uop hydrocracking technology · reactor internals • uop hydrogen purification (polybed ™ psa)...

UOP 7200-0© 2017 UOP Limited

Upgrading Fuel Oil to Euro V FuelsUOP Hydrocracking TechnologyIan Clarke

Hydroprocessing and Heavy Oil Technology Manager

5th December 2017 Bottom of the Barrel Workshop NIORDC, Tehran

Agenda

UOP Hydroprocessing Experience

Case Studies for Maximum ROI

Solutions for the Iranian MarketLatest Technology

Innovations

Hydrocracking is a key enabler to maximise transportation fuels and to reduce fuel oil to less than 10% of crude

Hydrocracking Unit2

SR Kerosene

SR Light Gasoil

CDU

At Res

Crude Oil

NHTSplitter

CCRUnit

Reformate

H2 LPG

Vac Res

NaphthaHydrotreating

Unit

Diesel Sales

Kerosene Sales

Gasoline Sales

LPG SalesSaturatedGas Plant

Refinery Fuel Gas

LPG

SDAUnit

SDA Pitch

IsomUnit

Isomerate

DHTUnit

Jet

DAO

Hydrogen Plant H2

Natural Gas

H2

Diesel

VDU

HCU

UCO

Wet Gas + LPG to Sat Gas Plant

HCU Kerosene

HCU Diesel

HCU Naphtha

H2

VGO

Slurry HCUnit

SHC Diesel

SHC VGO

UNI Naphtha

Pitch

Bitumen Sales

UOP Hydrocracking Process –Increasing Conversion and Profitability

Flexibility to Meet Refiner Processing Objectives

3

VGO Hydrotreating (<20%)

Mild Hydrocracking

(20-50%)

Partial Conversion

(50-90%)

Full Conversion

(90+%)

• Hydrocracking converts low value feeds to high value transportation fuels and petrochemical feedstock

• Adds hydrogen which increases the volume of the products• Converts heavy gas oils to clean jet and diesel,

UOP’s History of Hydrocracking Progress4

1950

1960

1970

1980

1990

2000

PresentUOP HDC Unibon™

Process (hydrotreating and

hydrocracking)

UOP HC Unibon™ Process

(hydrocracking)

UOP UnicrackingTM

Process

UOP Lomax Hydrocracking

Process

UOP ISOMAXProcess

UOP Hydrocracking Technology -long history, sustained innovation

Distillate

LCO

VGO

CGO

DAO

Hydrocracking Technology Portfolio5

Customized Solutions to Meet Customer Objectives

Naphtha

Kero/Jet Fuel

Diesel Fuel

Single Stage Recycle

HPNA Management

Dual Stripper/Dual Frac

Feedstock ProductsFractionation SectionReactor Section

TwoStage Recycle

Once Through

Lubes Base Stocks

65 years of Hydroprocessing Innovation

340+ Hydrotreating Units & 220+ Hydrocracking Units Licensed

6

0

40,000

80,000

120,000

160,000

200,000

1950 1955 1960 1965 1970 1975 1980 1985 1990 1995 2000 2005 2010 2015 2020

Lice

nsed

Cap

acity

, BPS

D

Award Year

UOP Hydroprocessing Experience

Unionfining UnitsUnicracking Units

1952 1st Hydrotreating

Unit

19601st Hydrocracking

Unit

10 Licensed Units in

Iran

2008E2S Process

2016

Unity

Hydroprocessing Catalysts

TM

2012UniflowTM

Reactor Internals5th Generation

1990s/2006HPNA Management

Comprehensive Hydroprocessing Solution7

Integrated Solutions • Bottom of the Barrel

(Uniflex™, RCD Unionfining, & SDA Processes)

• Hydrogen recovery & purification

Expert Knowledge• Training simulators• Experion Solution

Suites

Process Technology • Innovative flow

schemes

• Unicracking Process

• Unionfining Process

• HPNA Management

• New unit & revamp experience

Equipment Solutions• UniflowTM Reactor

Internals

• UOP Hydrogen Purification (Polybed™PSA)

