05 Bottom of Barrel

Bottom of Barrel Processing
Chapters 5, 6, & 8
Updated: August 12, 2016

Copyright 2016 John Jechura (jjechura@mines.edu)
Gases
Polymerization
Sulfur
Plant
Sat Gas
Plant
Gas
Butanes
Alkyl
Feed
Gas
Separation &
Stabilizer
Fuel Gas
LPG
Alkylation
Polymerization
Naphtha
Isomerization
Light Naphtha
Alkylate
Isomerate
Aviation
Gasoline
Automotive
Gasoline
Reformate
Naphtha
Hydrotreating
Heavy
Naphtha
Sulfur
LPG
Naphtha
Reforming
Solvents
Naphtha
Atmospheric
Distillation
Crude
Oil
Jet Fuels
Kerosene
Kerosene
Desalter
Distillate
Hydrocracking
AGO
LVGO
Vacuum
Distillation
Gas Oil
Hydrotreating
Fluidized
Catalytic
Cracking
Cat
Naphtha
Solvents
Distillate
Hydrotreating
Cat
Distillates
Treating &
Blending
Heating Oils
Diesel
Fuel Oil
HVGO
Cycle Oils
Residual
Fuel Oils
DAO
Solvent
Deasphalting
Visbreaking
Vacuum
Residuum
Coker
Naphtha
Heavy
Coker
Gas
Oil
SDA
Bottoms
Asphalts
Naphtha
Distillates
Fuel Oil
Bottoms
Lube Oil
Lubricant
Greases
Solvent
Dewaxing
Waxes
Waxes
Coking
Light Coker
Gas Oil
Coke

Need For Heavy Ends Processing

Worldwide crude slate has become
heavier
Concentration of sulfur & other

contaminants has been increasing
Sulfur specifications becoming more
stringent
Environmental protection
Demand for No. 6 Fuel Oil declining

Environmental protection
Cost of light crude relative to heavy

crude is increasing
Trends in the United States have
become more complicated due to the

flood of light, sweet, tight oil from shale
in the United States

Gunaseelan & Buehler

Changing US crude imports are driving refinery upgrades
Oil & Gas Journal, Aug. 10, 2009
Processing Options
Physical separations
Vacuum distillation
Volatility
Solvent Deasphalting
Solubility
Lube Oil Processing

Requires specialized feedstocks

Chemical reactions (in order of

increasing severity)
Visbreaking
Catalytic cracking
Coking
Delayed coking
Fluidized bed coking
Hydrocracking
U.S. Refinery Implementation
EIA, Jan. 1, 2016 database, published June 2016

http://www.eia.gov/petroleum/refinerycapacity/
Solvent Deasphalting
Purpose
Products
Remove asphalts from lube plant

feeds
Deasphalted Oil (DAO)
Increase gas oil yield from crude
Resins
Make commercial asphalts from

asphaltic crude unit bottoms
Bottoms/pitch asphaltenes
Characteristics
Physical recovery using light
hydrocarbon solvent (C3, C4, C5)
Dissolve saturated components
Leave behind/precipitate
asphaltenes
Resins split between phases
Residue Upgrading Technology Options for Cost Effective Solutions,

Steve Beeston, ARTC 2014, Singapore, March 5, 2014
http://www.fwc.com/getmedia/200f27cb-c130-439e-aa08-51adaca15dd0/Residue-upgrading-technology-options-for-cost-effective-solutions.pdf.aspx?ext=.pdf
Typical SDA Process
Foster Wheeler SDA process

Hydrocarbon Processings 2008 Refining Processes Handbook

Characteristics of Products
DAO resembles gas oil but is of drastically different boiling point range
0.0025
Feed
DAO
Bottoms
Mass Yield Distribution (1/F)
0.0020
Recombined (51.1wt% Lift)
0.0015
0.0010
0.0005
0.0000
500
600
700
800
900
1000
1100
1200
1300
1400
1500
Boiling Point (F)

Characteristics of Products
Residue Upgrading Technology Options for Cost Effective Solutions,

Steve Beeston, ARTC 2014, Singapore, March 5, 2014
http://www.fwc.com/getmedia/200f27cb-c130-439e-aa08-51adaca15dd0/Residue-upgrading-technology-options-for-cost-effective-solutions.pdf.aspx?ext=.pdf
Integration of SDA into Refinery

Atm Resid Feed
Vac Resid
SDA Bottoms
SDA DAO
Gas Oil
Feed to HDS
bpsd
API
wt% S
ppmw metals
bpsd
API
wt% S
ppmw metals
bpsd
API
wt% S
ppmw metals
bpsd
API
wt% S
ppmw metals
bpsd
API
wt% S
bpsd
API
wt% S
ppmw metals
Base
With SDA
50,000
50,000
15.1
15.1
4.02
4.02
69
69
20,000
20,000
5.6
5.6
5.55
5.55
160
160
5,400
-12.6
7.15
475
14,600
11.4
4.84
20
30,000
30,000
22.3
22.3
3.04
3.04
30,000
44,600
22.3
18.5
3
3.66
7
Feed to FCC
HDS Fuel Gas
FCC Fuel Gas
Total Fuel Gas
HDS C3/C4
FCC C3/C4
Total C3/C4
HDS Naphtha
FCC Naphtha
Total Naphtha
FCC Cycle Oil
FCC Slurry
HDS Distillate
bpsd
API
Mscfd
Mscfd
Mscfd
bpsd
bpsd
bpsd
bpsd
bpsd
bpsd
API
bpsd
API
bpsd
API
bpsd
API
Base
With SDA
27,340
40,651
24.0
4,200
6,310
4,430
6,582
8,630
12,892
190
289
5,220
7,765
5,410
8,054
260
388
15,420
22,927
15,680
23,315
54.5
54.5
7,108
10,569
25.5
25.5
1,367
2,033
0.9
0.9
2,750
4,090
32.5
32.5
Handbook of Petroleum Refining Processes

