out line base oil production lobs quality basics of lobs manufacturing technologies details of lobs...

OUT LINE

• Base Oil production • LOBS quality

• Basics of LOBS Manufacturing Technologies

• Details of LOBS Processing schemes

• Observations & Conclusions

LOBS Quality

Present LOBS quality fall under API Group I.

Spindle 150 N 500 N BS

Appearance B&C B&C B&C B&C

VI 98-100 100-101 95-97 95-97

Pour point C -6 -1 -1 -6

Color, ASTM 0.5 <1.0 <2.5 <3.5

Sulphur, wt% 0.8– 0.9 1.0-1.1 1.2-1.3 1.3-1.4

Saturates, wt%

NA @ 67 @ 65 NA

LOBS Quality

American Petroleum Institute (API) LOBS CategoriesAPI Sats Sulfur VI Typical Manufacturing ProcessI <90% >0.03% 80-119 Solvent ProcessingII >90% <0.03% 80-119 HydroprocessingIII >90% <0.03% 120+ Wax IsomerisationIV n.a n.a Polyalphaolefins (PAO)V All other Basestocks

LOBS Quality

• API specs are not regulatory as in case of automotive fuels, but are set by market & customer requirements.

• API specs are very broad.

• What level of API specs the LOBS need to comply with?

• A refiner may meet the bare minimum saturates as per Group II (90%) and yet may not meet market demand for 99% saturates.

LOBS Quality

• The refiner with this situation must address many questions.

• What are the target specs of each product?

• What are the various technology options available?

• Product slate (Grades of LOBS & whether wax is a product or not?)

• Integration of Lube block & Fuel block

• How doest it affect the over all profitability?

Base oil Manufacturing Technology

Crude SourceCrude Source

V.I. Upgrading

V.I. Upgrading FinishingFinishingDewaxingDewaxing Base OilBase Oil

Conventional Solvent Refining Solvent Dewaxing Low pressure Hydrotreating

Modern Hydrocracking CatalyticDewaxing Hydrofinishing

Alternate

Alternate

Hydrocracking

Solvent Refining/ Hydrotreating

Isodewaxing/MSDW

Isodewaxing/MSDW

Hydrofinishing

Hydrofinishing



Hydrocracking/Hydrotreating


Noble Metal HF

Noble Metal HFDewaxingDewaxing Base

OilBase Oil


• High Yield

• Feed Flexibility

• Satisfy Fuel & Lubes Demand

HCR/HDT boosts V.I. By converting low V.I. components to high V.I. base oils and also by cracking low V.I. components to lower boiling ranges----- Solvent refining simply removes low V.I. Aromatic components





Noble Metal HF

Noble Metal HFDewaxingDewaxing Base

OilBase Oil

Isodewaxing(IDW, CLG)/Mobil Selective Dewaxing (MSDW, EMRE)

• High V.I. Retention resulting in higher overall Yield for Lube train

• Ability to handle high wax feeds such as Slack wax.

IDW/MSDW reduces pour point primarily by Catalytic Wax Isomerization, giving higher overall product Yield and V.I. Than Solvent Dewaxing or conventional Catalytic Dewaxing.

ISODEWAXING

Isomerization With Minimum Branching Maintains V.I. and Lowers Pour Point

V.I Melting Point, oCN-Paraffin I-Paraffin N-Paraffin I-Paraffin

C20 174 164 36.6 -2.5 39.1

C30 156.5 143 66 8.6 57.4

Example of how isomerization can lower pour point, yet maintain high VIExample of how isomerization can lower pour point, yet maintain high VI

Comparison of Dewaxing ProcessesSolvent Dewaxing Catalytic Dewaxing IDW/MSDW

Wax removal

Product Pour Point

Yields

Dewaxed Product V.I.

