Optimization of the

feedstock blend for the new

H-Oil-RC™ ebullated bed

resid upgrading unit

at LukOil Neftochim Burgas,

to maximize the conversion

and yields of the on-site FCC

unit

Presented by:

Dr. Dicho Stratiev LukOil - Burgas

Wessel IJlstra Criterion - Amsterdam

Co-authors:

Dr. Ilshat Sharafutdinov LukOil - Burgas

Dr. Georgi Argirov LukOil – Burgas

Dr. Magdalena Mitkova Burgas University

Radoslava Nikolova Burgas University

Dr. David E. Sherwood Jr. Criterion - Houston

Burgas University

Disclaimer

Criterion, LukOil, and Burgas University are the trade names of independent entities. Where

an entitity is identified by its trade name, the reference is used for convenience, or may be

used where no useful purpose is served in referring to the entity by name. The services and

products of these entities may not be available in certain countries or political subdivisions

thereof.

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. No representations or warranties, express or implied, are made by the entity or

entities presenting these materials, or their affiliates, concerning the applicability, suitability,

accuracy or completeness of the information contained herein and these entities do not

accept any responsibility whatsoever for the use of this information. The entities presenting

these materials, and their affiliates, are not liable for any action you may take as a result of

you relying on such material or for any loss or damage suffered by you as a result of you

taking this action. Furthermore, these materials do not in any way constitute an offer to

provide specific services.

Copyright ©2015 Shell Oil Company. All rights reserved. No part of this publication may be

reproduced or transmitted in any form or by any means, electronic or mechanical including

by photocopy, recording or information storage and retrieval system, without permission in

writing from Shell Oil Company or Criterion Catalysts & Technologies L.P.

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3

Program

- Introduction to LukOil Neftochim, refinery Burgas

and the new H-Oil-RC™ unit licensed by Axens

- Study objectives for this presentation

- Introduction to ebullated bed pilot plant testing

- Pilot plant test plan

- Pilot plant test results

- Experimental and theoretical estimates FCC yields

- Refinery scheduling

- Conclusions

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Process Diagram of LUKOIL Neftohim

Burgas

Crude oil

6.5 MM t/y

+ 1.5 MM t/y

Atm. Residue

B L E N D I N G

FCC

Pre-

treate

r

Bitumen unit

LPG

Naphtha

Premium

gasoline

(A-95H)

Super

Gasoline

(А-98Н)

Jet A-1

Euro diesel

Road

Bitumen

Fuel oil

S<1%

Sulphur - New units

- Gasoline

- Kerosene

- VGO

- Diesel fuel - C1-C4 gas - Н2S

- Heavy residue

- Existing units

- Fuel oil

Fuel gas

AVD-1

AD-4

VDU-2

HDS-1

HDS-2

HDS-3

Reformer

AGFU CGFU

Naphtha

Hydrotreater

SRU-3

Prime-G

VBU

SMR

HDS-5 1 700

хил.т./г

MTBE

Alkylatio

n

FCCU

n-С4

Isomerization

SRU-4

2015

2015

H-Oil residue

hydrocracking

- Units out of operation

SMR

«ЛУКОЙЛ Нефтохим Бургас» АД

18

SRU-2

2015

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5

Program

Problem definition: • Commissioning of the new H-Oil-RC™ unit at LukOil Burgas will

allow for rescheduling of the refinery to optimize product yields.

• At start-up, not enough vacuum resid will be available to fully utilize

the capacity of the new unit, but alternative heavy feed components

(AR, VGO) can be rerouted to H-Oil-RC™ unit.

Study objectives:

Screen possible feed blends for the H-Oil-RC™ unit.

• Use yields- and product quality results from H-Oil pilot-plant study

to estimate/test FCC unit performance.

• Use conclusions in site scheduling program to optimize refinery

margins.

