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Engineering Solutions... Delivering Results © Lummus Technology Maximize Olefins - 1 Convert Bottom-of-the-Barrel to Diesel and Light Olefins PETROTECH.

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Presentation on theme: "Engineering Solutions... Delivering Results © Lummus Technology Maximize Olefins - 1 Convert Bottom-of-the-Barrel to Diesel and Light Olefins PETROTECH."— Presentation transcript:

1 Engineering Solutions... Delivering Results © Lummus Technology Maximize Olefins - 1 Convert Bottom-of-the-Barrel to Diesel and Light Olefins PETROTECH 2010 New Delhi, India November 2010 Dalip Soni Lummus Technology

2 Engineering Solutions... Delivering Results © Lummus Technology Maximize Olefins - 2 Refining Business Drivers Growth in diesel demand higher than gasoline Use of refinery as source for petrochemical feedstocks (i.e., propylene, ethylene) Necessity to process opportunity/heavier feedstocks Stringent automotive fuel specifications Fluctuations in crude and product prices resulting in frequent adjustment to refining operations

3 Engineering Solutions... Delivering Results © Lummus Technology Maximize Olefins - 3 Meeting the Challenges Refinery configuration and units need to be flexible Must incorporate bottom-of-the-barrel conversion processes Maximize conversion/upgrading to light products Reduce fuel oil or coke production Integrate refining and petrochemical operations Apply state-of-the-art processes to control emissions Install product purification processes to produce cleaner fuels

4 Engineering Solutions... Delivering Results © Lummus Technology Maximize Olefins - 4 Bottom-of-the Barrel Upgrading Processes Carbon rejection processes –Delayed coking – produces a lot of coke –Solvent Deasphating (SDA) – not a true conversion process Disposal problems with pitch from SDA due to high levels of metals and CCR –Visbreaking – not a high conversion process FCC process Hydrogen addition processes –ARDS, VRDS –LC-FINING ®

5 Engineering Solutions... Delivering Results © Lummus Technology Maximize Olefins - 5 Refinery Configuration Upgrade Study Study objectives: –Process heavier/cheaper feed –Maximize yield of diesel and light olefins from an existing refinery This study consider integrating LC-FINING and I-FCC processes –Installing new LC-Fining process –Revamp existing FCC unit Economic analysis uses LP model studies

6 Engineering Solutions... Delivering Results © Lummus Technology Maximize Olefins - 6 LC-FINING Process Ebullated bed residue hydrocracking process licensed by Chevron Lummus Global –Designed to process heavy, high metals, and/or high solid feeds (ATB, VR, DAO, Bitumen from Oil Sands) –High distillate yields, high hetro-atom and metals removal –Expanded bed is key process feature Isothermal reactor operation On-stream catalyst addition and withdrawal No pressure drop build up Greatly extends unit run length compared to fixed bed processes

7 Engineering Solutions... Delivering Results © Lummus Technology Maximize Olefins - 7 Schematic of LC-FINING Reactor 7 Thermowell Nozzle Typical Reactor Size 4.3 m O.D. 3.9 m I.D. 36 m tan to tan

8 Engineering Solutions... Delivering Results © Lummus Technology Maximize Olefins - 8 Indmax FCC (I-FCC) Process FCC type reaction system to maximize light olefins production from heavy oils Indmax* catalyst and process concepts developed and commercialized by IOCL R&D Center I-FCC SM process combines IOCL R&D development with Lummus FCC process and hardware design I-FCC reaction system is highly –selective to light olefins production –flexible with regard to operating mode *Indmax is a registered trademark of IOCL

9 Engineering Solutions... Delivering Results © Lummus Technology Maximize Olefins - 9 Heavy Crude Processing Issues Heavy Crude Processing Issues A substantial reduction in distillate yields Increase in yield of bottom-of-the barrel Inferior product yield and quality –Requiring additional product treating facilities –Poor feed/products from secondary processing units –More hydrogen and/or catalyst consumption Requires a significant capital investment to upgrade refinery operations

10 Engineering Solutions... Delivering Results © Lummus Technology Maximize Olefins - 10 Basis of Refinery LP Modeling Refinery crude throughput capacity is 200,000 BPSD The base refinery is processing a blend of 35 vol% heavy (mix of Maya and Urals) and 65 vol% light crudes (Bonny light and Sarir) The upgraded refinery to process 80 vol% heavy crude The capacity potential of all existing process units is to be fully utilized Maximize production of diesel, jet fuel, and propylene The fuel quality to meet Euro-IV specifications Crude and product prices are based on Rotterdam, 2007 average spot prices

11 Engineering Solutions... Delivering Results © Lummus Technology Maximize Olefins - 11 Existing Refinery Configuration (Base Case) Existing Refinery Configuration (Base Case)

12 Engineering Solutions... Delivering Results © Lummus Technology Maximize Olefins - 12 Upgraded Refinery Configuration (Case-1) Upgraded Refinery Configuration (Case-1)

13 Engineering Solutions... Delivering Results © Lummus Technology Maximize Olefins - 13 Crude Slate Comparison Crude Slate Comparison

14 Engineering Solutions... Delivering Results © Lummus Technology Maximize Olefins - 14 Process Units Capacities Process Units Capacities

15 Engineering Solutions... Delivering Results © Lummus Technology Maximize Olefins - 15 Process Units Capacities Process Units Capacities

16 Engineering Solutions... Delivering Results © Lummus Technology Maximize Olefins - 16 Comparison of Process Units Capacity

17 Engineering Solutions... Delivering Results © Lummus Technology Maximize Olefins - 17 FCC/I-FCC Feed Comparison FCC/I-FCC Feed Comparison

18 Engineering Solutions... Delivering Results © Lummus Technology Maximize Olefins - 18 Crude Prices

19 Engineering Solutions... Delivering Results © Lummus Technology Maximize Olefins - 19 Product Prices

20 Engineering Solutions... Delivering Results © Lummus Technology Maximize Olefins - 20 LP Study Results LP Study Results

21 Engineering Solutions... Delivering Results © Lummus Technology Maximize Olefins - 21 Conclusions Conclusions Re-configured refinery is able to handle heavier crudes efficiently and cost effectively Increases diesel and light olefins product yields Meets stringent product quality specifications Improves feed quality for secondary units Integrated process scheme maximizes efficiency High rate of return on capital investment

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