separator
MP Abs
HP Abs
HP Mem PSA Fuel Gas
Naphtha
Diesel
VGO
VR
Gas
H-Oil Reactors
Atmospheric
& Vacuum
Fractionation
HP LT
Separator
1st
Stage
2nd
Stage
3rd
Stage
Temperature 400 – 430°C
Pressure 120 – 190 bar
LHSV 0.1 – 1.3 hr-1
CRR 0.35 – 2.1 kg/t
Conversion 40 – 90 %
HDS 65 – 85 %
HDCCR 40 – 80 %
HDM 70 – 90 %
FRACTIONATION SECTION
Fresh
Catalyst
Used
Catalyst
CATALYST
SECTION
REACTION AND H2
COMPRESSION
SECTION
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UCO
H-Oil Overall Block Flow Diagram
Outstanding catalytic system
H-Oil ACS
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H-Oil Catalyst
Type: NiMo/Alumina 1.0-mm Extrudate. (Hydrotreatment catalyst type)
Catalyst replacement rate : metals in feed & objectives depend.
Vendor : Axens
Spent Catalyst Re-Processing • Worldwide based companies which process spent catalyst for metals reclamation
(Mo/Ni/V) – 15 references all around the world.
Additional revenue for customer from reclaimed metals
Catalyst Cascading: spent 2nd stage catalyst is used as replacement catalyst for 1st stage reactor
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Catalyst Handling Section Overall Scheme
Catalyst
Addition/
Withdrawal
Drum
Fresh Catalyst
Storage
Hopper
Fresh Catalyst
Provision
Catalyst
Measuring
hopper
Fresh Catalyst
Pneumatic
Transport System
Spent Catalyst Dump
Spent Catalyst
Storage
Hopper
Catalyst
Vapor
Separator
Drum
Re
ac
tor
1
Re
ac
tor
2
Transport/
Wash Oil
Drum
Wash/Cooling
Oil Drum
HVGO from
Fractionation
Diesel from
Fractionation
Spent
Catalyst
Cooling
Drum
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Why an H-Oil is not impacted by metals content in the feed?
UCO
90 ppm of metals H-Oil unit
HDM ~90%
Feed
250 ppm of metals
Fresh catalyst
~0.85 kg/t of feed
Eq. catalyst
23% of V
5% of Ni
Case 1
UCO
200 ppm of metals H-Oil unit
HDM ~90%
Feed
520 ppm of metals
Fresh catalyst
~1.4kg/t of feed
Eq. catalyst
23% of V
5% of Ni
Case 2
Catalyst Addition Rate Adjustment maintains constant
catalyst activity irrespective of metals in the VR feed
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H-Oil Pilot Scale Experience
Feedstock origin Metals content, ppm % conversion
Athabasca 431 58 to 78
Maya-Ismuth 566 45 to 50
Maya-Ismuth 688 45 to 50
Tahe 447 40 to 50
Athabasca/Cold lake 540 50 to 75
Maya/Ismuth 1040 54 to 65
Origin of the crudes
Canadian (Athabasca mined, Athabasca SAGD, Athabasca PFT, Lloydminster,
Cold Lake, ...)
Middle East (Safaniya, Buzurgan, Arabian Heavy, ...)
South-American (Zuata, Morichal, Cerro Negro, Boscan, Chichimene, ...)
Russian (Ural, Siberian, ...)
Chinese (Tahe)…
Metals: 0 to 1500 ppm, S: 0.2 to 6wt%, CCR: 0.1 to 35wt%, N: 10 to 8000 ppm
Focus on high metals feed
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H-Oil Industrial Scale experience
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%W
ENE-AGO 2004
CONTENIDO DE NIQUEL, CARGA NEGRA
VALOR
DISEÑO
50
150
250
350
450
550
650
750
850
950
01
/01
/200
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%w
ENE-AGO 2004
CONTENIDO DE VANADIO, CARGA NEGRA
VALOR
DISEÑO
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50
100
150
200
250
300
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400
450
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VANADIO
NIQUEL
More than 430 ppm of V+Ni is
contained in the feed.