CATALYST/ LIQUID/GAS

LIQUID/GAS

HYDROGEN and FEED OIL

FRESH CATALYST

EXPANDED CATALYST LEVEL

RECYCLE OIL

USED CATALYST

LIQUID

EBULLATION PUMP

GRID PLATE WITH MULTIPLE DISTRIBUTION CAPS

PRODUCT LIQUID/GAS

SETTLED

CATALYST

LEVEL

Level instrument Example of a commercial Ebullated Bed Reactor Defining characteristics: * Back-mixing of liquid and catalyst - Little temperature and concentration gradient - Uniform catalyst activity * Continues catalyst replacement - Stable performance of catalyst inventory

Introduction ebullated bed pilot plant testing

Criterion uses autoclave reactors equipped with Robinson-Mahoney type

internals. Back-mixed (CSTR) kinetics are assumed

to evaluate Ebullated Bed Catalyst Performance

• Fixed annular catalyst basket

with baffles inside and outside the basket

to prevent vortexing.

• Rotating shaft with agitator, creating flow

through the basket to the reactor wall for

upward and downward deflection.

• Liquid level controlled by overflow tube

• Gas hold-up controlled by mixer speed

• Multi-phase gradientless reactor.

From: http://www.autoclave-france.fr/english/cata.html

Introduction to Ebullated Bed pilot plant testing

Two of the four Criterion CSTR Pilot Plants

located in the Houston R&D laboratory

Test plan

• Three independent tests were done in the same Criterion pilot-

plant at Shell Technology Center, Houston (STCH) to simulate

the new H-Oil-RC™ unit at LukOil Burgas.

• Each test used one of 3 feed blends as specified and supplied by

LukOil:

A. 100% VR

B. 75% VR + 25% heavy VGO

C. 50% VR + 50% heavy AR

(All feed blends were additionally blended with FCCUHCO +

FCCU Slurry Oil [diluents], as specified and supplied by LukOil)

• Each test was done at equal conditions. The feed rates were kept

constant, but, to allow for interpolation to the target conversion

level, the evaluations were done at 2 different conversion levels.

Test plan --- Feed Blends A, B and C (after diluent addition)

Analysis Unit

VR

100%

(+diluents)

VR/VGO

75%/25%

(+diluents)

VR/AR

50%/50%

(+diluents)

Density kg/l 1.010 0.984 0.978

Sulphur wt-% 2.73 2.38 2.03

Nitrogen wt-% 0.4964 0.4051 0.3679

Carbon residue, MCR wt-% 16.0 11.0 11.0

Ni ppm 82 53 48

V ppm 258 175 143

SimDis

538 oC+ wt-% 82.1 65.5 58.6

565 oC+ wt-% 75.2 55.5 52.1

Test Results

• For each test, 2 (or 4) test-periods were selected for

complete analysis (fractionation + product quality

analysis).

• All samples of the VGO and VR products were shipped to

LukOil Burgas for further evaluation by LukOil and Burgas

University.

Test Results

Test Results

• Net 540°C+ conversion appears higher for vacuum resid

only feed, compared to the lighter blends.

35.0

40.0

45.0

50.0

55.0

60.0

65.0

70.0

75.0

80.0

406 408 410 412 414 416 418 420

Net

54

0°C

co

nve

rsio

n [

wt%

]

Operating temperature [°C]

Target Conversion

Test Results

• For each of the feed blends the yield pattern was

determined.

• This example is for the100% VR feed.

2.0

7.0

12.0

17.0

22.0

27.0

32.0

37.0

50 52 54 56 58 60 62 64 66 68 70 72 74 76 78 80

Pro

du

ct y

ield

s [w

t%]

Net 540°C+ conversion [wt%]

Target Conversion

VGO

Test Results

• The yield patterns can be directly compared for the

different feed blends.

• Lighter feed blends, containing more VGO, give higher

VGO yields at equal 540°C+ conversion.

12.0

17.0

22.0

27.0

32.0

37.0

42.0

47.0

50 52 54 56 58 60 62 64 66 68 70 72 74 76 78 80

VG

O y

ield

s [w

t%]

Net 540°C+ conversion [wt%]

Target Conversion

75/25 VR/VGO

100% VR

Test Results

• Lighter feed blends, containing more diesel, result in

higher diesel yields at equal 540°C+ conversion.

2.0

7.0

12.0

17.0

22.0

27.0

32.0

37.0

50 52 54 56 58 60 62 64 66 68 70 72 74 76 78 80

Die

sel y

ield

s [w

t%]

Net 540°C+ conversion [wt%]

Target Conversion

Test Results

• Hydrogenation performance and product quality data were

interpolated to the target 540°C+ conversion level.

