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

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. 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. 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. 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. 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. Schematic of LC-FINING Reactor
Catalyst Addition Line
Density Detector
Radiation Source Well
Density Detectors
Normal Bed Level
Catalyst
Withdrawal Line
Recycle Pump
Skin
TCs
Effluent
Feed
Thermowell Nozzle
Typical Reactor Size
4.3 m O.D.
3.9 m I.D.
36 m tan to tan

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-FCCSM 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. 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. 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. Existing Refinery Configuration (Base Case)

12. Upgraded Refinery Configuration (Case-1)
DC C4s
HC Bot
Hydrocracker
Distillate Hydrotreater
Naphtha
Hydrotreater
C5/C6 Isomerization Unit
CCR
Reformer
Gasoline
Pool
Jet/Diesel
FCC Gasoline
Treater
Alkylation
Delayed
Coker
I-FCC +
Gas Plant
SHT
Crude Unit
Sat Gas Plant
Vacuum Unit
Petrochemical Naphtha
LC-FINING & Integrated HT/HC
Crude Oil
Alkylate
Propylene
LPG
Light Gas Oil
Atm Gas Oil
Kerosene
Hvy Naphtha
Lt Naphtha
LC-F Bottoms
FCC Slurry Oil
Coke
C4s
LC-F VGO
HVGO
LC-F Diesel
HCGO
LVGO
LC-F Lt Nap
HT Lt Nap
HC Hvy Nap
HC Lt Nap
HC Dist
HT Hvy Nap
Reformate
HT Distillates
LCGO
LCO
Atm Residue
Vac Residue
DC C3s
DC Naphtha
LC-F Hvy Nap

13. Crude Slate Comparison

14. Process Units Capacities

15. Process Units Capacities

16. Comparison of Process Units Capacity

17. FCC/I-FCC Feed Comparison

18. Crude Prices

19. Product Prices Product USD/BBL Propylene-PG 74.70
Euro-IV 92 RON Gasoline
76.93
Petrochemical Naphtha
72.78
Euro IV Diesel
82.26
Jet fuel
85.01
Sulfur
25.00 ($/MT)
Coke
30.00 ($/MT)
Imported Feeds
Natural Gas ($/MMBTU)
7.00
MTBE
90.07

20. LP Study Results

21. 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