Robert Meyers
McGraw-Hill, Inc, 1986
10
Visbreaking
Purpose
Cut viscosity in of feed (specs for
heavy fuel oil)
Reduces "cutter stock
Reduces heavy fuel oil amount
Characteristics
Relatively mild thermal cracking
operation
Flexible on feedstock quality
Typically high resin crude oils
Low capital cost for process
Products
About 20% feed cracked to light ends,
naphtha, gas oil & sometimes
distillate.
Low yield of valuable naphtha
Products contain a lot of olefins

Olefinic C3s & C4s often recovered
Naphtha & distillate often
hydrotreated because of olefins &
sulfur
Gas oil high in aromatics more

appropriate for hydrocracking than
cat cracking
Large volumes of heavy fuel oil with
high sulfur content
Bottoms (visbreaker tar) sent directly
to heavy fuel oil

11
Typical Coil Visbreaker
http://www.fwc.com/industries/pdf/Residue_upgrading_English_10th_Sept.pdf?DIRNAME=%23dirName%23
12
Catalytic Cracking
Purpose
Products
Make gasoline & distillates

(diesel/heating oil)
Light gases
Try to minimize heavy fuel oil
Light & Heavy Naphtha
Characteristics
Medium severity cracking process
Olefins
Light & Heavy Cycle Oils

Slurry
Gas oils are typical feedstocks

Not normally used on whole
atmospheric or vacuum resids
PNAs tend to condense, leading to
coking
Catalysts sensitive to poisoning by
sulfur & metals present in PNAs

13
Hydrocracking
Purpose
Minimize heavy fuel oil
Characteristics
Severe cracking process
Combines cracking & hydrogenation
Products
Produces high yields of liquids
Hydrogen suppresses coke
formation
Liquids low in sulfur & olefins
Coking better for resids

High pressures & large amounts of
hydrogen required

14
Coking
Purpose
Create light gases & distillates
Carbon rejection
Characteristics
Severe thermal cracking process
Can process a wide variety of
feedstocks
High metals (nickel and vanadium),
sulfur, resins & asphaltenes with
PNAs
Separates thermally stable PNA cores

from their side chains
PNAs contain majority of the
heteroatoms (sulfur, nitrogen,
metals)
Products
Produces light gases, distillates
(naphthas & gas oils) for catalytic
upgrading
Low yields of liquids relative to
hydrocracking
Liquids contain large amounts of
sulfur & olefins but little aromatics
Coke
Contains large amounts of metals &
sulfur.
Coke use depends upon quality
o
May pose a disposal problem
Concentrate in the coke as PNAs

condense
15
Supplemental Slides
SDA technology providers
Visbreaking technology providers

16
SDA Technology Providers

Provider
Features
Foster Wheeler
KBR
Light hydrocarbon solvent with DAO/solvent separation at supercritical

conditions
Foster Wheeler
KBR ROSE

17
Visbreaking Technology Providers

Provider
Features
Foster Wheeler
Shell Global Solutions
Visbreaker heater & downstream coil
Foster Wheeler
Shell Global Solutions

18

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Bottom of Barrel Processing

Updated: August 12, 2016

Updated: August 12, 2016

Need For Heavy Ends Processing

Concentration of sulfur & other

Demand for No. 6 Fuel Oil declining

Cost of light crude relative to heavy

Trends in the United States have

become more complicated due to the

Updated: August 12, 2016

Gunaseelan & Buehler

Lube Oil Processing

Updated: August 12, 2016

Chemical reactions (in order of

U.S. Refinery Implementation

EIA, Jan. 1, 2016 database, published June 2016

Remove asphalts from lube plant

Deasphalted Oil (DAO)

Increase gas oil yield from crude

Make commercial asphalts from

Residue Upgrading Technology Options for Cost Effective Solutions,

Typical SDA Process

Foster Wheeler SDA process

Updated: August 12, 2016

Mass Yield Distribution (1/F)

Recombined (51.1wt% Lift)

Boiling Point (F)

Updated: August 12, 2016

Residue Upgrading Technology Options for Cost Effective Solutions,

Integration of SDA into Refinery

Handbook of Petroleum Refining Processes

Products contain a lot of olefins

Gas oil high in aromatics more

Updated: August 12, 2016

Typical Coil Visbreaker

Make gasoline & distillates

Try to minimize heavy fuel oil

Light & Heavy Naphtha

Light & Heavy Cycle Oils

Gas oils are typical feedstocks

Updated: August 12, 2016

Coking better for resids

Updated: August 12, 2016

Separates thermally stable PNA cores

May pose a disposal problem

Concentrate in the coke as PNAs

Updated: August 12, 2016

SDA Technology Providers

Light hydrocarbon solvent with DAO/solvent separation at supercritical

Hydrocarbon Processings 2008 Refining Processes Handbook

Updated: August 12, 2016

Visbreaking Technology Providers

Visbreaker heater & downstream coil

Shell Global Solutions

Hydrocarbon Processings 2008 Refining Processes Handbook

Updated: August 12, 2016

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