Feed blend VR VR/VGO VR/AR

Blending ratio 100 75/25 50/50

540°C+ Conversion Base Same Same

Sulfur in unconverted resid wt% Base -0.2 -0.2

HDS wt% Base +4 +4

HDN wt% Base +5 Same

HDMCR wt% Base +5 +6

HDMetals wt% Base +4 +2

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H-Oil-RC™ products from 3 different feed blends

were separated and analyzed for product quality

100% VR

75/25 VR/VGO

50/50 VR/AR

Diesel VGO VR

Feed blends

H-Oil-RC(TM) Product Density

100% VR

75/25 VR/VGO

50/50 VR/AR

Diesel VGO VR

Feed blends

H-Oil-RC(TM) Product Sulfur

100% VR

75/25 VR/VGO

50/50 VR/AR

Diesel VGO

Feed blends

H-Oil-RC(TM) ProductNitrogen

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FCC feed specific properties for VGO product

100% VR

75/25 VR/VGO

50/50 VR/AR

Kw Saturates light middle heavy ResinsAromatics

Feed blends

100% VR

75/25 VR/VGO

50/50 VR/AR

Kw Saturates Aromatics Resins Asphaltenes

Feed blends

Specific properties for the unconverted product

Specific properties of the H-Oil-RC™ products, needed for

predicting the FCC unit performance were analyzed in the

LukOil laboratory

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H-Oil-RC™ pilot-plant products were used as feed

for Micro Laboratory FCC pilot units

FCC yield patterns simulated at max gasoline yield, when

using H-Oil-RC™ VGO products neat from different feed

blends

100% VR

75/25 VR/HVGO

50/50 VR/AR

drygas LPG gasoline LCO HCO Coke conversion

VGO product

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In addition, Micro Laboratory FCC simulations were performed

for blends of H-Oil-RC™ products with straight-run HVGO

FCC yield patterns simulated at max gasoline yield, when using

blends of SR HVGO and H-Oil-RC™ VGO products

Compared to the blend 50%/50% blend with VGO product from

100% VR run, the 50%/50% blend with VGO product from the

75%/25% VR/VGO run gave ~+4% gasoline + LPG at the

expense of ~-4% cycle oils.

100% SR HVGO

50% SR HVGO + 50% H-OilVGO (100% VR)

50% SR HVGO + 50% H-OilVGO (75/25 VR/HVGO)

drygas LPG gasoline LCO HCO Coke conversion

VGO blends

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Simulated LUKOIL Neftohim Burgas Constrained FCCU yields

Product Yields, wt.%

90%/10% HTVGO/

VGO

50%/50% HTVGO/

H-Oil-RC™ VGO

(100%VR)

50%/50% HTVGO/

H-Oil-RC™ VGO (75%/25% VR/HVGO)

dry gas 2.5 3.30 2.8

PPF 8.7 7.48 8.1

BBF 13.4 11.80 12.4

Cracked Naphtha 52.4 49.00 51.0

LCO 9.9 11.48 10.9

HCO 5.3 6.70 5.5

Slurry 3.9 5.85 5.2

Coke 4.0 4.40 4.1

Conversion 81.0 76.0 78.4

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Yield- and product property data were used in the

refinery’s LP-model to evaluate the profitability

When the H-Oil-RC™ unit capacity is not fully

utilized, processing SR HVGO in the unit appears

very favorable for overall refinery profitability

100% VR 75/25VR/HVGO

50/50 VR/AR

BaseBase + 5%

Base + 7.5%

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Conclusions

• LukOil, Burgas is starting up it’s new H-Oil-RC™ unit. Initially, not enough

VR will be available to fully utilize the unit capacity.

• Criterion’s pilot-plants were used to simulate the new H-Oil-RC™ unit of

LukOil Burgas, processing 3 different feed blends.

• Products of the pilot-plant studies were analyzed and used for FCC

simulations and micro FCC conversion tests.

• The FCC laboratory yields, simulated on the basis of LukOil derived

correlations and properties of VGO products from H-Oil-RC™ pilot-plant

tests, revealed an opportunity for an FCC conversion increase between

about 5 and 10%.

• Applying predicted commercial yields and product property data in the

refinery’s LP model showed a clear profitability advantage to use the

remaining unit capacity for co-processing of SR HVGO.

Burgas University

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Thanks for your attention

Burgas University