HH--Oil technology descriptionOil technology …...6 Vacuum Residue (VR) Feedstock • 40 - 85% VR conversion Unconverted residue application • Low sulfur (up to S< 1%) & stable

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Delphine LE BARS

H-Oil technology description H-Oil technology description

Alexandre Javidi Jean-Philippe Toupance

Teheran - November 2017

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Oil Refining

CLAUS ACID GAS REMOVAL TGT SULFUR

SULFUR RECOVERY S

FOSSIL &

RENEWABLE

FEEDSTOCKS CDU

VDU

TOP OF

THE

BARREL

BOTTOM

OF THE

BARREL

FCC post-

treatment

VGO/Res.

conversion

REFINERY GASES

LPG

NAPHTHA

GASOLINE

JET FUEL / KEROSENE

DIESEL / GASOIL

HEATING OILS

FUEL OILS

LUBE OILS

ASPHALT

SYNCRUDE

SULFUR

Lube Oils


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Bottom of the Barrel Axens Offer


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Axens Residue HydroCracking Offer

Objective: Conversion of Vacuum Residue (VR)

Feedstock into Valuable Products

High Flexibility

Fixed Bed Technology

• Limited conversion level

Ebullated Bed Technology

• Deep conversion level possible

Deep Conversion


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Axens H-Oil®RC Residue HydroCracking Feedstock

Vacuum Residue (VR) Feedstock

Conversion into valuable products

› Naphtha, Diesel, VGO

Unconverted Residue (UCO)

› Low Sulfur & Stable Fuel Oil

› Feed for Coker, SDA, Boilers or Gasification

High Value Products

UCO is a Liquid Fuel

Various Options for UCO Outlet


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Vacuum Residue (VR) Feedstock

• 40 - 85% VR conversion

Unconverted residue application

• Low sulfur (up to S< 1%) & stable fuel oil

• Feed for coker, SDA or gasification units

On-line Addition/Withdrawal of

catalyst

• Fully Automated System

• Constant product quality

• APC from Axens used to control catalyst

bed expansion

Availability > 96%

• 2 to 6 years cycle

• No shutdown for catalyst required

Settled Catalyst Level

Expanded Catalyst

Level

Distributor

Grid

Plate

Hydrogen and

Feed Slurry Feed

Catalyst Addition

Recycle Cup

Ebullated Bed

Ebullating Pump

Gas / Liquid

Separator

Recycle Oil Catalyst Withdrawal

Axens H-Oil RC – Residue HydroCracking


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Axens H-Oil Process - Flexibility

Feedstock of Motiva Refinery

Design Feedstock of Motiva unit • 70% Arabian Light

• 30% Arabian Medium

• Arabian Light

• Arabian Medium

• Arabian Heavy

• Basrah

• Bonny Light, Brass River

• Brent, Ekofish and Escravos

• Iranian Light

• Kirkuk

• Maya

• Alaskan North Slope

• Eugene Island

• …


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Axens H-Oil®RC – Simplified scheme overview

Make-Up

H2

Resid Feed

Heater

Heater

HP HT

Separator

Inter-Stage

Separator

MP HT

Separator

MP LT

Separator

MP Abs

HP Abs

HP Mem PSA Fuel Gas

Naphtha

Diesel

VGO

VR

Gas

H-Oil Reactors

Atmospheric

& Vacuum

Fractionation

HP LT

Separator

1st

Stage

2nd

Stage

3rd

Stage

Temperature 400 – 430°C

Pressure 120 – 190 bar

LHSV 0.1 – 1.3 hr-1

CRR 0.35 – 2.1 kg/t

Conversion 40 – 90 %

HDS 65 – 85 %

HDCCR 40 – 80 %

HDM 70 – 90 %

FRACTIONATION SECTION

Fresh

Catalyst

Used

Catalyst

CATALYST

SECTION

REACTION AND H2

COMPRESSION

SECTION


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UCO

H-Oil Overall Block Flow Diagram

Outstanding catalytic system

H-Oil ACS


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H-Oil Catalyst

Type: NiMo/Alumina 1.0-mm Extrudate. (Hydrotreatment catalyst type)

Catalyst replacement rate : metals in feed & objectives depend.

