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Research and Engineering Commercial Technology to Convert Group I Facilities to Group II/III Lube Production PETROTECH: November 1-3, 2010.

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Presentation on theme: "Research and Engineering Commercial Technology to Convert Group I Facilities to Group II/III Lube Production PETROTECH: November 1-3, 2010."— Presentation transcript:

1 Research and Engineering Commercial Technology to Convert Group I Facilities to Group II/III Lube Production PETROTECH: November 1-3, 2010

2 PETROTECH: November 1-3, 2010 History of Lubricants and Basestocks Lubricants have been used since ancient times Petroleum-based lubricants business began in the mid-1800’s Initial processing was limited to separation by boiling point

3 PETROTECH: November 1-3, 2010 Group II and Group III Base Oils are the high growth areas –Demand for improved fuel economy and lower emissions mean lower viscosity/volatility engine oils –Demand for increased equipment reliability –Extended service intervals/fill for life for engines requires both performance and stability –Group II/III plants have Opex advantages versus Group I plants Hydroisomerization Capacity (kbpd) Lube Product,( kbpd) Lube Activity Focused on Group II & Group III Production ExxonMobil Technologies Others

4 PETROTECH: November 1-3, 2010 Performance Requirements Pushes Quality  Improved fuel economy  Lower Emissions  Longer Life  Better low temperature performance  High temperature performance  Viscometrics  Thermal stability  Soot handling (diesels)  Lower Viscosity  Lower Volatility  Higher Saturates  Lower Pour, Lower CCS  Higher VI  Higher Saturates  Higher Saturates

5 PETROTECH: November 1-3, 2010 Volatility a Driver for Increased VI °C, cSt Noack Volatility, Mass% API SM 5W30 API SM Max GM Proposed Global Spec. Group I / Group II 95 VI Group II+ Mid Tier Group III Top Tier Group III Group IV / PAO’s

6 PETROTECH: November 1-3, 2010 Gasoline & Diesel HC Bottoms Vacuum Distillation Common Routes for Base Oil Production Catalytic Dewax Fuels Hydrocracker Lube Hydrocracker Solvent Extraction Solvent Dewaxing Distillate/DAO Group I Group II Group II /III Catalytic Dewax RHC TM Group II Group II /III Hydrofinishing Solvent Dewax Vacuum Distillation Hydrofinishing Catalytic Dewax RHC TM Hydrofinishing

7 PETROTECH: November 1-3, 2010 Process Choice: Blocked or Broadcut? Blocked: Lube Grades Processed Individually –Pro: Smaller catalytic equipment Production to optimum specification for each product Clear target response to feed change –Con: Intermediate tankage required between units More complex operation Broadcut: Unfractionated Fuels H/C Bottoms or VGO to Lube H/C –Pro: Single operation, no stock switch—simpler control Minimal/no intermediate tankage –Con: Larger catalytic vessels One grade dictates operating severity—possible overtreating of others

8 PETROTECH: November 1-3, 2010 Integrated Group I Facilities Group II Group III Hydroprocessing (RHT or RHC™) Catalytic Dewaxing (MSDW™ ) Hydrofinishing (MAXSAT™) Converting Vacuum Gas Oil and DAO to High Quality Lube Base Stocks is a multi-step Process Atmospheric Resid Vacuum Gas Oil DAO Vacuum Resid VacuumDistillation Group I Facilities Extract SolventDewaxing Group II Group III Remove Asphaltic Material and Adjust Viscosity AdjustViscosity Improve Cold Flow Properties Convert wax to High VI Lube Improve Color and Stability, Saturate Polynuclear Aromatics Improve VI, Reduce Sulfur & Nitrogen, Saturate or Extract Aromatics, Reduce CCR, Remove Metals Deasphalting

9 PETROTECH: November 1-3, 2010 Integrated Route to Base Oils Base VI Increase Conversion to 360- O C Fuels Group III Group II Aromatic Extract Group III Group II Group III Catalytic Dewaxing (MSDW) Catalytic Dewaxing (MSDW) Hydrofinishing (MAXSAT) Existing Solvent Dewaxing Existing Solvent Dewaxing Group II Group III Group I Integrated into Group II & Group III Lube Plant 8 RHC or RHT units in operation or in design Group I solvent operation improves VI with a yield loss to aromatic extracts Removal of 3-4 ring aromatic compounds and complex sulfur and nitrogen compounds allows reduction in hydroprocessing severity, hydrogen consumption and associated yield loss Hydroprocessing (RHT/RHC) Hydroprocessing (RHT/RHC) Group I Solvent Plant Group I Solvent Plant

