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Doug Kocher-Cowan Heavy Oil Conversion Options

Honeywell UOP Setting a Strategy for Heavy Oil Conversion


2017 UOP India Refining and Petrochemicals Technology Conference
March 6-7 Delhi, India
UOP 7804T-0 2017 UOP LLC. A Honeywell Company All rights reserved.
1

Considerations for Upgrading Strategies


Identify Key Project Drivers
Improve heavy oil conversion capability
Improve high values product slate olefins / gasoline / diesel
Reduce fuel oil / coke
Technology Assessment
Separation of AR or VR for optimum yields
Crude / Vacuum Column (Deep Cut Separation)
SDA (DAO to hydrocracker Resin to FCC)

Conversion of the AR or VR
Thermal / Catalyst (Uniflex Process)
Catalytic Cracking (RCD-RFCC)

Post Treatment to produce finished products


Hydrotreating (Distillates and lighter)
Hydrocracking (DAO, VGO, HCGO)
Project Considerations
New refinery / Expansion of Existing Refinery
Current and new Infrastructure (plot space, utilities )
Phased Investment / construction

UOP 7804T-1
Highlights of UOP Portfolio for Crude to 2

Chemical and Crude to Fuels

Solvent Deasphalting (UOP / AmecFW USA Alliance)


Recovers incremental feedstock for FCC and HC unit
Low cost way to reduce VR
UOP Uniflex Process
Converts VR/Fuel Oil into higher value products in the distillate range
UOP RCD Unionfining Process
Hydrotreats residue feedstocks (AR, VR and DAO)
Pretreats feeds for FCC, RFCC

UOP Residue Crude Conversion Process (RFCC)


Maximizes conversion of AR and VR into
gasoline and petrochemicals

Flexible Portfolio for Heavy Oil Upgrading


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UOPs Heavy Oil Upgrading Processes


Naphtha Naphtha
Hydrotreating
& Reforming

Distillates Distillate
Hydrotreating
Distillation

Transportation
Crude Oil Vacuum Gas FCC or
Fuels:
Oil Hydrocracking
Gasoline,
Jet Fuel, Diesel
Olefins:
Residue Alkylate,
Propylene

AR / VR Upgrading
Residues:
Heavy Fuel Oil,
Pitch, Coke
UOP Solutions for Residue Upgrading
UOP RCD UOP Reduced UOP AmecFW AmecFW SYDEC UOP Uniflex
Unionfining Crude Cracking Solvent Delayed Coking Process
Process Process Deasphalting Process

UOP 7804T-3
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Solvent Deasphalting (SDA) Technology


Non-thermal process that physically separates either AR
or VR residues into:
Less-contaminated deasphalted oil (DAO)
Viscous, highly-contaminated pitch
Intermediate-quality resin (if desired)
Utilizes light paraffinic solvents (C3-C5), with the separation
occurring as a result of the density differences between the
solvent/DAO and pitch phases.
Product Yields / Qualities dictated by Feed Contaminants /
Distribution

Quality of DAO product can be impacted by:


DAO Recovery Rate (Lift)
Solvent selection and quantity
Operating Conditions (Temp: 100 - 300C, Pressure: 45 bar(g))

UOP 7804T-4
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SDA DAO, Resin and Pitch Stream Monetizing

10-60% Lift Lube Oils


Hydrocracking
DAO

30-80% Lift FCC


Hydrotreating/RFCC

Resins RFCC Feed


SDA Asphalts
Fuel Oil
Asphalts
Pitch Fuel Oil
Solid Fuel
Visbreaking or Coking
Gasification or Partial Oxidation
UOP Uniflex Process

UOP 7804T-5
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Uniflex Process Thermal Cracking of Asphaltenes


Slurry Hydrocracking is a robust technology
capable of processing a wide rage of heavy
oil products
VR, CSO 425+ C, SDA Pitch, DAO,
Resin
The process benefits from combination
of:
Thermal cracking to shorter chain
lengths

Inhibiting formation of coke through:


Hydrogenation of free radicals from
thermal cracking
Catalyst physically hinders mesophase
coalescence

Archipelago Model of Asphaltenes, Carbon # = 313, MW = 4705


Source: M. Gray, Univ of Alberta

UOP 7804T-6
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Uniflex Process Reactor Achieves High Conversion


Products
and Catalyst

Optimal design for high conversion


Upflow Bubble Column
High temperature: 820 - 845C
Moderate pressure: 155 bar(g)
Efficient utilization of reactor volume
Low gas voidage
High product vaporization
Near Isothermal

Asphaltene management
Inhibit formation of coke pre-cursors via
catalysts HVGO recycle or CSO in Blend,
Reactor Temperature and Pressure
Feed, H2
and Catalyst
Commercially proven Reactor design and system
to Manage Coke Pre-Cursors
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Uniflex Unit with Integrated Unionfining Reactor


Make-up DHT
Hydrogen Heater
External
Feeds
HHPS

Hydrotreating
WHPS Reactor
Uniflex External
Reactor Diesel

Recycle
Gas HLPS WLPS
Heater WLPS CHPS

Uniflex
Fractionation CLPS
Feed Section To DHT
Heater
Fractionation
Vacuum Section
Residue Recycle HVGO from
Feed Uniflex Fractionation
Catalyst Section

Integrated Hydrotreater significantly minimizes the number


of pieces of equipment, therefore Capex is reduced
External streams can also be hydrotreated to Euro V
UOP 7804T-8
Uniflex Performance with 9