• Callidus Combustion Equipment

• Honeywell Advanced Process Control

• Mitsui smiLLeTM

Metallurgy

• Filtrex® ACR Filtration

Catalyst Solutions•Unified portfolio for hydrotreating & hydrocracking

•Crystaphase®

UOP Hydrocracking Differentiators

• Extensive experience in revamping existing Hydrocracking Units- Maximize value from existing assests

• Novel Fractionation- Reduced CAPEX and OPEX of fractionation section

• HPNA Managament- Enabler for higher conversion

• Uniflow reactor internals- Maximize catalyst utilization

• Catalyst- pre treat and cracking

8

Improving Profitability from Existing Asset9

• A challenging market demands innovative solutions• UOP can provide a variety of revamp options to meet your

objectives- Innovative process solutions- Experience with different flow schemes- Uniflow reactor internals- Complete catalyst portfolio- Targeted studies to resolve issues, assess future expansion or

investigate different processing objectives

• UOP Worldwide Hydroprocessing Revamp experience

- 74 Revamp Studies and 42 Revamp Schedule A’s conducted in the last 10 years

Energy Savings with Novel Fractionation10

• The separation accomplished in the hot and cold separators is further improved in separate hot and cold strippers

• Improved Diesel/UCO separation with heavy fractionator

The Novel Fractionation Flow Scheme Traditional Single Stripper Design

FractionatorFeed Heater

Stripper

Steam

Off GasProduct

Fractionator

UnconvertedOil

ColdStripper

HotStripper

Steam

Steam

Off Gas

LightFractionator

HeavyFractionator

Heavy FractionatorFeed Heater

UnconvertedOil

Steam

Cold Separator/ Flash Drum

Hot Separator/ Flash Drum

Cold Separator/

Flash Drum

Hot Separator/

Flash Drum

Novel Fractionation Benefits11

• Dual Zone Stripper + Dual Fractionator – Improved fractionation efficiency – Diesel yields improved by approximately 1%– Produces dry diesel directly from fractionator

201554%

UOP HPNA Management TechnologyEnables Higher Conversion

12

• Heavy Polynuclear Aromatics can build up in recycle oil

• HPNA Management Solutions ‒Split shell fractionator

concentrates HPNA’s in a small bleed stream 15 units designed with split

shell fractionator, 5 operating

‒External HPNA stripper is available as a revamp

VGO Feed

DistillateSplit ShellProduct

FractionatorReactor

HotSeparator

HPS

HPNA rich material to

fuel oil or FCC

Slip stream toHPNA Stripping

SectionUp to 99.5% conversion for

entire catalyst cycle

Example: Installed in 5-bed HC reactor in Nov, 2014. Unit operating at 32% higher feed rate compared to previous cycle.

• New design offering a step change in performance & speed of installation

• First sale in 2013• Sold into 16 units (new and

revamp) with 6 operating successfully

13Improved Distribution with UOP Uniflow Reactor Internals

Customer Feedback:

HydrocrackingBed

Radial Spread (ºF)New Cycle

Radial Spread (ºF)Previous Cycle

Bed 1 Top: 1Bottom: 1

Top: 3Bottom: 18


Top: 2Bottom: 6


Top: 5Bottom: 6


Top: 12Bottom: 36


Top: 11Bottom: 45

“We would never have been able to operate this unit where it is today without these new internals.