By – Products

Operating costs

Physical – Wax Crystallization and filtration

-10 to –15 o C

Base Case

Base Case

Slack wax

Base (100%)

Chemical – wax Cracking with shape selective catalyst

-10 to –50 o C

Same or Lower

Generally 5 –10 Numbers Lower

Gas, Naphtha

50 –60 %

Chemical – wax Isomerization with shape selective catalyst

-10 to –50 o C

Same or Higher

Generally 5 –10 Numbers Higher

Gas, Naphtha, Jet, Diesel

55 – 65%

Product Comparison of Different Dewaxing Processes – Constant Refining Severity

Waxy V.I.

IDW/MSDW

SDW

CDWDewaxed V.I.

Waxy Viscosity

Dewaxed Viscosity

CDW

SDW

IDW/MSDW

Isodewaxing preserves V.I. and viscosity of waxy oil.V

.IV

isco

sity

ISODEWAXING

During the Dewaxing Step, Wax Molecules Are Either Removed, Cracked, or Converted

Wax Molecules

Example: nC20, 174 V.I., Melting Point 37 oC

^^^^^^^^^^^^^^^^^^^^^^^^^

Solvent Dewaxing

Conventional CatalyticDewaxing

Isodewaxing/MSDW

Wax^^^^^^^^^^^ ^ + ^^

C3 C4, C5, C6iC20: 164 V.I., Melting Point –2.5oC

Wax separated from Oil

^^^^^^^^^^

Wax Cracked to Light gases & Naphtha

Wax Isomerized to Lube Oil

Existing Refinery – Over view

• Integrated Lube and Fuel complex which operate in tandem

• Segregated crude/vacuum units which process low sulfur/non lube bearing and lube bearing crudes.

• Fuel Block • Fluid Catalytic Cracking (FCC)• Diesel Hydrodesulphuriser

• Lube Block• Extraction units• Hydrofinishing units• Solvent dewaxing unit

CDU1

CDU2

VDU 1

VDU2

VDU3

SEU

PDA

SDU

FCC

H2

DHDS

LPG

SR Naphtha

H2

High Sulfur Crude

Low Sulfur Crude

VR

DAO

SPINDLE150 N500N

BS

IO-100IO-1600

SIMPLIFIEDSIMPLIFIED REFINERY- EXISTINGREFINERY- EXISTING

DIESEL

GASOLINE

NAPHTHA

FUELS BLOCK

LUBEBLOCK

LUBE REFINERY PROCESS UNITSLUBE REFINERY PROCESS UNITS

IOH

P DU

LOBS

SSEEU U

PPDDAA

ASPHALT

VTB

TOBS

150N

500N

1300N

BS ( ( 3 3 Nos )Nos )

IO-100

VVDDUU

PG

RCO

NM

P

EX

TR

AC

TIO

N

SDU

SDA

VPS

Extracts Spindle SS-I SS-II

DAO

Spindle Raffinate

150 N Raffinate

500 N Raffinate

IO-100

IO- 1600

Spindle

150 N500 N

BS

IO-100

IO -1600

Base Oil Processing Scheme- ExistingBase Oil Processing Scheme- ExistingGroup I Base OilGroup I Base Oil

1) Arab Mix Crude processed in Lube blockNotes

BS Raffinate

VACUUM DISTILLATION UNITVACUUM DISTILLATION UNIT

• DISTILLATION IS SEPARATION OF PRODUCTS BY

DIFFERENCE IN BOILING POINT

• DISTILLATION OF REDUCED CRUDE OIL UNDER

VACUUM

• SEPARATION UNDER VACCUM TO AVOID

DECOMPOSITION OF CRUDE

• MAIN PRODUCTS ARE VACUUM GAS OIL, DISTILLATES

FOR LUBES & VTB.

• COLOR, VISCOSITY, FLASH POINT OF SIDESTREAMS

AND VTB PEN ARE MONITORED.

SOLVENT EXTRACTION UNITSOLVENT EXTRACTION UNIT

• REMOVAL OF AROMATICS FROM DISTILLATE

USING NMP AS SOLVENT BY LIQUID - LIQUID

EXTRACTION PROCESS . ORIGINALY PHENOL

WAS USED AS SOLVENT.

