Maximizing Bottom-of-the Barrel Conversion with ... · 1 Delphine Le-Bars Maximizing Bottom-of-the Barrel Conversion with Commercially Proven TechnologiesProven Technologies Delphine

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Delphine Le-Bars

Maximizing Bottom-of-the Barrel

Conversion with Commercially Proven Technologies

Maximizing Bottom-of-the Barrel

Conversion with Commercially Proven Technologies

Delphine Le Bars

Russia & CIS BBTC 2015 - Moscow

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1. Context

2. H-Oil®RC Highlights & Commercial Experience

3. H-Oil®- SDA Combination to Maximize Conversion

4. Conclusion

Agenda


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1. Context



4. Conclusion

Agenda


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2010 2020 2030Source: Axens & other

sources (2014)

Oil Product Demand CIS Outlook 2030

Other* = Kerosene (≠ Jet

Kerosene), Refinery Gas,

Ethane, Petroleum Coke, NGL,

Lube oils, Bitumen, Paraffin

Wax, Refinery Losses, …

Other*

LPG

Naphtha

Motor Gasoline

Jet Kerosene

On-road diesel

Off-road diesel

Fuel Oil

Motor Gasoline: + 1.7% / y

Jet Kerosene: + 0.5% / y

Off-road diesel: + 0.4% / y

On-road diesel: + 2.0% / y

4.7

5.7

Mbdoe

16.8%

10.4%

7.7%

27.0%

7.3%

8.9%

14.2%

7.7%

17.6%

9.5%

9.9%

28.7%

6.6%

10.0%

12.4%

5.5%

(Mt/y) (350)

(300)

(250)

(150)

(100)

(50)

Fuel Oil: - 0.8% / y

2014

(200)


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CIS : Product Demand Will Be Driven By…

-0.05

0.04 0.16

0.03

0.39

0.21

0.06

0.22

-0.3

0.0

0.3

0.5

Fuel oil Off Road Diesel

On Road Diesel Jet Kerosene

Motor Gasoline Naphtha

LPG Other*

Mbdoe

Incremental Demand

2014-2030

Other* = Kerosene (≠ Jet Kerosene), Refinery Gas, Ethane, Petroleum Coke, NGL,

Lube oils, Bitumen, Paraffin Wax, Refinery Losses, …

(-15)

(15)

(25)

(Mt/y)

Demand growth in almost all

categories, especially for Gasoline,

Other and Naphtha

Only heavy fuel oil demand will fall

slightly over the period


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Increase CIS Refineries Conversion Rate

Favorable Russian taxation on heavy fuels runs out in 2015

Higher conversion rates can be achieved for more competitiveness

Conversion Markets Large Potential

Total of 66 Refineries with 8.2

Mbpd (410 Mtpy) capacity

Avg. Nelson Index : 5.4

CIS Today

11.1 8.2

5.2

6.9

6.2

4.2

5.4

Competitive Nelson Indices

Source: HART WRFS 2014


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1. Context



4. Conclusion

Agenda


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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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Axens H-Oil®RC Residue HydroCracking Principles


H2 + Feed

Catalyst Addition

Ebullated Bed

Ebullating Pump

Recycle Oil Catalyst Withdrawal

Robustness

Flexibility

Inter-stage

Separator

Ebullated-Bed Reactor

• Internal Liquid Recycle to

Fluidize Catalyst Bed

• Nearly Isothermal Reactor

• Low & Constant Pressure

Drop

• Daily Addition/Withdrawal of

Catalyst

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Availability of H-Oil® Units (2001-2010/2013)

Superior Reliability

Avg. 96.6%


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Axens H-Oil® Commercial Experience

First unit started in 1968

9 units in operation today

6 units in design/construction

4 awards in 2013/2014

Mature Technology

Total Capacity > 820,000 BPSD

Operating Cumulated Experience

> 200 unit-years


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Product Cost hypothesis

• Extra Heavy Crude Oil: 70 US$/Bbl = 440 US$/ton

• Same price for VR

• Middle distillates objectives

• Naphtha: 903 USD/ton

• Diesel: 933 USD/ton

Same conversion level: 90wt%

Capacity: 2500kTA

On-stream Factor Impact for VR Conversion Units


-7.6

-22.8

-45.6

-50

-45

-40

-35

-30

-25

-20

-15

-10

-5

0

96% 95% 93% 90%

Impact of Stream Factor on Economics

BASE

45 MUS$/year loss by

reduction of stream factor

from 96% down to 90%

Proven

H-Oil®RC

Stream Factor

Expected New

Technology

Stream Factor

MUS$/y

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1. Context



4. Conclusion

Agenda


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H-Oil® & Solvent DeAsphalting Process (SDA) Combination

