Axens Consulting Services Upgrading Refinery to Achieve New
Product Specifications and to Minimize the Residue
Payam Heidararabi
2 2 2
Introduction of Axens Consulting Services
Case study
• Background and Objectives
• Solution developed by Axens
• Economic Evaluation
Conclusion
Agenda
Axens’ Iran Seminar – 19-20 July 2016 – Paving the Way to a Highly Competitive Refining Industry
3 3 3
Operational Organization
Consulting
Services
Software Services
Production
Technical Proposals
Sales
Assistance to
Customer
Process Design
Technical Proposals
Sales
Associated
Technical Services
CEO
Executive Committee
9 Subsidiaries
Catalysts &
Adsorbents
Business Units
Development of
new products and
technologies
Technology
Development &
Innovation
Support to the Business Units
Process
Licensing
Performance
Programs
Axens’ Iran Seminar – 19-20 July 2016 – Paving the Way to a Highly Competitive Refining Industry
4 4 4
Simulators
License Detailed
Engineering Construction
Asset and Operation
optimization
Products (Catalysts & Adsorbents BU)
Technologies (Process Licensing BU)
Consulting Services (Performance Programs BU)
Operations Support (all BU)
Outside Axens perimeter
Start-up & Follow-up
Assistance
Replacement
Load
Catalysts
First
Load
Catalysts
Tender and
technology
choice
Pre-Project
Studies Project Achievement Unit on-stream
Basic
Engineering
Technical
Consulting
Catalyst Management
Unit Revamping
Training / Web Training
Equipment Supply
Integrated Process Solution (IPS)
How Do We Operate?
Axens’ Iran Seminar – 19-20 July 2016 – Paving the Way to a Highly Competitive Refining Industry
5 5 5
1. How to take the right decision for expansion or upgrading to
cope with new market requirements?
2. How to boost performance of the units with advanced control
technologies?
3. How to optimize the margin to be more competitive?
Modern Refinery has Multiple Challenges…
Axens’ Iran Seminar – 19-20 July 2016 – Paving the Way to a Highly Competitive Refining Industry
6 6 6
Axens Consulting Services: Taking Right Investment Decision and Minimizing Risks
Axens’ Iran Seminar – 19-20 July 2016 – Paving the Way to a Highly Competitive Refining Industry
“I’m finding it difficult to take the right investment decision to meet new
specifications efficiently while maximizing the revenue”
Refinery management
7 7 7
Integrated Process
Solutions (IPS)
Major
Revamping
Existing
Facilities
Grassroots
Facilities
Project
Execution
Asset & Operation
Optimization
Configuration
Development
With Process
Design Package
Specific Studies
Studies
Operational Support
Capacity Creep
Web-based Process
Operation Simulators
webPOS™
Advanced Process
Control
Linear Programming
Model Management
Crude Management
CO2 Mitigation and
Monetization
Support for Project
Financing
Executive Consulting
Services
Due Diligence
Assessment
Energy Efficiency
Oil Loss
Improvement Margin
Solutions
Supply and Product
Chain Optimization
Market Study
Site Location Study
Pre-environmental
Impact Assessment
Petroleum Terminal
Study
Marine Study
Feasibility Study
(FS)
Conceptual Engineering
Study (CES)
Pre-hazard Impact
Assessment
Axens’ Iran Seminar – 19-20 July 2016 – Paving the Way to a Highly Competitive Refining Industry
Integrated Process
Review (IPR)
8 8 8
Study Workflow
Axens’ Iran Seminar – 19-20 July 2016 – Paving the Way to a Highly Competitive Refining Industry
the Path to optimum investment decisions and maximum refinery profitability
Existing
site
with a
specific
production
pattern
Project
Financing
Basic Design
Detail
Engineering
Construction
Market review
Crude supply
Technologies
Financial analysis
Screening
LP
models
BFD, M&UB Units
capacity Pools Spec. Economics
Analysis,
ranking
Pre-Hazard & env
impact assesment
Utilities & off site
9 9 9
Introduction of Axens Consulting Services
Case study
• Background and Objectives
• Solution developed by Axens
• Economic Evaluation
Conclusion
Agenda
Axens’ Iran Seminar – 19-20 July 2016 – Paving the Way to a Highly Competitive Refining Industry
10 10 10
Axens has been consulted in 2012 to carry out a
study for improving quality of fuel while maximizing
the bottom conversion to valuable products
Main objectives of the upgrading project
• Comply with the latest specifications for diesel, gasoline, fuel
oil & asphalt
• Increase motor fuels & LPG production in order to minimize
the imports
• Upgrade vacuum residue
Background
Axens’ Iran Seminar – 19-20 July 2016 – Paving the Way to a Highly Competitive Refining Industry
11 11 11
Strong LPG demand
• Higher demand than domestic production
• Demand currently met by imports
Gasoline Specification
• About 75% of the Gasoline consumption is low-octane
Gasoline.