10 PETROTECH: November 1-3, 2010 Raffinate Hydroconversion (RHC) or Hydrotreating (RHT) Add Flexibility Lower investment than grass roots Maintains use of solvent-based lube facilities and Debottlenecks solvent extraction Produces high quality Group II & II+ base stocks; also Group III capable –Higher VI, higher saturates, lower volatility, lower sulfur –Improved color and stability Easily processes full range of viscosity grades Preserves wax production with solvent dewaxing, or… May use Catalytic Dewaxing (MSDW) to eliminate solvent dewaxing

11 PETROTECH: November 1-3, 2010 Maximize Use of Existing Group I Equipment Lube Vacuum Distillation Aromatic Extract Fuels Light Neutral Medium Neutral Heavy Neutral Solvent Dewaxing RHC™ or RHT Solvent Extraction 50-70% Yield with VI Uplift 80-98% yield with 3-30 VI Uplift and H2 use of scf/B DW: 70-85% Base Oil Yield High-quality wax with upstream Hydroprocessing

12 PETROTECH: November 1-3, 2010 Case Studies – Overview Solvent Extraction Unit (SEU) and Solvent Dewaxing Unit (SDW) Exist to Process a Full Range of Lubes (Can Include Bright Stock) Flexibility Required to Produce Group II / II+ Lubes Options: –CASE 1: SEU, RHC and SDW – keep Neutral grades of wax production with improved slack wax quality –CASE 2: SEU, RHT and catalytic dewaxing (MSDW) – maximum production, but no wax product All Products Produced to 110VI with Addition of RHC or RHT Solvent Dewaxing and Catalytic Dewaxing (MSDW) Considered

13 PETROTECH: November 1-3, 2010 Case Studies – Overview (2) Three Products – 100N/325N/600N Base Production of 100VI/95VI/95VI SEU Solvent Ratio Decreased to Increase Overall Production SEU Raffinate produced at 85 VI (DWO basis) Two Crudes Considered: –Arab Light – high quality crude source example –Urals – low quality crude source example

14 PETROTECH: November 1-3, 2010 Case Studies – Results Total Production Maintained with Both Solvent Dewaxing and Catalytic Dewaxing (MSDW) – 110VI Products – by Balancing Process Steps Large Increase in Extraction Capacity with Reduction in Severity; Substantial Product Rate Increase Possible VDU Side Streams Viscosity Increased to Meet Constant Product Viscosity –Hydroprocessing viscosity impact differs from solvent processing Wax Production Increase is Possible When SDW Can Support Effects are Crude Independent – Relative Changes Consistent for AL and Urals

15 PETROTECH: November 1-3, 2010 Study Case 1 – Summary of Effects Impact of RHC Addition with Optimization To Existing Basic SEU/SDW 100N/325N/600N products Production Change Group I Base Case — 100/95/95 VI Products BaseOps today Group II 110 VI Products — Constant SEU Feed Rate and Severity --Raise VI Group II 110VI Products — Reduce SEU Severity to 85 VI Base First step-recover capacity Group II 110VI Products—Max SEU Feed to Solvent Limit + Wax production based on SDW + Increase raffinate to raise base oil & wax production

16 PETROTECH: November 1-3, 2010 Study Case 2 – Summary of Effects Impact of RHT Addition with Optimization To Existing SEU Replace SDW with Catalytic Dewaxing (MSDW) 100N/325N/600N products Production Change Group I Base Case — 100/95/95 VI Products BaseOps today Group II 110 VI Products — Constant SEU Feed Rate and Severity --Raise VI Group II 110VI Products — Reduce SEU Severity to 85 VI Base First step-recover capacity Group II 110VI Products — Max SEU Feed to Solvent Limit + Increase raffinate to raise base oil production

17 PETROTECH: November 1-3, 2010 RHC is Commercially Proven... First Unit Streamed in 1999 – Ten Years of Consistent Performance Commercial Sequence of SEU/RHC/SDW (Ketone) Very Low Catalyst Ageing EHC TM Group II+ Products Show Excellent Performance in Formulations Multiple Units Designed and Operating/In-construction Excellent Flexibility for Complete Slate of Viscosity Grades including Bright Stock Group III Capable