• IMPROVES VISCOSITY INDEX.

• IMPROVES COLOR, THERMAL & OXIDATION

STABILITY.

• REDUCES AROMATIC CONTENT

HYDROFINER UNITHYDROFINER UNIT

• FIXED BED CATALYTIC HYDROGENATION

PROCESS

• HYDROGEN IS USED AS TREAT GAS

• IMPROVES COLOR,COLOUR STABILITY,

OXIDATION STABILITY.

• REDUCES SULPHUR & NITROGEN

CONTENT

PROPANE DEWAXING UNITPROPANE DEWAXING UNIT

• PHYSICAL SEPARATION PROCESS

• WAX IS CRYSTALLISED AT LOW

TEMPERATURES AND REMOVED BY

FILTERING IN ROTARY DRUM FILTERS

• PROPANE IS USED AS SOLVENT AND

AUTOREFRIGERANT.

• IMPROVES THE POUR POINT OF LUBE

OIL BY REMOVING WAX

PROPANE DEASPHALTING UNITPROPANE DEASPHALTING UNIT

• PRODUCES DE ASPHALTED OIL BY REMOVING

ASHPHALT FROM VACUUM TOWER BOTTOMS (VTB)

• ASPHALT REMOVAL CARRIED OUT BY

COUNTERCURRENT LIQUID - LIQUID EXTRACTION

• PROPANE USED AS SOLVENT

• PRODUCES HIGH QUALITY BRIGHT STOCK OR

FEEDSTOCK FOR FCC UNIT AND ASPHALT FROM

VTB.

• DECREASES ASPHALTENE, RESIN, CARBON RESIDUE,

SULPHUR AND NITROGEN CONTENT.

• IMPROVES COLOUR

Existing LOBS Processing scheme

Solvent Extraction Units (SEU) + Hydrofinishers + Solvent Dewaxing unit

Multiple units (SEU & HF) are provided to allow simultaneous processing of different grades.

No wax production is considered. Slack wax is processed in FCC.

DAO from SDA is processed in SEU & SDU to produce BS.

Existing LOBS Processing scheme

Present quality of LOBS (especially Sulfur & saturates ) are far away from Group II specifications.

Existing Hydrofinishers are low pressure (58 bar) and hence are not suitable for meeting Group II specs.

Even with deeper extraction level of aromatics & sulfur can not be of Group II quality

Production of Group II base oils require some form of hydroprocessing route.

Demand PatternDemand Pattern

Setting Demand Pattern

Total make 200,000 TPA 300,000 TPA API category Remarks

Base Oil(‘000 TPA)

Spindle 15 15 Group II Saturates >99%

150 N 25 80 Group II Saturates >99%

500 N 115 160 Group II Saturates >99%

IO-100 5 5 Group I/Present

IO-1600 5 5 Group I/Present

BS 35 35 Group I/Present

Total Group II base oils

155 255

Base oil Upgrading scheme -1Group –II oils 255, 000 TPA

Add a New 150 bar Hydrotreater (HDT) to existing scheme.

Raffinates from existing SEU are processed in a high pressure hydrotreater.

Hydrotreated raffinates are further processed in existing Solvent Dewaxing unit.

HD

T (1

50

b

ar)

35

0,0

00

NM

P

EX

TR

AC

TIO

N

SDU

SDA

VPS

Distillate to fuel Complex


DAO

Spindle Raffinate

150 N Raffinate

500 N Raffinate

IO-100

IO- 1600

Spindle 15,000 150 N 80,000

500 N 160,000 BS 35,000

IO-100 5,000 IO -1600 5,000

Base Oil Upgrading Scheme- 1Base Oil Upgrading Scheme- 1Group II Base Oil : 255,000 TPAGroup II Base Oil : 255,000 TPA


2) VI of 500N 104


Findings of the scheme.

Advantages:Base oils meet all the bare minimum Group II specs.

Aromatic levels in base oils, especially 500 N will be around 10%. (disadvantage?)

