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HYDROCRACKING OPTIONS FOR<br />
FUEL OIL UPGRADING AND DIESEL<br />
PRODUCTION<br />
ERTC Barcelona<br />
November 2011<br />
John Baric<br />
Licensing <strong>Technology</strong> Manager, <strong>Shell</strong> <strong>Global</strong> Solutions International BV<br />
Copyright of <strong>Shell</strong> <strong>Global</strong> Solutions<br />
Hydrocracking options for fuel oil upgrading and diesel production<br />
5 December 2011<br />
1
DISCLAIMER<br />
<strong>Shell</strong> <strong>Global</strong> Solutions is a network of independent technology companies in the <strong>Shell</strong> Group. In<br />
this document, the expressions “<strong>Shell</strong>” or “<strong>Shell</strong> <strong>Global</strong> Solutions” are sometimes used for<br />
convenience where reference is made to these companies in general, or where no useful purpose<br />
is served by identifying a particular company.<br />
The information contained in this material is intended to be general in nature and must not be relied<br />
on as specific advice in connection with any decisions you may make. <strong>Shell</strong> and <strong>Shell</strong> <strong>Global</strong><br />
Solutions are not liable for any action you may take as a result of you relying on such material or<br />
for any loss or damage suffered by you as a result of you taking this action. Furthermore, these<br />
materials do not in any way constitute an offer to provide specific services.<br />
Some services may not be available in certain countries or political subdivisions thereof.<br />
Copyright © 2011 <strong>Shell</strong> <strong>Global</strong> Solutions International BV. All rights reserved. No part of this<br />
publication may be reproduced or transmitted in any form or by any means, electronic or<br />
mechanical including by photocopy, recording or information storage and retrieval system, without<br />
permission in writing from <strong>Shell</strong> <strong>Global</strong> Solutions International BV.<br />
Copyright of <strong>Shell</strong> <strong>Global</strong> Solutions<br />
Hydrocracking options for fuel oil upgrading and diesel<br />
production<br />
5 December 2011<br />
2
AGENDA<br />
Current trends in hydrocracking<br />
Bottom-of-the-barrel alternatives<br />
<strong>Shell</strong>’s integrated hydrocracking solutions:<br />
Case studies<br />
Operational<br />
improvements<br />
Short-term<br />
revamps<br />
Long-term<br />
phased<br />
investments<br />
Copyright of <strong>Shell</strong> <strong>Global</strong> Solutions<br />
Hydrocracking options for fuel oil upgrading and diesel<br />
production<br />
5 December 2011<br />
3
FUEL OIL UPGRADING OPTIONS – DIFFERENT<br />
SOLUTIONS APPLIED<br />
SDA/DCU/HCU<br />
SDA/HCU<br />
DCU/HCU<br />
DCU/HCU DCU/HCU<br />
DCU/HCU DCU/HCU<br />
DCU/HCU<br />
SL/HCU<br />
SDA/HCU<br />
EB/HCU<br />
SDA/HCU<br />
EB/HCU<br />
SDA/HCU<br />
SDA/DCU//HCU DCU/HCU<br />
EB/HCU<br />
SDA/HCU<br />
SDA/DCU/HCU DCU/HCU<br />
DCU/HCU HCU<br />
VBU/HCU<br />
VRDS/HCU<br />
FCU/HCU<br />
DCU/HCU SDA/HCU VRDS/HCU<br />
SDA/FCCU<br />
DCU/HCU<br />
DCU/HCU ARDS/HCU<br />
DCU/HCU/FCCU<br />
DCU/FCCU<br />
DCU/HCU<br />
DCU/HCU<br />
DCU/HCU<br />
VBU/HCU<br />
DCU/HCU<br />
Copyright of <strong>Shell</strong> <strong>Global</strong> Solutions<br />
Hydrocracking options for fuel oil upgrading and diesel production<br />
5 December 2011<br />
4
FUEL OIL UPGRADING OPTIONS – DIFFERENT<br />
SOLUTIONS APPLIED<br />
3%<br />
3%<br />
6%<br />
8%<br />
51%<br />
DCU<br />
SDA<br />
EB<br />
FCC<br />
ARDS<br />
Slurry<br />
29%<br />
Copyright of <strong>Shell</strong> <strong>Global</strong> Solutions<br />
Hydrocracking options for fuel oil upgrading and diesel production<br />
5 December 2011<br />
5
SHELL LICENSED HYDROCRACKER 2009/2011<br />
START-UPS<br />
<strong>Shell</strong> licensed hydrocrackers<br />
Full acceptance and highly integrated within refineries<br />
CNOOC – new refinery in China<br />
