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Copyright © 2016 DuPont. The DuPont Oval Logo, DuPont™ and The miracles of science™ are trademarks or registered trademarks
of E. I. du Pont de Nemours and Company or its affiliates. All rights reserved.
Innovative & Cost-Effective Technology for Producing Low Sulfur Diesel
Matthew Clingerman, DuPont Clean Technologies
EGYPT DOWNSTREAM SUMMIT & EXHIBITION
February 2016
Copyright © 2016 DuPont. All rights reserved. 2
Introduction to DuPont Clean Technologies
Meeting Diesel Specifications
IsoTherming® Hydroprocessing Technology
Case Studies
Agenda
1
2
3
4
Summary 5
Copyright © 2016 DuPont. All rights reserved. 3
Through science and engineering,
we solve some of the world’s greatest challenges.
DuPont has been bringing world-class science and engineering to the global marketplace in the form of innovative products, materials, and services since 1802.
Our Purpose
© National Geographic Image Copyright © 2016 DuPont. All rights reserved. 3
Copyright © 2016 DuPont. All rights reserved. 4
DuPont 2015 Segment Sales
$25B
DuPont Nutrition & Health ($3.3B)
Core Markets: Food & Nutrition Products
DuPont Agriculture ($9.8B)
Core Markets: Seeds | Agricultural Chemicals
DuPont Electronics & Communications ($2.1B)
Core Markets: Photovoltaics | Consumer Electronics | Advanced Printing | Displays
DuPont Industrial Biosciences ($1.2B)
Core Markets: Industrial Enzymes | BioBased Materials
DuPont Safety & Protection ($3.5B)
Core Markets: Industrial | Construction | Military & Law Enforcement | Transportation | Consumer
DuPont Performance Materials ($5.3B)
Core Markets: Transportation | Industrial | Packaging | Electrical/Electronics
Copyright © 2016 DuPont. All rights reserved. 5
DuPont Clean Technologies
IsoTherming® Hydroprocessing
Technology
STRATCO® Alkylation Technology
MECS® Sulfuric
Acid Technology
BELCO® and DynaWave® Scrubbing Technologies
Text 1 Text 1 Text 1 Text 1
Leading technology for the production of low-
sulfur, high octane gasoline blend stock
Leading technology for the production of
sulfuric acid and related high performance
products
Leading technologies for air emissions reduction in FCCs & SRUs for SOx, NOx, and particulates
Improved hydroprocessing
technology for the production of low sulfur
diesel
Copyright © 2016 DuPont. All rights reserved. 6
Worldwide Fuel Specifications are Evolving
Europe <10ppm (2009) USA
<10ppm (2017) China
<10ppm (2018) Japan
<10ppm (2007)
Russia <10ppm (2016)
Thailand <50ppm (2012)
South Africa <10ppm (2017)
Brazil <50ppm (2014)
India <10ppm (2020)
Countries around the world are adopting low-sulfur diesel specifications that emulate Euro-V
Australia <10ppm (2012)
Copyright © 2016 DuPont. All rights reserved. 7
Worldwide Fuel Specifications are Evolving
• Three key issues:
• satisfy global demand
• meet regional specifications
• maximize return on investment
• Refiners must ensure that the fuel meets local market specifications plus
any specifications for pipelines and ‘at the pump’.
• Increasingly stringent legislation means that diesel sulfur levels will continue to fall.
Copyright © 2016 DuPont. All rights reserved. 8
IsoTherming® Hydroprocessing Technology
Straightforward, Flexible Design
• Versatile reactor design and unit configuration
• Customized revamp applications
Cost Effective
• Reduced OpEx / decreased utilities consumption
• Capital cost savings
• Maximum usage of existing equipment
Copyright © 2016 DuPont. All rights reserved. 9
25 Licenses
Grassroots: 20 Revamps: 5 Operating: 12 2016 Startups: 5
IsoTherming® Hydroprocessing Technology Proven Experience
Applications
Diesel Hydrotreating Kerosene Hydrotreating FCC Pretreat / Mild Hydrocracking VGO & LCO Mild Hydrocracking Dewaxing Gas-to-Liquids Upgrading Heavy Oil Upgrading
Copyright © 2016 DuPont. All rights reserved. 10
Conventional Hydrotreating Process
Blended Feed
Product
Make-up Hydrogen M
M
Rich Amine
Lean Amine
Stripper Off Gas
Naphtha Product
STEAM
HHPS
CHPS
Copyright © 2016 DuPont. All rights reserved. 11
IsoTherming® Hydroprocessing Technology
Blended Feed
Product
Make-up Hydrogen M
Stripper Off Gas
Naphtha Product
STEAM
• Liquid Phase Reactor
• Liquid Recycle
• Hydrogen in solution within the catalyst bed
• Distribution less critical
HLPS
CLPS
Copyright © 2016 DuPont. All rights reserved. 12
Major Equipment Comparison
CONVENTIONAL
• Recycle Gas Compressor • HP Lube and Seal Systems • HP Surge/Recycle Controls • HP Suction Knockout Drum • Continuous Vibration Monitoring • Vibration Control Foundation
• Hot HP Separator • HP Condenser • Cold HP Separator • HP Amine Scrubber • Lean Amine Pump • Larger Feed/Effluent Exchanger • Larger Reactor Charge Heater