This is a step change for UOP”

UOP 7432D-13

Hydrocracking Catalyst System Components

Grading System

Hydrotreating Catalyst

Hydrocracking Catalyst

• Controls pressure drop• Removes metals

• Sulfur removal• Nitrogen removal• Aromatic saturation

• Selective cracking to reduce boiling range

• Aromatic saturation• Selective isomerisation

14

Iranian Hydrocracking Opportunities15

• Key enablers for staged investment and fuel oil reduction

• Maximum utilisation of existing refinery assets

• Revamp Opportunities for increased throughput

• Phased investment for Bottom of the Barrel upgrading

• Delayed investment of major unit revamp

Revamp of existing Iranian units16

Existing Unit – Iranian Isomax Unit17

Existing Isomax

Unit

12,000 BPSD

LIGHT ENDS

FULL RANGE NAPHTHA

KEROSENE

DIESEL

UNCONVERTED OIL

RECYCLE OIL2,000 BPSD

FRESH FEED (HVGO)

10,000 BPSD

19% Fuel Oil


Existing Unit – Iranian Isomax UnitPhase 1 – New VDU

18

Existing Isomax

Unit

12,600 BPSD

LIGHT ENDS

FULL RANGE NAPHTHA

KEROSENE

DIESEL

UNCONVERTED OIL

FRESH FEED (HVGO)

10,000 BPSD

HVGO2,600 BPSD

Original Capacity = 12,000 BPSDCurrent Capacity = 12,600 BPSD

13% Fuel Oil


Existing Unit – Iranian Isomax UnitPhase 2 – New SDA

19

Existing Isomax

Unit1.0 CFR

14,880 BPSD

LIGHT ENDS

FULL RANGE NAPHTHA

KEROSENE

DIESEL

UNCONVERTED OIL

FRESH FEED (HVGO)

10,000 BPSD

HVGO2,600 BPSD


DAO3,000 BPSD

30% Higher than

Design

4% Fuel Oil


Existing Unit – Iranian Isomax UnitPhase 3 – New Slurry Hydrocracker

20

Existing Isomax

Unit1.0 CFR

14,880 BPSD

LIGHT ENDS

FULL RANGE NAPHTHA

KEROSENE

DIESEL

UNCONVERTED OIL

FRESH FEED (HVGO)

10,000 BPSD

HVGO2,600 BPSD


DAO3,000 BPSD

40% Higher than

DesignSLURRY VGO1,200 BPSD

0% Fuel Oil

Existing Unit – Iranian Isomax Unit21

Current Operation

Phase 1New VDU

Phase 2Add SDA

Phase 3Add Slurry

HCK

12,000 BPSD 12,600 BPSD 15,600 BPSD 16,800 BPSD

No Recycle

60-70% Conversion

Increasing Complexity

Unit Revamp Required

Maximise yield of DistillatesMaximum Conversion

UNCONVERTED OIL

Unit Revamp Options22

Existing Isomax

Unit

12,000 BPSD

Fractionation Section

HVGO, DAO and SLURRY VGO

16,800 BPSD

RECYCLE OIL

12,000 BPSD

At original design

capacity

LIGHT ENDS

NAPHTHA

KEROSENE

DIESEL

New 1st

Stage

16,800 BPSD

HPNA Management

Uniflow Reactor Internals

mahdavi

Textbox

VCMStudy.ir

Impact on Refinery Yields23

0

10

20

30

40

50

60

70

80

90

100

Current Performance Phase 1 - New VDU Phase 2 - New SDA Phase 3 - New SlurryHydrocracker

PRO

DU

CT Y

IELD

, VO

L%

Fuel Oil Bitumen Euro 5 Diesel Kerosene Naphtha LPG

Summary of Case Study24

Phase 1 Phase 2 Phase 3

+VDU +SDA +Slurry HCU

Hydrocracking Unit Revamp Concept

Creep of existing unit Add additional stage to existing unit

Euro 5 Diesel (vol% of product) 43 vol% 52 vol% 61 vol%

Fuel Oil (vol% of product) 13 vol% 4 vol% 0 vol%

UOP has the knowledge and capability to provide an integrated revamp solution to phase your project to

maximise transportation fuels and to reduce fuel oil to less than 10% of crude

MIDOR Refinery Expansion ProjectBoosting Refinery Capacity – 100,000 to 160,000 BPSD

Project Objectives (all achieved)• Refinery throughput increased 60%• Increase middle distillate yield 75%• Meet future legislation of high

quality EuroV specifications• Zero fuel oil production• Internal rate of return 30%

Additional Requirements• Maximum utilisation of existing

refinery units• Minimise refinery downtime• Limited plot space

25

UOP 7432D-10


26

UOP 7432D-26

Coke

Euro VDiesel

LocalDiesel

Kerosene

Euro VGasoline

R95

LPGSGP LPGMerox

LPGFrac.