Aromatics in 150 N will be around 5% (disadvantage?)



Disadvantages:Yield loss (for 500 N) from HDT is significant, for the

same LOBS production, raffinate feed reqmt is more and hence higher HDT unit capacity.

Higher capital cost because of higher HDT capacity


Add a New 150 bar Hydrotreater (HDT) + New Hydroisomerisation (HDW) unit to existing scheme.


Hydrotreated raffinates are further processed a new Hydroisomerisation unit.

Other Base oils are processed in conventional route.

Base Oil Upgrading Scheme- 2Group-II Base Oils : 255,000 TPA

VPS

HD

T (1

50

b

ar)

28

90

00

NM

PE

XT

RA

CT

ION

HY

DR

O I

SO

M/

HY

F

SDA

SDU


Extracts

SS-I

DAO

Spindle

SS-II

Spindle Raffinate

150 N Raffinate

IO-100

IO- 1600

Spindle 15,000 150 N 80,000

BS BS 35,000

IO-100 5,000

IO- 1600 5000

500 N 160,000 500 N Raffinate


2) VI of 500N 104


Add a New 150 bar Hydrotreater (HDT) + New Hydroisomerisation unit to existing scheme.

Hydroisomerisation catalyst is noble metal catalyst and can tolerate low levels of Nitrogen & other contaminants

Hydrotreater prepares the feed for this unit. Hydroisomerisation unit upgrades this feed by

converting wax to high value VI base oils.Hydrofinishing step is included in this scheme.



Advantages:Base oils meet or exceed all Group II specs. Aromatic levels in base oils < 1 %Yield loss in HDT compensated in HDW unit.Lower raffinate feed reqmt less than scheme-1.Lower raffinate feed reqmt increases the feed to FCC unit.



Advantages:The pressure levels of HDT & HDW can be kept same to

facilitate integrated operation and both units will have a single recycle loop.

Lower capital cost than scheme-1.Provides flexibility for staged investment. Implement

scheme-1 and at a later stage integrate HDT with HDW.



Disadvantages:Destroys wax. In this particular case, wax is not a

product.


Add a New 150 bar Hydrotreater (HDT) + New Hydroisomerisation (HDW) unit for slack wax


Slack wax from SDU is processed in a new Hydroisomerisation unit.

Other Base oils are produced in conventional route.

HD

T (1

50

b

ar)

35

0,0

00

NM

P

EX

TR

AC

TIO

N

SDU

SDA

VPS



DAO

Spindle Raffinate

150 N Raffinate

500 N Raffinate

IO-100 IO- 1600

Spindle 15,000 150 N 80,000

500 N 160,000 BS 35,000

IO-100 5,000 IO -1600 5,000

Base Oil Upgrading Scheme- 3Base Oil Upgrading Scheme- 3Group II Base Oil : 255,000 TPAGroup II Base Oil : 255,000 TPA


2) VI of 500N 104

HD

W/

HF 150 N 70,000

Slack wax 100,000

Group III



Advantages:Base oils from SDU meet bare minimum Group II specs. Slack wax processed in HDW produces 150 N of Group III.Maximum utilization of SDU capacityOption for staged investment.

Base oil Upgrading scheme - 3Group –II oils 255, 000 TPA


Disadvantages:Aromatic levels in 500 N will be around 10%.

Higher capital cost because of high RHT unit capacities & wax Isomerisation unit.


New Hydrocracker + New Hydroisomerisation

All side streams from VDU are routed to Lube hydrocracker (LHCU).

The waxy streams from LHCU processed in HDW.

LHCU also produces hydrocracked VGO (non-lube material) which is routed to FCC.