Integrated Unionfining Unit


4 H2S, NH3
11 Gas, LPG
Naphtha Hydrotreated in
15
Integrated DHT

Vacuum
100
Residue Feed UNIFLEX UNIT Diesel
(Wt-%) 50-55

8-10 VGO to HCU feed


Catalyst 9 - 11 Pitch
H2

90-95% : Higher conversion than other competing residue conversion processes


conversion
Euro V Diesel : Highest yield of diesel compared to other slurry processes
Minimum VGO : Can be accommodated in existing conversion units
Naphtha : < 5 ppm S and N
Pitch: : Cement Plant, Gasification Unit, Boiler/Kiln, or solidified into pellets

UOP 7804T-9
UOP Zero Fuel Solution for Vacuum Residue 10

Conversion Complex
Naphtha & Diesel

Lubes Stock
VGO Unicracking Unconverted Lubes Lubes
16,000 bpd Oil 4,000 bpd
Distillation
Vacuum

Atm
Resid

VGO
DAO

Lubes Extract Distillate from Crude

Vacuum
Distillate
Resid Uniflex Naphtha & Diesel
Unionfining
9,000 bpd
27,000 bpd
Vacuum Solvent
Resid Deasphalting
SDA Existing Unit
Pitch Pitch to
Cement Plant New Units

Maximum Transportation Fuel Strategy


11

Opportunities Using RCD-RFCC Technology


Gasoline, mixed or crude to chemical mode
of operation
Typically processing AR or AR,VR blends
- Quality of crude has an impact on Opex, Capex
Hydrotreated feed can achieve reasonable
yields of olefins while making a blendable
gasoline
Modest distillate recovery from RCD
Feedstock qualities of commercial RCD
Unionfining process units have ranged from:
API: 9-18
Sulfur: 3 - 5 Wt-%
Conradson Carbon: 5 - 15 Wt-%
Organometallics (Ni+V): 10 - 200 wppm
Viscosity: 25 - ~1000 cSt @100C

Gasoline / Olefin Technology Opportunity


Propylene Yield Highly Dependent on 12

Feed Quality & Reactor Severity

24
Propylene Yield, Wt%FF

Pure-play
18 C3= Producers

12

Base
FCC
f (RxT, PP, C/O, Recycle)
Increasing FCC Processing Severity

UOP 7804T-12
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Commercial Data for C3= Yields

Conventional
R/FCC

Enhanced
C3= R/FCC
+ZSM-5

VGO Commercial Data PetroFCC


HTVGO Commercial Data Process
AR Commercial Data Low P,
HTAR Commercial Data High RxT, RxCat
PetroFCC Operation 1
PetrFCC Operation 2

0 5 10 15 20 25
Propylene Yield, Wt-%

UOP 7804T-14
Recent Advances in UOP RCD Unionfining 15

Technology Including 2 Stage Configuration

UOPs licensed residue hydrotreating technology for


processing highly-contaminated feedstocks such as AR,
VR and DAO
Maximum Hydrogen Addition for RCD/RFCC complexes
to boost yield of gasoline and olefins
Maximum Sulfur reduction technology for production
of 0.5 Wt-% fuel oil
Life Cycle improvement to minimize turnarounds
Asia RCD Unionfiing Unit completed a 21 month
operating cycle

UOP 7804T-15
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RCD Unionfining Process Unit Flow Scheme

Reactors

Feed Hot
Feed Filters Separator

H2
Makeup
Fractionator
Hot
H2 Flash Gas
Recovery
Naphtha
To Fuel Gas
Purge Distillate
Cold
Separator
H2S Cold Hydrotreated
Scrubber Flash Residue

UOP 7804T-16
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RCD-RFCC Optimization

5.00
Operating Costs, $/bbl of RCD Feed

4.00

3.00

2.00 Hydrogen RCD

1.00
RFCC RCD
Catalyst

0.00 RFCC RCD


Power
Cooling H2O
Fuel Fired

-1.00
70 75 80 85 90 95 100
Percent Desulfurization

RCD-RFCC Optimization Necessary for Complex


18

UOP RCD-RFCC Optimized Complex Offering

New 2 stage RCD Unionfining process


to maximize hydrogen addition
New 2 stage RFCC regenerator for high
con carbon feeds
Integration of RCD and RFCC to
minimize Capex and Opex for:
Maximum gasoline
Gasoline and enhanced propylene
Maximum propylene

In 2016 UOP was awarded a world-class


RCD-RFCC complex at ZPC China
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Honeywell UOP Continue to Invest in Heavy Oil


2016 New Product Introduction
Improved SDA estimating
capabilities
Uniflex/SDA pitch separation
process introduced
Enhanced 2 stage RCD
Unionfining
New low capex 2 stage RFCC
regenerator

2017 Developments in
Progress
Improvements in Uniflex
Process
New Moly Catalyst for Uniflex
Four new heavy oil pilot plants
in construction

2017 Launch of Next Generation Uniflex


20

Optimum Solutions for Upgrading Summary


UOPs extensive heavy oil technology portfolio
allows UOP to develop the optimum residue
upgrading solutions
The SDA is a minimum CAPEX way to separate
VR into low molecular weight components as
feed (DAO, Resin) and reject asphaltenes as pitch
Uniflex process efficiently converts fuel oil
components to middle distillates

RCD-RFCC complex can be designed for


maximum gasoline or maximum propylene
production

Flexible Solutions
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UOP 7804T-21