Design was made for 670 ppm in the
feed
Quantity of vanadium in the feed
varies a lot : no issue
Flexibility of the H-Oil towards metals
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UCO
H-Oil Overall Block Flow Diagram
Superior Internals Safe and robust
design
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Axens H-Oil®RC Ebullating pump
Safety
• Easy leak detection when external
• Should a fire occur, risk to the reactor is minimal when external
Maintenance
• Direct access to the pump (easier & safer)
Operability / Reliability
• Direct flow measurement
• Butterfly valve on pump discharge
› Easy start up and shutdown
› Avoids reverse flow through pump and catalyst bed collapsing in emergency situation
“H-Oil®” Ebullating Pump
(External: case mounted)
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Axens H-Oil®RC Ebullating Pump
Axens H-Oil unit
design features an
external location for the
ebullating pump for:
safety
maintenance
operability
Available Only from Axens
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Axens H-Oil®RC Ebullating Pump – Iran case
Type of pump
• Pump flowrate in the middle range of existing pump in operation (Typical sizing of reactor)
Supplier
• Sulzer
› Relevant experience with “Isotherming” process
› Have been short listed by Hengli (China) for H-Oil unit
• Flowserve
› Leader in EB market
› Latest two EB pumps supplied and serviced 100% from EU base
› On-going Company business compliance process
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UCO
H-Oil Overall Block Flow Diagram
Optimal Vacuum Tower bottoms arrangement
Energy efficient Spiral heat exchangers
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90 %
Conversion
wt%
80 %
70
%
60
%
50 %
Middle east
Light Middle East Heavy Shengli Ural Maya
Feed
Difficult
y
Athabasca Zuata
How much conversion can you get with H-Oil?
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H-Oil® reactor design leverage
Sequential Deasphalting
Coker Integration
- Maximize the use of existing assets
- Unlock sediment constraints for H-Oil® UCO
- Create value not only with high conversion but also with better coke quality
H-Oil® : Assets & Values Streamline
- Maximize catalytic
performance for both
conversion and
hydrorefining
- Balance reactor
size and operating
conditions
- Control
sedimentation
- Accommodate high
capacity
- Overcome stability
issues thanks to
asphaltene rejection
- Balance Hydrogen
and/or utilities with
pitch valorisation
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Understanding Effluent Stability
Conversion
Asphaltenes are:
the heaviest structures difficult to characterize difficult to convert potentially unstable
Saturates / Aromatics / Resins / Asphaltenes
MATRIX
When destabilized, Asphaltenes floculate and cause:
- Fouling & downtime for cleaning
- Sediment in products
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80
100
120
140
Conversion HD Asphaltenes HDCCR HDS
Case 1
Case 2
Case 3
Case 4
Increase Temperature or Reduce space velocity?
• From Pilot Test Results with true EB pilot testing unit
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% Sediments vs Stability Limit
How to Push the Conversion?
LHSV Temperature Conversion
Case 1 Base Base Base
Case 2 Base Base + 14°C Base x 120%
Case 3 Base/3 Base - 18°C Base
Case 4 Base /3 Base Base x 120%
Target good stability
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Temperature Increase
• Conversion increase driven by thermal cracking: compromises
operability (sediments, fouling)
Reduce LHSV
• Lower LHSV is favorable towards sediment control at iso
conversion
• At same temperature, lower LHSV is a powerful way to boost
conversion and hydrogenation reactions
• Effluent quality is improved
• Catalytically driven conversion increase: delivers higher
performance in HDCCR and HDAsph. Unlocks sedimentation
barrier
How to Push the Conversion?
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H-Oil® Suite Conversion To Capacity Effect
Lower capacity operation
industrial demonstration
• Higher conversion
• Less sediment production
• Enhanced refining
performance
LHSV / WABT prove
powerful to break
conversion ceiling
40% VR availability
reduction
Up to 15% of
conversion
Four-fold sediment
reduction
Conversio
n
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H-Oil® reactor design leverage
Sequential Deasphalting
Coker Integration
- Maximize the use of existing assets
- Unlock sediment constraints for H-Oil® UCO
- Create value not only with high conversion but also with better coke quality
H-Oil® : Assets & Values Streamline
- Maximize catalytic
performance for both
conversion and
hydrorefining
- Balance reactor size
and operating
conditions
- Control
sedimentation
- Accommodate high
capacity
- Overcome stability
issues thanks to
asphaltene rejection
- Balance Hydrogen
and/or utilities with
pitch valorisation
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axens.net
Teheran - November 2017