18 PETROTECH: November 1-3, 2010 First RHC Unit Streamed in 1999 EHC™ 45EHC™ 60 40°C Pour point, °C-18 VI NOACK Volatility, wt%148 Saturates by Clay Gel, wt%9695 Group II+ Production

19 PETROTECH: November 1-3, 2010 MSDW – Leading Selective Dewaxing Catalyst System Integrates with RHC/RHT, and Lubes or Fuels Hydrocracking Waxes Selectively Isomerized to High VI Lube Highest Lube Product Yield and Low Fuels/Gas Production Two Reactor Cascade System –Reactor 1: Zeolite Catalyst for dewaxing –Reactor 2: Noble Metal Hydrofinishing Catalyst Low Hydrogen Consumption Processes Full Range of Base Stocks MSDW-2 Life Demonstrated >7 Years in Jurong and > 9 Years with Licensee MSDW Licensed in 23 Units with 20 Units Starting up from 2002 to 2011 New MSDW Catalyst – Commercialized in 6+ Units Since 2005 ExxonMobil Technologies Others

20 PETROTECH: November 1-3, 2010 MSDW: Leads by... Feed Flexibility from Light Neutral to Bright Stock...Excellent Viscosity Retention Product Flexibility for Group II and Group III High Lube Product Yields with Minimum Fuels Byproducts Excellent Low Temperature Properties of Products Latest MSDW Shows Higher Activity than Prior Generations, Yet Maintains Exceptional Yield Selectivity, Robust Operation when Faced with Feed Contamination, and Superb Feed Rate Maintenance No MSDW Load Ever Replaced for Reaching End-of-Cycle Condition, or Because of Feed Contamination Upset –Fully recovers activity after feed contamination upset – including hydro- processed coker gas oil –High tolerance for contaminants in feed: S, N, PNA’s

21 PETROTECH: November 1-3, 2010 MSDW: Proven Catalyst Stability ExxonMobil Selective Dewaxing HDW Catalyst Aging With More Advanced Catalysts Days on Stream, [Day] Delta Temperature, °C Cat: MSDW-2 Year N,150N,500N, BS Group II Feed S < 150 wt ppm Feed N < 3 wt ppm LHSV: Jurong Cat: MSDW-2 Year N, 500N Group II Feed S < 50 wt ppm Feed N < 20 wt ppm LHSV: Cat: MSDW-2 Year N, 500N Group II+ Feed S < 10 wt ppm Feed N < 2 wt ppm LHSV: Cat: MSDW-2 Year N,150N Group III Feed S < 7 wt ppm Feed N < 1 wt ppm LHSV: Cat: MSDW Year N,150N Group III Feed S < 30 wt ppm Feed N < 1 wt ppm LHSV: Cat: MSDW Year N,150N Group III Feed S < 30 wt ppm Feed N < 1 wt ppm LHSV: Cat: MSDW-2 Year N, 150N, 600N Group II Feed S < 10 wt ppm Feed N < 1 wt ppm LHSV: Jurong Cat: MSDW Year N, 500N Group II Feed S < 50 wt ppm Feed N < 20 wt ppm LHSV:

22 PETROTECH: November 1-3, 2010 MSDW Will Continue to Improve by... Continuous Development Work to Further Improve Flexibility and Operation. New generations in Development Today to… –Expand already wide range of LHSV operation –Enhance already high tolerance to feed contaminants of S and N –Expand present exceptional operating stability and flexibility for very low pour point products (<-40°C)

23 PETROTECH: November 1-3, 2010 Catalytic Lube Application of EMRE’s Technologies... Since 2000 Operating or in Design/Construction Lube Hydrocrackers5 RHT or RHC8 MSDW23 MAXSAT18

24 PETROTECH: November 1-3, 2010 In Conclusion... Adding RHC to Existing Solvent-Based Lube Facilities Raises Lube Quality from a Wide Range of Crude Sources SEU/RHC/SDW will Produce Group II/II+ Lubes and is Capable for Group III Lubes (All Viscosity Grades) Adding RHC to Existing Solvent-Based Plant Retains (And May Increase) Wax Production; Improves Wax Appearance Quality MSDW for the Dewaxing Step May Further Increase Production, will Eliminate Wax Products Join Our Satisfied Clients and Let EMRE's Lube Experience Work For You!

25 PETROTECH: November 1-3, 2010 THANK YOU !


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