Noticeable Fuel Oil consumption mainly for Power
Generation
Market Overview
Axens’ Iran Seminar – 19-20 July 2016 – Paving the Way to a Highly Competitive Refining Industry
12 12 12
Gasoline
• Sulfur content reduction from 750/1000 to 10 wppm max
• Increase of RON (from 81/90 to 91/95)
• Aromatics content 35 vol% max & Olefins content 18 vol% max
• Stringent specification on Benzene content 0.6 vol% max
On-road Diesel
• Sulfur content reduction from 7000/500 (different grades) to 10 wppm max
• Polyaromatics 11 vol% max
• Increase of Cetane Index (from 45 to 52)
Fuel Oil
• Sulfur content reduction in order to comply with SO2 emission regulation
Transition toward New Specifications
Axens’ Iran Seminar – 19-20 July 2016 – Paving the Way to a Highly Competitive Refining Industry
13 13 13
Initial Refinery Configuration
Axens’ Iran Seminar – 19-20 July 2016 – Paving the Way to a Highly Competitive Refining Industry
AR
VT
x 2
VR
VGO FCC
Jet
Diesel
LPG
Gasoline
Gasoline
treatment
Fuel Oil
Visbreaker x 2
Crude
Oil
Bitumen
GO HDS
Kero
treatment
NHDS CCR
LN HDT ISOM
LPG Washing
LN
HN
Kero
AT
x 2
14 14 14
Same crude as the one currently processed
Crude Characteristics
Axens’ Iran Seminar – 19-20 July 2016 – Paving the Way to a Highly Competitive Refining Industry
Properties Value
API gravity, °API 23.1
Specific Gravity @ 60°F 0.9153
Sulfur, %wt 1.54
Nitrogen, wt ppm 3 358
Kinematic viscosity @ 40°C, cSt 52.7
Conradson Carbon, %wt 10.0
Nickel, wt ppm 77
Vanadium, wt ppm 207
15 15 15
Introduction of Axens Consulting Services
Case Study
• Background and Objectives
• Solution developed by Axens
• Economic Evaluation
Conclusion
Agenda
Axens’ Iran Seminar – 19-20 July 2016 – Paving the Way to a Highly Competitive Refining Industry
16 16 16
Developed Solution for Distillates and Bottom of the Barrel
Axens’ Iran Seminar – 19-20 July 2016 – Paving the Way to a Highly Competitive Refining Industry
AT
x 2
AR
VT
x 2
VR
VGO FCC
Jet
Diesel
LPG
Gasoline
Cracked
Naphtha
DO
Fuel Oil
Resid HCK
Crude
Oil
Bitumen
GO HDS
Kero
treatment
NHDS CCR
LN HDT ISOM
LPG
Treatment
LN
HN
Kero
Unconverted oil
HCK VGO
LS OLIGO
NHDS/ISOM/CR
Existing Unit
New Unit LS: LPG Sweetening
CR: Catalytic Reforming
Distillate: 176-350°C: To ensure
ASTM FBP temperature below
350°C
Vacuum Gasoil : 350-509°C
Vacuum Resid : 509°C+ to
ensure Asphalt specification
17 17 17
Developed Solution for Distillates and Bottom of the Barrel
Axens’ Iran Seminar – 19-20 July 2016 – Paving the Way to a Highly Competitive Refining Industry
AT
x 2
AR
VT
x 2
VR
VGO FCC
Jet
Diesel
LPG
Gasoline
Cracked
Naphtha
DO
Fuel Oil
Resid HCK
Crude
Oil
Bitumen
GO HDS
Kero
treatment
NHDS CCR
LN HDT ISOM
LPG
Treatment
LN
HN
Kero
Unconverted oil
HCK VGO
LS OLIGO
NHDS/ISOM/CR
Existing Unit
New Unit
Addition of an Ebullated
Bed Vacuum Resid HCK
in place of the existing
Visbreakers
LS: LPG Sweetening
CR: Catalytic Reforming
18 18 18
Developed Solution for Distillates and Bottom of the Barrel
Axens’ Iran Seminar – 19-20 July 2016 – Paving the Way to a Highly Competitive Refining Industry