• Reactor Recycle Pump • Hot LP Separator • Smaller Feed/Effluent Exchanger • Smaller Reactor Charge Heater
ISOTHERMING®
Copyright © 2016 DuPont. All rights reserved. 13
Advantages of IsoTherming® Technology
30 to 40% reduction
Reactor recycle pump vs. recycle gas compressor
30 to 60% reduction
Heat of reaction absorbed by liquid recycle and used to heat the feed
Lower heater firing rates in normal operation
Quick recovery from unit upsets
Minimal HP equipment & reduced hydrogen inventory
No runaway reaction
Lower greenhouse gas emissions
30 to 50% increase
Optimized heat integration/heat recovery allowing for steam or power generation
Reduced Fuel Gas Usage Lower Power Consumption
Better Energy Recovery Reliable and Safe
Copyright © 2016 DuPont. All rights reserved. 14
Revamping Existing Capacity
• Motivations
• Capacity Increases
• Product Quality Requirements
• Process More Difficult Feedstock
• Increase Catalyst Cycle Length
• Challenges
• Hydraulic limitations
• Existing catalyst volume
• Extensive modifications
Major modifications require long shut downs to implement and can be very costly
Copyright © 2016 DuPont. All rights reserved. 15
Conventional Revamps
Make-up Hydrogen
Blended Feed
M
Product M
Lean Amine
Rich Amine
Stripper Off Gas
Naphtha Product
STEAM
NEW / MODIFIED EQUIPMENT IN RED
Copyright © 2016 DuPont. All rights reserved. 16
IsoTherming® Revamp Solutions Integration of Conventional and IsoTherming® Technologies
Make-up Hydrogen
Blended Feed
M
Product
Rich Amine
Stripper Off Gas
Naphtha Product
STEAM
M
Lean Amine
NEW / MODIFIED EQUIPMENT IN RED
Copyright © 2016 DuPont. All rights reserved. 17
IsoTherming® Revamp Solutions
Conventional IsoTherming®
Reactors New Required May Retrofit Existing
Recycle Gas Loop
Recycle Gas Compressor Modify/Replace No Modification
Reactor Recycle Pump Not Required Required
High Pressure Gas Loop
Charge Heater Modify/Replace No Modification
Feed/Effluent Exchangers New Exchangers No Modification
Gas-Liquid Separators Modify No Modification
High Pressure Piping Modify/Replace Some Tie-Ins
Project Timing Longer Shorter
Plot Space Requirements Greater Lesser
Project Cost Higher Lower
Equipment Investment Higher Lower
Copyright © 2016 DuPont. All rights reserved. 18
Revamps with IsoTherming® Technology
• Maximize Unit Throughput
• Improve Diesel Product Quality
• Process More Cracked Feedstock
• Increase Catalyst Cycle Length
• Minimize Capital Investment
• Reduce Operating Expenses
Copyright © 2016 DuPont. All rights reserved. 19
IsoTherming® Technology Case Studies
Grassroots Diesel Hydrotreater in China
ULSD Revamp in India
Full Conversion to IsoTherming® Technology
Copyright © 2016 DuPont. All rights reserved. 20
IsoTherming® for Grassroots DHT Units Production of China National IV
• Throughput: 0.6 MMTPA
• Product Target: S < 50 wppm (China IV)
• Project Execution: ~ two years
• From Process Design kickoff to fresh feed introduced into the unit
• Unit successfully achieved < 50 wppm S diesel specifications, per design, while at the following conditions:
Throughput BPD 0.6 MMTPA (design)
Reactor WABT oC 360 - 368
Reactor Pressure kg/cm2 65
Diesel Product Sulfur wppm 35 - 50
Copyright © 2016 DuPont. All rights reserved. 21
IsoTherming® Revamp Solutions Benefits Achieved in a 37,000 BPSD Trickle Bed Unit
• 35% Capacity Increase with Minimal Modifications • 2% Reduction in Charge Heater Duty • 10% Reduction in Feed / Effluent Exchanger Duty
Pre-Revamp Case
Post-Revamp - Conventional Technology
Post-Revamp - IsoTherming® Technology
Delta
Capacity BPSD 37,000 50,000 50,000
Power consumption per barrel of feed
KWh/bbl 2.42 2.16 1.72 -20%
Fuel gas consumption per barrel of feed
lb/bbl 1.23 1.40 1.02 -27%
Cooling water consumption per barrel of feed
ft3/bbl 18.0 18.1 17.3 -4%
Copyright © 2016 DuPont. All rights reserved. 22
IsoTherming® Revamp Solutions Trickle Bed Reactor Conversion
Utilize Existing Nozzles
All internal parts pre-fabricated and were installed through existing manway
Reused supports
No welding to the reactor
40 days from shutdown to beginning of startup
Copyright © 2016 DuPont. All rights reserved. 23
DECOMMISSIONED EQUIPMENT
IsoTherming® Revamp Solutions Full Conversion to IsoTherming®
Make-up Hydrogen
Stabilized Naphtha Product
M
Stripper Off Gas
Unstabilized Naphtha Product
Diesel Product
STEAM
STEAM
M
Lean Amine
Rich Amine
Blended Feed
Product
Copyright © 2016 DuPont. All rights reserved. 24
IsoTherming® Hydroprocessing Technology Summary
A reliable & robust process for Grassroots or Revamp HDT Units
Simple & Straightforward
• Less equipment required
• Fewer modifications in revamps
Cost Effective
• Lower capital cost
• High energy efficiency
• Shorter project schedules & implementation time