H-OilRC Process

EBULLATED-BED HEAVY RESIDUE HYDROCRACKING

A FLEXIBLE HYDROCRACKING PROCESS cycle lengths, the H-OilRC process can achieve the
FOR HEAVY FEEDSTOCKS two- to four-year turnaround cycles to match that of
the FCC unit and requires only one or two reactors.
The H-OilRC process uses ebullated-bed hydrocracking
technology to process heavy feedstock residues with PROCESS DESCRIPTION
high metals, sulfur, nitrogen, asphaltenes and solid
contents. High levels of conversion can be reached In the simplified H-OilRC process flow diagram below,
without any production of coke material. oil feed and hydrogen are preheated and fed to the
first ebullated-bed reactor. An ebullating pump
Catalyst Addition provides back mixing and maintains the expanded
Gas / Liquid
Separator
catalyst bed level. An inter-stage separator is installed
Recycle Cup so that maximum single-train capacities exceeding
90,000 barrels per day are possible, depending upon
Expanded Catalyst Level
severity of operation, shipping constraints for the
Settled Catalyst Level reactors and the design configuration of the plant.
Ebullated Bed Atmospheric and vacuum fractionators recover the
distillate products.
Distributor Grid Plate
Fuel G
11stst 22ndnd 33rdrd
Stage Stage HP
HP Mem
Mem PSA
PSA
Stage Stage Stage
Hydrogen and Feed Oil Ebullating Pump Stage

Make-Up H2
Catalyst Withdrawal Recycle Oil HP Air
Cooler HP
HP Abs
Abs

The ebullated-bed reactor scheme Inter Stage

Separator

HP HT

Reactor liquid feed, hydrogen and catalyst particles Heater

Separator
HP LT MP
MP Abs
Abs
Separator
are back-mixed in the ebullated bed reactor. Back
mixing eliminates potential plugging or channeling MP LT
while the internal liquid recycle helps maintain nearly MP HT
Separator
Separator
Sour Gas
isothermal operation with low and constant pressure Naphtha
Resid Feed
drop. Atmospheric
Atmospheric
&& Vacuum
Vacuum
Gasoil
Fractionation
Fractionation VGO
H-Oil
Fresh catalyst can be added and spent catalyst Heater Reactors VR

withdrawn to control the level of catalyst activity in
the reactor enabling constant yields and product
quality over time. There is no run-length constraint as
catalyst is added on-line. Alternatively, operating
conditions can be varied to achieve a range of
conversion and product quality to meet seasonal
demands or changes in crude slate.
H-OilRC process effectively utilizes the exothermic
heat of reaction to pre-heat the feedstock, substantially
reducing pre-heat furnace duties. Where conventional
fixed-bed residue hydrotreaters are limited to catalyst
Typical two-stages H-OilRC unit configuration
We have made major improvements in reducing
capital and operating costs. Among the improvements
are: a new hydrogen management system where
recycle compressor are no longer needed; the
InterStage Separator (IS); and the reduced catalyst
consumption through the Cascade Catalyst Utilization
(CU).
The design pressure, number of reactor stages, catalyst
type, and catalyst replacement rate are selected to
optimize the H-OilRC units performance to meet
refiners objectives.
H-OilRC ALONE OR INTEGRATED WITH
OTHER CONVERSION TECHNOLOGIES
An H-OilRC reactor can achieve residue conversions
over 75% while producing high quality distillates and
unconverted bottoms that can be can be sent to the
low or medium sulfur fuel oil storage facilities.
To meet the latest product quality specifications, we
provide integrated hydroprocessing units to upgrade
primary products from the H- OilRC unit.
formation). By adding a CCR conversion unit
upstream of a delayed coker, the refinery can
dramatically increase crude throughput and maximize
the production of middle distillates.
REFERENCES
Today we have nine (9) licensed H-OilRC units and
five (5) licensed H-OilDC units with a total capacity of
584,000 BPSD.

Maximizing the ULSD production: We have

licensed two integrated Prime-D units and one
integrated High Conversion Hydrocracking (HyK)
unit processing distillate streams produced within the
H-OilRC which can be combined with straight run
products (see figure below).
These integrated solutions take advantage of the high
purity, high pressure circulating hydrogen to reduce
overall investment cost while guaranteeing totally
independent operation of the unit and absolute
flexibility.
Complete Conversion: The H-OilRC process can Two H-OilRC reactors with integrated Prime-D
be integrated with Solvahl, our solvent deasphalting
technology. Studies at Axens have found that vacuum The first H-OilRC unit was started-up in 1968 and is
residue conversions over 80% are optimal for continuing to operate at full capacity today. The
balancing hydrogen production and consumption. recently awarded units are in various stages of design
Several design improvements have been made to or construction. A commercial unit received an award
enhance overall reliability of this integrated scheme. for maintaining unit availability above 98.5% for 2
consecutive years.
Debottlenecking Delayed Coking Units: Given
the large number of delayed cokers on the market, the With more than 40 years of experience in ebullated
H-OilRC process is unique in converting Conradson bed technology and maintaining an intense R&D
Carbon Residue CCR (i.e., a precursor to coke program, we propose optimized designs and adapted
solutions in residue conversion and valorization.

H2 11stst Stage
Stage 22nd
nd Stage
Stage 33rd
rd Stage
Stage COMMON
COMMON
HP
HP && MP
MP Amine
Amine to FG
Common Make-Up Compressor PSA
PSA && MPU
MPU

H2 Rich Gas

VGO
VGO HyK
HyK Naphtha
VGO
VGO HyK
HyK Separation
Separation and
and
Jan.11-HoilRC

VGO Reaction
Reaction Euro V ULSD
Fractionation
Fractionation
Block flow diagram of an
VDU VGO ex H-Oil integrated H-OilRC VGO
Hydrocracking unit
H-Oil
H-OilRC
H-Oil
H-OilRC RC
RC Separation
Separation and
and Naphtha & Gas Oil
VR Reaction
Reaction Fractionation
Fractionation
LSFO