NHT

DelayedCoker

SDA

CDU

CDU

NS

HC LPG

LPG Fuel GasC3/C4

IsomerateISOM

Reformate

CCR

LPG from other unitsCDU LPG

CrudeOil

SRN

Kero

SRD

CDU LPG

At Res

VGO

SRN

Kero

CrudeOil

KHTNAP

SRD

VDU

At Res VGO

Pitch

HCGODC

NAPVDU

HC NAPHC LPG to LPG Frac

DHT NAP

HT Diesel

DAO

HC Diesel

HC KeroHC

NewDHT

LCGO

KHT

New Unit

Revamp

Existing Unit

UCO

MIDOR Refinery Expansion ProjectCurrent Kerosene and Diesel Processing Configuration

27

Existing DHT29,000 BPSD

Local Diesel 50 wtppm S

Jet A1Existing Kerosene

Merox11,000 BPSD

Current Configuration• Targets local diesel production • Kerosene to Jet A1 pool only• No ability to achieve EuroV diesel specifications

UOP 7432D-12

SR Diesel + LCGO

SR Kerosene

MIDOR Refinery Expansion ProjectMaximising Euro V Diesel Production

28

KHT(Revamped DHT)

18,000 BPSDLocal Diesel 50 wtppm S

Euro V Diesel10 wtppm S

Jet A1

SR Kerosene

Existing Kerosene Merox

11,000 BPSD

SR Kerosene

New DHT48,000 BPSD

SR Diesel + LCGO

Ultimate flexibility between Jet A1 and EuroV Diesel production. Minimum shutdown and plot space

with optimised investmentUOP 7432D-13

29

Separation Fractionation33,000 BPSDVGO+HCGO

Make-up Gas

17,000 BPSD

Naphtha

Kerosene

Diesel

UCO

Unicracking Unit Existing Configuration

UOP 7432D-14

30

Separation Fractionation

35,000 BPSDUCO

Make-up Gas

Naphtha

Kerosene

Diesel

New RG Scrubber

Separation Fractionation

HPNA Management

MUG

Naphtha

Kerosene

Diesel

UCO

Common H2Recovery

Unicracking UnitNew Configuration

Uniflow Reactor Internals

UOP 7432D-130

50,000 BPSDVGO+HCGO+DAO


31

UOP 7432D-16

• Maximum utilisation of existing refinery units• Minimise refinery downtime• Refinery throughput increased 60%• Increase middle distillate yield 75%• Meet future legislation of high quality EuroV specifications• Zero fuel oil production• Internal rate of return 30%

Enhanced Two-Stage UnicrackingTüpras Residue Upgrading Project Success Story

32

UOP Hydroprocessing Complex

Hydrogen Generation Unit

Delayed Coker

Vacuum Distillation

Control Room


33


34

• Smooth and safe unit start-up• On spec product with 36 hours of feed introduction• All guarantees and met in August 2015• One of the most profitable units in Tüpras• Operating at 110% of design feed meeting all product qualities• Forecast to exceed the catalyst cycle length

Summary – UOP Hydrocracking TechnologyUpgrading Fuel Oil to Euro V Fuels

35

• Licensor of choice for integrated hydrocracking solutions

• Technology to enable the phasing of Iranian bottom of the barrel projects

• Existing hydrocracking units are key enablers for staged investment

• Extensive experience of revamp design to align with existing unit

constraints and minimize downtime

• History of partnering with customers for successful bottom of the barrel

upgrading projects

36

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.

uop hydrocracking technology · reactor internals • uop hydrogen purification (polybed ™ psa)...

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