NEW DEVELOPMENTS IN HYDROPROCESSING

INTRODUCTION FEED AND PRODUCT CHANGES TECHNOLOGY DEVELOPMENT CATALYST DEVELOPMENT MOST IMPORTANT DEVELOPMENT OF THE COMING YEARS The refinery industry is continuously faced with changes. These changes are in the quality of: The crudes processed. The product slate. the required qualities of the products.

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TOPIC

NEW DEVELOPMENTS IN HYDROPROCESSING

Instrustor: Ph.D Nguyen Manh HuanPresentation by: Group 1

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I INTRODUCTION

II FEED AND PRODUCT CHANGES

III TECHNOLOGY DEVELOPMENT

IV CATALYST DEVELOPMENT

V MOST IMPORTANT DEVELOPMENT OF THE

COMING YEARS

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I Introduction

The refinery industry is continuously faced with changes

These changes are in the quality of:

The crudes processed.

The product slate.

 the required qualities of the products.

www.themegallery.com

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I Introduction

Must introduce new

technologies

or improve technologies.

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II.FEED AND PRODUCT CHANGES

2.1 Feed changes

 The average quality of crudes processed

worldwide was fairly constant the last ten years

 However, important differences can be observed

for the various geographic areas

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Fig1.Changes in crude quality processed in the USA

during the last ten years

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Fig1.Changes in crude quality processed in Japan

during the last ten years

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2.2 Product slate changes

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2.2 Product slate changes

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2.3 Product quality changes

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III Technology development

3.1 Technology installed to meet changes in feed and products

The changes in feed quality

 In product slate and in product qualities

 The refining industry has installed both well established and new technologies

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Changes in product oil specification

Table 1:

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Conversion capacity

Table 2: Installed conversion capacities ~ early 1985,

1990 and 1995 in various geographic areas

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 North America about 50 % of the added

conversion capacity in between 1985 - 1995 was based on hydrocracking; FCC adding only 20 %

 For Japan were 19 % and 81 %.

 Japan did not install thermal cracking capacity

but thermal cracking remains to play an important role in North America

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 The most important trend in product qualities

changes for all oil

 products is the continuous decrease in sulfur

level resulting in a worldwide increase in hydrotreating capacity as is shown

The type of conversion units installed differ greatly for the various regions

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3.2 New hydroprocessing technologies

Each year new hydroprocessing technologies are

announced

Mostly at well attended conferences such as the

annual spring meeting of the National Petroleum Refiners Association

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IV TECHNOLOGY DEVELOPMENT

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 Most of these technologies lack success due to:

 Less interest in resid upgrading mainly caused by: The low profitability of the refining industry

Abundant supply of sweet crudes

 Successful introduction of resid FCC

technologies

Selection of well proven technologies such as

fixed bed processes and ebullated bed

processes.

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 Two new technologies were recently announced for hydrocracking of VGO type feeds

 Ebullated bed licensed by Texaco and a lower pressure process

Lower investment costs.

Technology :licensed as MAK

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 Most of the technologies announced in the

nineties do have the production of high quality diesel oil as objective

Dewaxing

Desulfurization Hydrogenation

high quality diesel oils

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3.2.1 OCR process

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 Catalysts used in the OCR: ICR 138 and ICR

143

The OCR process can be applied in two ways:

1 In new designs to decrease reactor volume and

to improve flexibility to process different crudes

2 As pretreat step in existing units to allow

refiners to process heavier crudes

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3.2.1 OCR process

 The main objective of OCR process is demetallization of residues

 To decrease reactor volume and to make

an effective use of the catalyst Chevron developed a technology in which oil and catalyst are fed to the reactor in counter- current flow.

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3.2.2 Akzo-Fina CFI process

 The main objective of the Akzo-Fina CFI process is

to improve cold flow properties (cloud point, pour point, cold filter plugging point) of hydrocarbon feedstocks

 However, in addition to dewaxing activity,

desulfurization,denitrogenation, hydroconversion or hydrogenation activity also can be incorporated giving this technology a high degree of flexibility

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3.2.2 Akzo-Fina CFI process

 For instance, high sulfur gasoils can be

processed to yield diesel oils low in sulfur with excellent cold flow properties Light vacuum gasoils can be processed to yield a product which can be sent without further treatment or distillation to the diesel oil pool

 Catalysts applied in the process are only

available under license

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3.2.3 Dodd process

 The objective of this process is the deep

desulfurization of middistillate types of feedstocks

 Exxon licensed hydrotreating units in the past, but

decided that a new technology had to be developed for deep desulfurization of diesel oil Main differences from the existing technology is the different desulfurization kinetics for deep desulfurization

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3.2.3 Dodd process

 The Exxon process for diesel oil production with

sulfur levels between 200-500 ppm was introduced in 1989

 Various catalysts are approved for this process

RT 601 is the most active one

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3.2.4 Synsat process

 The objective of the Synsat process is to convert

feedstocks boiling between 200 and 360~to high quality diesel oils low in sulfur and aromatics

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IV.CATALYST DEVELOPMENT

 Catalyst:

 HC-H and C-411 of Criterion.

 HC-K, Ketjenfine 843 of Akzo Nobel.

 New catalysts from technology licensors

as Unocal/UOP and Chevron.

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V CATALYST DEVELOPMENTS

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V MOST IMPORTANT DEVELOPMENT OF THE COMING YEARS

 In summary the most important developments are:

 Crude oil supplied to the refineries will not change significantly in quality.

 Distillate and jet will be the products with the strongest growth.

 Technlogy development.

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New technologies are:

 The OCR process licensed by Chevron

 The Akzo-Fina CFI process licensed by Akzo

Nobel

 The DODD process licensed by Exxon.

 The Synsat process licensed by ABB Lummus.

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Technology development

Catalyst

development

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