Base Oil Upgrading Scheme- 4Group II Base Oil : 255,000 TPA

FCCU870,000

Light FeedHeavy Feed

Lube Hydrocrac

kerBlocked

Operation 1340,000

TPA

HD

W2

90

,00

0

TP

A

1) Arab Mix Crude processed Notes

2) VI of 500N > 120

Spindle Oil Waxy 150N

Waxy 500N

<360ºCSpindle150 N500N

Heavy Diesel

Streams

VDU Side Streams Hydrocracker DS VGO

0.005% Sulfur

360ºC & lighter



Advantages:Flexibility to process higher volumes of high sulfur crudes.

Greatest crude flexibility.Base oils exceed Group II quality.FCC feed quality has significantly improved which results in

high yields of value distillates such as LPG, gasoline.Quality of FCC products w.r.t sulfur significantly improves.

Base oil Upgrading scheme - 4Group –II oils 255, 000 TPA


Disadvantages:High Hydrogen consumptions and hence additional

hydrogen plant required.Existing Lube processing facilities become

redundant.Highest capital costs.

Utilization of Existing Lube processing facilities

Existing 60 bar Hydrofinishers.

The pressure levels of HDT & HDW are around 150 bar. Existing HF can not be used because the product quality as measured

by aromatics and color would actually degrade by using these HF

Existing Solvent Dewaxing Unit: In scheme-2 only BS & IO’S are processed in SDU. This results in

underutilization of SDU. Reduce the 500 N Group II requirements. Utilize the existing scheme

to produce 500 N, BS & IOs of Group I quality. This will allow the refiner the greatest flexibility to produce Group I as

well as Group II depending on market demand.

Integration of Hydroprocessing and Solvent Extraction

SEUSEU SDWSDW HFHF

HDTHDT Hydro ISOMHydro ISOM HDFHDF

Group IIIGroup III

Group IIGroup II

Group I

Slack Wax/Soft WaxSlack Wax/Soft WaxRaffinate Raffinate

HydroprocessingHydroprocessing can be Integrated with Solvent Extraction plants to can be Integrated with Solvent Extraction plants to improve product Quality/Yield & flexibility to make Group II/III Oilsimprove product Quality/Yield & flexibility to make Group II/III Oils

Base Oil Upgrading Scheme- 5Group-II Base Oils : 155,000 TPA

VPS

HD

T (1

50

b

ar)

17

60

00

NM

PE

XT

RA

CT

ION

HY

DR

O I

SO

M/

HY

F

SDA

SDU

Distillate to fuel ComplexExtracts

SS-I

DAO

Spindle

SS-II

Spindle Raffinate

150 N Raffinate

IO-100

IO- 1600

Spindle 15,000

150 N 25,000

BS Raffinate BS 35,000

IO-100 5,000

IO- 1600 5000

500 N 115,000 500 N Raffinate


2) VI of 500N 104

Addl feed to FCC

Observations & Conclusions

If an Extraction unit is present, it is more economical to produce Group II LOBS via raffinate HDT route.

Staged investment is an option for the refiner. In the first phase HDT can be considered and at a later stage Hydro Isom can be added.

Observations & Conclusions Quantity of 500 N affects the over all economics. Since the trend is

to move towards lighter viscosity grades, refiner has to judiciously decide the break up of Group I & Group II.

Consider VI of LOBS (especially 500 N with in Group II). Increasing the VI beyond Group II requirements will reduce the yields, increase the capital investments and hence not economical.

While revamping the FCC unit, consider additional feed in FCC unit, keeping in view the fluctuating demand of LOBS.

Observations & Conclusions Can LOBS quality improvement alone justify investment?

This is a difficult question to answer.

With 255,000 TPA of Group II LOBS, revenues are better but these do not give better IRR because of higher capital costs & impact on Fuel block products.

With 155,000 of Group II LOBS, IRR could be better. Thus each refiner should evaluate the economics based on target LOBS production.

While maximizing LOBS production, consider maximizing value added products such as LPG from FCC etc. to improve over all refinery profitability.

THANK YOU

out line base oil production lobs quality basics of lobs manufacturing technologies details of lobs...

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base oils

base oil upgrading scheme

n raffinate io

group ipresent io

existing scheme

api group

higher hdt capacity

bare minimum group