Naphthenic crude and HCGO co-processing<br />
Ethylene cracker and FCC feed<br />
Marathon – existing refinery in USA<br />
Mixed crudes, including Venezuelan, HCGO, LCO and extracts<br />
FCC feed and base oils<br />
Grupa Lotos – existing refinery in EU<br />
Urals crude and DAO<br />
FCC feed and base oils<br />
Copyright of <strong>Shell</strong> <strong>Global</strong> Solutions<br />
Hydrocracking options for fuel oil upgrading and diesel<br />
production<br />
5 December 2011<br />
6
FIRST OPTION – COKER/HYDROCRACKER<br />
Economic considerations<br />
Balance conversion and feed quality<br />
Hydrogen use<br />
Coke disposition<br />
SRN<br />
SR kero<br />
HDT 1, 2, 3<br />
Crude<br />
SRGO<br />
CKN<br />
LCGO<br />
Atmospheric residue<br />
HVU<br />
VGO<br />
HCU<br />
Naphtha<br />
Jet/diesel<br />
Vacuum<br />
residue<br />
DCU<br />
HCGO<br />
Hydrowax<br />
FCC U<br />
Lubes<br />
Coke<br />
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Hydrocracking options for fuel oil upgrading and diesel production<br />
5 December 2011<br />
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CNOOC HYDROCRACKER – NAPHTHENIC FEEDS<br />
CNOOC refinery:<br />
Naphthenic crude<br />
Delayed coker<br />
First two-year cycle completed<br />
Criterion/Zeolyst catalyst refill<br />
High-nitrogen feed<br />
Poor SR distillate properties<br />
MVGO<br />
(360–450)<br />
HVGO<br />
(450–545)<br />
HCGO<br />
%wt in feed 49 31 20<br />
D 15/4 0.9164 0.9390 0.9215<br />
Nitrogen, wppm 1,471 3,423 6,378<br />
Sulphur, %wt 0.24 0.29 0.29<br />
Ni + V, wppm 2 5 2<br />
Conradson carbon, %wt
CNOOC HYDROCRACKER – REACTOR INTERNALS<br />
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Hydrocracking options for fuel oil upgrading and diesel production<br />
5 December 2011<br />
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MARATHON HYDROCRACKER – DIVERSE FEEDS<br />
Marathon refinery:<br />
Diverse crudes<br />
Delayed coker, FCCU and ROSE<br />
First two-year cycle in progress<br />
Expansion study<br />
Diverse feed challenges<br />
Varying properties<br />
Property HVGO FCC LCO Coker HGO ROSE DAO<br />
TBP FBP, °C 611 381 556 740<br />
Specific gravity at 15°C 0.935 0.956 0.973 0.965<br />
Ni + V, ppmwt 2 – 1 19<br />
C 7 insolubles, %wt
SECOND OPTION – SDA/HYDROCRACKER<br />
Economic considerations<br />
Balance conversion and feed quality<br />
DAO lift and cost<br />
Asphaltenes disposition<br />
HDT 1,2,3<br />
Crude<br />
Atmospheric residue<br />
HVU<br />
VGO<br />
HCU<br />
Naphtha<br />
Jet/diesel<br />
Vacuum<br />
residue<br />
SDA<br />
DAO<br />
Hydrowax<br />
FCC U<br />
Lubes<br />
Asphaltenes<br />
HSFO, bitumen, power<br />
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Hydrocracking options for fuel oil upgrading and diesel<br />
production<br />
5 December 2011<br />
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GRUPA LOTOS HYDROCRACKER – HEAVY FEED<br />
Gdansk refinery:<br />
Urals crude<br />
ROSE<br />
First three-year cycle in progress<br />
Optimisation study<br />
Heavy feed challenges<br />
Demetallisation and<br />
pretreatment catalysts<br />
Property VGO DAO<br />
Specific gravity 0.925 0.9497<br />
Sulphur, %wt 1.9 2.3<br />
Nitrogen, ppmw 1,573 2,664<br />
Total Ni + V, ppmw
GRUPA LOTOS HYDROCRACKER – HEAVY FEED<br />
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Hydrocracking options for fuel oil upgrading and diesel production<br />
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LOTOS DAO HYDROCRACKER – SUSTAINED<br />
PERFORMANCE<br />
Increasing feed difficulty<br />
Feed nitrogen, wppm<br />
3,000<br />
2,500<br />
2,000<br />
1,500<br />
1,000<br />
Nitrogen<br />
CCR<br />
3.0<br />
2.5<br />
2<br />
1.5<br />
1<br />
Feed CCR, %wt<br />
500<br />
250 days<br />
0.5<br />
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5 December, 2011<br />
14
LOTOS DAO HYDROCRACKER – SUSTAINED<br />
PERFORMANCE<br />
Increased conversion<br />
90<br />
Conversion, %wt<br />
