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Convert Bottom-of-the-Barrel to Diesel and Light Olefins

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Presentation on theme: "Convert Bottom-of-the-Barrel to Diesel and Light Olefins"— Presentation transcript:

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


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