Vendor : Axens

Spent Catalyst Re-Processing • Worldwide based companies which process spent catalyst for metals reclamation

(Mo/Ni/V) – 15 references all around the world.

Additional revenue for customer from reclaimed metals

Catalyst Cascading: spent 2nd stage catalyst is used as replacement catalyst for 1st stage reactor


F:/petro asia rds final 2009 speaker.ppt#19. Axens Main Residue HDT catalysts

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Catalyst Handling Section Overall Scheme

Catalyst

Addition/

Withdrawal

Drum

Fresh Catalyst

Storage

Hopper

Fresh Catalyst

Provision

Catalyst

Measuring

hopper

Fresh Catalyst

Pneumatic

Transport System

Spent Catalyst Dump

Spent Catalyst

Storage

Hopper

Catalyst

Vapor

Separator

Drum

Re

ac

tor

1

Re

ac

tor

2

Transport/

Wash Oil

Drum

Wash/Cooling

Oil Drum

HVGO from

Fractionation

Diesel from

Fractionation

Spent

Catalyst

Cooling

Drum


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Why an H-Oil is not impacted by metals content in the feed?

UCO

90 ppm of metals H-Oil unit

HDM ~90%

Feed

250 ppm of metals

Fresh catalyst

~0.85 kg/t of feed

Eq. catalyst

23% of V

5% of Ni

Case 1

UCO

200 ppm of metals H-Oil unit

HDM ~90%

Feed

520 ppm of metals

Fresh catalyst

~1.4kg/t of feed

Eq. catalyst

23% of V

5% of Ni

Case 2

Catalyst Addition Rate Adjustment maintains constant

catalyst activity irrespective of metals in the VR feed


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H-Oil Pilot Scale Experience

Feedstock origin Metals content, ppm % conversion

Athabasca 431 58 to 78

Maya-Ismuth 566 45 to 50

Maya-Ismuth 688 45 to 50

Tahe 447 40 to 50

Athabasca/Cold lake 540 50 to 75

Maya/Ismuth 1040 54 to 65

Origin of the crudes

Canadian (Athabasca mined, Athabasca SAGD, Athabasca PFT, Lloydminster,

Cold Lake, ...)

Middle East (Safaniya, Buzurgan, Arabian Heavy, ...)

South-American (Zuata, Morichal, Cerro Negro, Boscan, Chichimene, ...)

Russian (Ural, Siberian, ...)

Chinese (Tahe)…

Metals: 0 to 1500 ppm, S: 0.2 to 6wt%, CCR: 0.1 to 35wt%, N: 10 to 8000 ppm

Focus on high metals feed


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H-Oil Industrial Scale experience

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%W

ENE-AGO 2004

CONTENIDO DE NIQUEL, CARGA NEGRA

VALOR

DISEÑO

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950

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%w

ENE-AGO 2004

CONTENIDO DE VANADIO, CARGA NEGRA

VALOR

DISEÑO

0

50

100

150

200

250

300

350

400

450

500

0 5 10 15 20 25 30

VANADIO

NIQUEL

More than 430 ppm of V+Ni is

contained in the feed.

Design was made for 670 ppm in the

feed

Quantity of vanadium in the feed

varies a lot : no issue

Flexibility of the H-Oil towards metals


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UCO


Superior Internals Safe and robust

design


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Axens H-Oil®RC Ebullating pump

Safety

• Easy leak detection when external

• Should a fire occur, risk to the reactor is minimal when external

Maintenance

• Direct access to the pump (easier & safer)

Operability / Reliability

• Direct flow measurement

• Butterfly valve on pump discharge

› Easy start up and shutdown

› Avoids reverse flow through pump and catalyst bed collapsing in emergency situation

“H-Oil®” Ebullating Pump

(External: case mounted)


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Axens H-Oil®RC Ebullating Pump