AT
x 2
AR
VT
x 2
VR
VGO FCC
Jet
Diesel
LPG
Gasoline
Cracked
Naphtha
DO
Fuel Oil
Resid HCK
Crude
Oil
Bitumen
GO HDS
Kero
treatment
NHDS CCR
LN HDT ISOM
LPG
Treatment
LN
HN
Kero
Unconverted oil
HCK VGO
LS OLIGO
NHDS/ISOM/CR
The VGO coming out
the Resid HCK will feed
a new HCK to increase
the overall conversion
Existing Unit
New Unit LS: LPG Sweetening
CR: Catalytic Reforming
19 19 19
Developed Solution for Distillates and Bottom of the Barrel
Axens’ Iran Seminar – 19-20 July 2016 – Paving the Way to a Highly Competitive Refining Industry
AT
x 2
AR
VT
x 2
VR
VGO FCC
Jet
Diesel
LPG
Gasoline
Cracked
Naphtha
DO
Fuel Oil
Resid HCK
Crude
Oil
Bitumen
GO HDS
Kero
treatment
NHDS CCR
LN HDT ISOM
LPG
Treatment
LN
HN
Kero
Unconverted oil
HCK VGO
LS OLIGO
NHDS/ISOM/CR
Decrease sulphur content
in oligomerisation unit
feed to 5 wppm
Existing Unit
New Unit LS: LPG Sweetening
CR: Catalytic Reforming
20 20 20
Developed Solution for Distillates and Bottom of the Barrel
Axens’ Iran Seminar – 19-20 July 2016 – Paving the Way to a Highly Competitive Refining Industry
AT
x 2
AR
VT
x 2
VR
VGO FCC
Jet
Diesel
LPG
Gasoline
Cracked
Naphtha
DO
Fuel Oil
Resid HCK
Crude
Oil
Bitumen
GO HDS
Kero
treatment
NHDS CCR
LN HDT ISOM
LPG
Treatment
LN
HN
Kero
Unconverted oil
HCK VGO
LS OLIGO
NHDS/ISOM/CR
Existing Unit
New Unit LS: LPG Sweetening
CR: Catalytic Reforming
GO HDS
To be revamped with new
cut points to achieve
diesel specification
(10 wppm Sulphur)
21 21 21
Developed Solution for Distillates and Bottom of the Barrel
Axens’ Iran Seminar – 19-20 July 2016 – Paving the Way to a Highly Competitive Refining Industry
AT
x 2
AR
VT
x 2
VR
VGO FCC
Jet
Diesel
LPG
Gasoline
Cracked
Naphtha
DO
Fuel Oil
Resid HCK
Crude
Oil
Bitumen
GO HDS
Kero
treatment
NHDS CCR
LN HDT ISOM
LPG
Treatment
LN
HN
Kero
Unconverted oil
HCK VGO
LS OLIGO
NHDS/ISOM/CR
Existing Unit
New Unit LS: LPG Sweetening
CR: Catalytic Reforming
22 22 22
Developed Solution for Distillates and Bottom of the Barrel
Axens’ Iran Seminar – 19-20 July 2016 – Paving the Way to a Highly Competitive Refining Industry
AT
x 2
AR
VT
x 2
VR
VGO FCC
Jet
Diesel
LPG
Gasoline
Cracked
Naphtha
DO
Fuel Oil
Resid HCK
Crude
Oil
Bitumen
GO HDS
Kero
treatment
NHDS CCR
LN HDT ISOM
LPG
Treatment
LN
HN
Kero
Unconverted oil
HCK VGO
LS OLIGO
NHDS/ISOM/CR
Existing Unit
New Unit LS: LPG Sweetening
CR: Catalytic Reforming
CCR
23 23 23
Developed Solution for Distillates and Bottom of the Barrel
Axens’ Iran Seminar – 19-20 July 2016 – Paving the Way to a Highly Competitive Refining Industry
AT
x 2
AR
VT
x 2
VR
VGO FCC
Jet
Diesel
LPG
Gasoline
Cracked
Naphtha
DO
Fuel Oil
Resid HCK
Crude
Oil
Bitumen
GO HDS
Kero
treatment
NHDS CCR
LN HDT ISOM
LPG
Treatment
LN
HN
Kero
Unconverted oil
HCK VGO
LS OLIGO
NHDS/ISOM/CR
Existing Unit
New Unit LS: LPG Sweetening
CR: Catalytic Reforming
CCR Addition of an
Oligomerization unit for a
high RON aromatic-free
cut from LPG
24 24 24
Developed Solution for Distillates and Bottom of the Barrel
Axens’ Iran Seminar – 19-20 July 2016 – Paving the Way to a Highly Competitive Refining Industry