Market Trend:

Maximize Conversion

Maximize Middle Distillates production

for higher profitability

Combination of H-Oil® & Solvahl™ (SDA)

Option is to use SDA to eliminate Asphaltenes

OIL REFINING

PETROCHEMICALS

Maximize Heavy Naphtha production for

Petrochemical application

Stability is the limiting factor due to

Asphaltenes condensation

0% 28% 48% 56% 74% 85%

With increased conversion in

Residue HCK alone

540+ Conversion, wt%


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Tailored option to meet target depends on:

• Project Objective

• Products Requirement

• Feedstocks

• Site constraints

H-Oil® & Solvahl™ Combination Options


H-Oil Reactor

Solvahl

H-Oil Reactor

Optimized Scheme for 90 wt% conversion

Axens Expertise & Know-how

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Conventional VR Feeds

› Middle East, Ural, etc.

Maximum Conversion

› Petrochemical application

› Middle Distillates production

No specific constraints in

downstream units

H-Oil® & Solvahl™ Combination - Option 1

H-Oil®RC

Gasifier

CFB

Pitch H2

VR

Feed

SolvahlTM

DAO

UCO

Light

products

UCO: Unconverted Oil

DAO: Deasphalted Oil

CFB: Circulating Fluidized Bed

Feedstock well suited for H-Oil®RC

Axens’ experience

› First unit started in 1968 (KNPC, Kuwait)

› 7 units in operation & 6 units in

design/construction phase

High conversion in stand-alone H-Oil®RC

Up to 80 wt%


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HyK™ Maxi Naphtha

Option 1 – Case Study Example

Heavy

Naphtha

Diesel+VGO H-Oil®RC

Gasifier

CFB

Pitch

Middle

East

VR

Solvahl™

DAO

UCO

NHT

Naphtha

H2

Light

Naphtha

VR Conversion = 90wt%

ParamaX®

Aromatic Complex Paraxylene

SR GO/VGO

Heavy Naphtha (170°C+)

Yield = 45wt%


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Low Cut Point & Low

Asphaltenes Content VR Feeds

› CIS Mazut M100

Opportunity Fuel

Maximum conversion target

CIS feedstock Axens’ experience

› 2 units in operation & 3 units in

design/construction phase

SDA: guard section for H-Oil®DC feed quality

control

H-Oil®DC: proven high conversion, very high

availability

H-Oil®DC

Gasifier

CFB

Pitch VR Solvahl™

DAO

Light

products

UCO

H2


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Naphtha

Diesel

H-Oil®DC Gasifier

CFB

M100 SolvahlTM

DAO

Pitch

UCO

NHT Naphtha

H2

Overall yield from VR, wt%

Prime-D™

HyK™

Prime-D™: 2% loss

VGO HCK: 65% conv

Diesel+VGO

VR Conversion = 92wt%


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H-Oil®

Block

Gasifier

CFB H2

VR

Feed

UCO+Pitch

Light

products

High Viscosity, High

Asphaltenes VR Feeds

› South America, etc.

Maximum conversion

target

Specific constraints in

downstream units

Refractory Feedstock

Axens’ experience: 2 operating units (Mexico)

SDA: guard section for H-Oil®DC feed quality

control

H-Oil®DC: proven high conversion, very high

availability


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Prime-D™

HyK™ Diesel

H-Oil®

Block

Gasifier

CFB Venezuelan

VR

UCO+Pitch

Diesel +VGO

NHT

Naphtha

H2

Naphtha

Prime-D™: 2% loss

VGO HCK: 65% conv


VR Conversion = 87wt% Overall yield from VR, wt%

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Axens Expertise & Know-how

H-Oil® & Solvahl™ Combination – Case Study Summary

› Maximum Conversion

Target Reached

› Tailored Scheme

For Each Case:

Thanks to…

Conversion Level


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1. Context



4. Conclusion

Agenda


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Summary

Net VR Conversion,%

800

300

200

100

0 … 30 40 50 60 70 80 90 100

H-OilRC®

Ebullated Bed

1000

Ni + V in the Feed, wppm

Hyvahl™ Fixed Bed

H-OilRC®

Combined with

Other units (SDA,Coker)


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H-Oil® ebullated-bed technology

• Proven & mature technology

• Achieves high residue conversion with

high reliability (96+%)

• H-Oil selected in 8 of last 10 competitive

international bids

Innovative options to maximize

conversion by combining H-Oil®

with SDA

• 90% Conversion

• Proven Technolgies

Conclusion


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axens.net


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Maximizing Bottom-of-the Barrel Conversion with ... · 1 Delphine Le-Bars Maximizing Bottom-of-the Barrel Conversion with Commercially Proven TechnologiesProven Technologies Delphine