Axens H-Oil unit

design features an

external location for the

ebullating pump for:

safety

maintenance

operability

Available Only from Axens


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Axens H-Oil®RC Ebullating Pump – Iran case

Type of pump

• Pump flowrate in the middle range of existing pump in operation (Typical sizing of reactor)

Supplier

• Sulzer

› Relevant experience with “Isotherming” process

› Have been short listed by Hengli (China) for H-Oil unit

• Flowserve

› Leader in EB market

› Latest two EB pumps supplied and serviced 100% from EU base

› On-going Company business compliance process


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UCO


Optimal Vacuum Tower bottoms arrangement

Energy efficient Spiral heat exchangers


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90 %

Conversion

wt%

80 %

70

%

60

%

50 %

Middle east

Light Middle East Heavy Shengli Ural Maya

Feed

Difficult

y

Athabasca Zuata

How much conversion can you get with H-Oil?


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H-Oil® reactor design leverage

Sequential Deasphalting

Coker Integration

- Maximize the use of existing assets

- Unlock sediment constraints for H-Oil® UCO

- Create value not only with high conversion but also with better coke quality

H-Oil® : Assets & Values Streamline

- Maximize catalytic

performance for both

conversion and

hydrorefining

- Balance reactor

size and operating

conditions

- Control

sedimentation

- Accommodate high

capacity

- Overcome stability

issues thanks to

asphaltene rejection

- Balance Hydrogen

and/or utilities with

pitch valorisation


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Understanding Effluent Stability

Conversion

Asphaltenes are:

the heaviest structures difficult to characterize difficult to convert potentially unstable

Saturates / Aromatics / Resins / Asphaltenes

MATRIX

When destabilized, Asphaltenes floculate and cause:

- Fouling & downtime for cleaning

- Sediment in products


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0

20

40

60

80

100

120

140

Conversion HD Asphaltenes HDCCR HDS

Case 1

Case 2

Case 3

Case 4

Increase Temperature or Reduce space velocity?

• From Pilot Test Results with true EB pilot testing unit

0

20

40

60

80

100

120

140

160

180

200

% Sediments vs Stability Limit

How to Push the Conversion?

LHSV Temperature Conversion

Case 1 Base Base Base

Case 2 Base Base + 14°C Base x 120%

Case 3 Base/3 Base - 18°C Base

Case 4 Base /3 Base Base x 120%

Target good stability


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Temperature Increase

• Conversion increase driven by thermal cracking: compromises

operability (sediments, fouling)

Reduce LHSV

• Lower LHSV is favorable towards sediment control at iso

conversion

• At same temperature, lower LHSV is a powerful way to boost

conversion and hydrogenation reactions

• Effluent quality is improved

• Catalytically driven conversion increase: delivers higher

performance in HDCCR and HDAsph. Unlocks sedimentation

barrier

How to Push the Conversion?


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H-Oil® Suite Conversion To Capacity Effect

Lower capacity operation

industrial demonstration

• Higher conversion

• Less sediment production

• Enhanced refining

performance

LHSV / WABT prove

powerful to break

conversion ceiling

40% VR availability

reduction

Up to 15% of

conversion

Four-fold sediment

reduction

Conversio

n


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H-Oil® reactor design leverage

Sequential Deasphalting

Coker Integration

- Maximize the use of existing assets

- Unlock sediment constraints for H-Oil® UCO

- Create value not only with high conversion but also with better coke quality

H-Oil® : Assets & Values Streamline

- Maximize catalytic

performance for both

conversion and

hydrorefining

- Balance reactor size

and operating

conditions

- Control

sedimentation

- Accommodate high

capacity

- Overcome stability

issues thanks to

asphaltene rejection

- Balance Hydrogen

and/or utilities with

pitch valorisation


29

axens.net


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Documents

HH--Oil technology descriptionOil technology …...6 Vacuum Residue (VR) Feedstock • 40 - 85% VR conversion Unconverted residue application • Low sulfur (up to S< 1%) & stable