AT
x 2
AR
VT
x 2
VR
VGO FCC
Jet
Diesel
LPG
Gasoline
Cracked
Naphtha
DO
Fuel Oil
Resid HCK
Crude
Oil
Bitumen
GO HDS
Kero
treatment
NHDS CCR
LN HDT ISOM
LPG
Treatment
LN
HN
Kero
Unconverted oil
HCK VGO
LS OLIGO
NHDS/ISOM/CR
Existing Unit
New Unit LS: LPG Sweetening
CR: Catalytic Reforming
CCR
Desulfurization of FCC
Gasoline via HDT Unit &
replace the existing
gasoline sweetening
25 25 25
Developed Solution for Distillates and Bottom of the Barrel
Axens’ Iran Seminar – 19-20 July 2016 – Paving the Way to a Highly Competitive Refining Industry
AT
x 2
AR
VT
x 2
VR
VGO FCC
Jet
Diesel
LPG
Gasoline
Cracked
Naphtha
DO
Fuel Oil
Resid HCK
Crude
Oil
Bitumen
GO HDS
Kero
treatment
NHDS CCR
LN HDT ISOM
LPG
Treatment
LN
HN
Kero
Unconverted oil
HCK VGO
LS OLIGO
NHDS/ISOM/CR
Existing Unit
New Unit LS: LPG Sweetening
CR: Catalytic Reforming
CCR
Treatment of
Naphtha from Resid
HCK and HCK
26 26 26
Addition of an Hydrogen Production Unit to satisfy
Hydrogen consumption of HDT, VGO HCK and VR
HCK units
Addition of environmental dedicated units
• Amine Washing and Regeneration facilities
• Sour Water Stripper
• Sulfur Recovery Unit for H2S removal
Developed Solution Supporting and Auxiliary Units
Axens’ Iran Seminar – 19-20 July 2016 – Paving the Way to a Highly Competitive Refining Industry
27 27 27
5% 7%
35%
7%
26%
47%
30% 37%
3% 2%
0%
10%
20%
30%
40%
50%
60%
70%
80%
90%
100%
Product slate beforestudy
Products slate afterstudy
LPG
Gasoline/Naphtha
Distillates
Fuel
Asphalt
Refinery Product Slate after Study
Axens’ Iran Seminar – 19-20 July 2016 – Paving the Way to a Highly Competitive Refining Industry
Main Features of the
Selected Scheme
• Conversion level of the refinery
increased significantly
• Production of Euro V Gasoline
& Diesel and low sulphur fuel
oil.
28 28 28
Introduction of Axens Consulting Services
Case Study
• Background and Objectives of the Study
• Solution developed by Axens
• Economic Evaluation
Conclusion
Agenda
Axens’ Iran Seminar – 19-20 July 2016 – Paving the Way to a Highly Competitive Refining Industry
29 29 29
Project Capital Requirement
Axens’ Iran Seminar – 19-20 July 2016 – Paving the Way to a Highly Competitive Refining Industry
30 30 30
Introduction of Axens Consulting Services
Case Study
• Background and Objectives of the Study
• Solution developed by Axens
• Economic Evaluation
Conclusion
Agenda
Axens’ Iran Seminar – 19-20 July 2016 – Paving the Way to a Highly Competitive Refining Industry
31 31 31
The project reveals interesting opportunity in upgrading
the refinery to comply with new specifications
In addition to the main bottom upgrading process units,
the detail review of existing units, auxiliaries and
infrastructures is also important for decision making
Axens’ technology know-how combined with linear
programing tool and expertise in analysis of project
economic lead the study to the most feasible solution
Conclusion
Axens’ Iran Seminar – 19-20 July 2016 – Paving the Way to a Highly Competitive Refining Industry