85<br />
80<br />
75<br />
70<br />
65<br />
60<br />
Design 60% conversion<br />
Recycle feed,<br />
%wt<br />
30<br />
20<br />
10<br />
0<br />
Copyright of <strong>Shell</strong> <strong>Global</strong> Solutions<br />
Residue upgrading – KBR ROSE and <strong>Shell</strong> deasphalted oil (DAO) hydrocracker<br />
5 December, 2011<br />
250 days<br />
15
LOTOS DAO HYDROCRACKER – SUSTAINED<br />
PERFORMANCE<br />
Constant hydrogen consumption<br />
90<br />
Conversion, %wt<br />
85<br />
80<br />
75<br />
70<br />
65<br />
60<br />
Design 60% conversion<br />
Total hydrogen,<br />
%wt<br />
30<br />
20<br />
10<br />
0<br />
Copyright of <strong>Shell</strong> <strong>Global</strong> Solutions<br />
Residue upgrading – KBR ROSE and <strong>Shell</strong> deasphalted oil (DAO) hydrocracker<br />
5 December, 2011<br />
250 days<br />
16
LOTOS DAO HYDROCRACKER – SUSTAINED<br />
PERFORMANCE<br />
Kerosene sulphur<br />
Diesel sulphur<br />
10<br />
9<br />
Guarantee 10 ppm max.<br />
8<br />
7<br />
ppmwt<br />
6<br />
5<br />
4<br />
3<br />
2<br />
1<br />
0<br />
250 days<br />
Copyright of <strong>Shell</strong> <strong>Global</strong> Solutions<br />
Residue upgrading – KBR ROSE and <strong>Shell</strong> deasphalted oil (DAO) hydrocracker<br />
5 December, 2011<br />
17
SHELL HYDROCRACKER REVAMP<br />
Refinery expansion project:<br />
Process heavier crudes, including Maya<br />
Heavier conversion unit feeds for HCU<br />
HCU is integrated with a downstream FCCU<br />
Hydrocracker impact:<br />
Reduced throughput by about 20%<br />
Shorter cycle: from >two years to one year<br />
FCCU impact:<br />
Negative downstream FCCU economics<br />
Copyright of <strong>Shell</strong> <strong>Global</strong> Solutions<br />
Hydrocracking options for fuel oil upgrading and diesel production<br />
5 December 2011<br />
18
SHELL HYDROCRACKER REVAMP<br />
Hydrocracker Revamp objectives<br />
Restore capacity and cycle length<br />
Minimal investment: small revamp project<br />
Quick payback<br />
<strong>Shell</strong> Scope<br />
Reactor Internals only<br />
Catalyst optimisation<br />
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Hydrocracking options for fuel oil upgrading and diesel production<br />
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SHELL HYDROCRACKER REVAMP<br />
Summary of reactor<br />
modifications compared with<br />
original design<br />
~29% more HT catalyst<br />
Bed 1 – HT<br />
Bed 2 – HT<br />
Bed 3 – HT<br />
Bed 4 – HT<br />
New HD tray<br />
New HD tray<br />
Bed 5 – HC<br />
New HD tray<br />
~18% more HT catalyst<br />
Bed 6 – HC<br />
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Hydrocracking options for fuel oil upgrading and diesel production<br />
Replaced bottom<br />
catalyst screen with<br />
outlet collector<br />
5 December 2011<br />
20
SHELL HYDROCRACKER REVAMP<br />
Bubble cap tray<br />
HD tray<br />
Bed A<br />
Bed A<br />
Void<br />
space<br />
Minimise<br />
void space<br />
Spray<br />
zone<br />
More catalyst !!<br />
Catalyst<br />
Bed B<br />
Bed B<br />
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Hydrocracking options for fuel oil upgrading and diesel<br />
production<br />
5 December 2011<br />
21
SHELL HYDROCRACKER REVAMP<br />
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Hydrocracking options for fuel oil upgrading and diesel production<br />
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KEY TAKEAWAYS:<br />
<strong>Shell</strong> customers are operating in a challenging business environment<br />
We have responded with timely and cost-effective solutions:<br />
Process technology development enabling processing of difficult<br />
feed and deeper upgrading<br />
Low-cost revamps for improved performance from sophisticated<br />
internals<br />
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Hydrocracking options for fuel oil upgrading and diesel production<br />
5 December 2011<br />
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