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History of Lubricants and Basestocks

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Presentation on theme: "History of Lubricants and Basestocks"— Presentation transcript:

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

1 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 1

2 Lube Activity Focused on Group II & Group III Production
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 50 100 150 200 250 1993 1995 1996 1997 1998 1999 2000 2001 2002 2003 2004 2005 2006 2007 Hydroisomerization Capacity (kbpd) ExxonMobil Technologies Others Lube Product,( kbpd)

3 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

4 Volatility a Driver for Increased VI
Group I / Group II 95 VI 19 Group II+ 17 API SM Max 15 Mid Tier Group III 13 Noack Volatility, Mass% Top Tier Group III 11 9 GM Proposed Global Spec. Group IV / PAO’s 7 5 3 3.5 4 4.5 5 5.5 6 6.5 7 7.5 8 8.5 100°C, cSt API SM 5W30

5 Common Routes for Base Oil Production
Solvent Extraction Solvent Dewaxing Hydrofinishing Group I RHCTM Group II RHCTM Catalytic Dewax Hydrofinishing Group II /III Distillate/DAO Fuels Hydrocracker Gasoline & Diesel Vacuum Distillation Solvent Dewax Group II HC Bottoms Catalytic Dewax Vacuum Distillation Group II /III Lube Hydrocracker Catalytic Dewax Hydrofinishing Group II / III

6 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 Single operation, no stock switch—simpler control Minimal/no intermediate tankage Larger catalytic vessels One grade dictates operating severity—possible overtreating of others

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

8 Integrated Route to Base Oils
Group I Integrated into Group II & Group III Lube Plant Group I Solvent Plant Hydroprocessing (RHT/RHC) Catalytic Dewaxing (MSDW) Hydrofinishing (MAXSAT) Group II Group III Existing Solvent Dewaxing Group II Group III 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 Group III Group II Group III Group II VI Increase Aromatic Extract Base Conversion to 360-O C Fuels

9 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

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

11 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

12 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

13 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

14 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 Base Ops today Group II 110 VI Products — Constant SEU Feed Rate and Severity -- Raise VI Group II 110VI Products — Reduce SEU Severity to 85 VI 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

15 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 Base Ops today Group II 110 VI Products — Constant SEU Feed Rate and Severity -- Raise VI Group II 110VI Products — Reduce SEU Severity to 85 VI First step-recover capacity Group II 110VI Products — Max SEU Feed to Solvent Limit + Increase raffinate to raise base oil production

16 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 EHCTM 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

17 First RHC Unit Streamed in 1999
EHC™ 45 EHC™ 60 40°C 150 200 Pour point, °C -18 VI 116 114 NOACK Volatility, wt% 14 8 Saturates by Clay Gel, wt% 96 95 Group II+ Production

18 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

19 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

20 MSDW: Proven Catalyst Stability
ExxonMobil Selective Dewaxing HDW Catalyst Aging With More Advanced Catalysts -30 -20 -10 10 20 30 200 400 600 800 1000 1200 1400 1600 1800 2000 2200 2400 2600 2800 3000 3200 3400 Days on Stream, [Day] Delta Temperature, °C Cat: MSDW-2 Year 2003 100N,150N,500N, BS Group II Feed S < 150 wt ppm Feed N < 3 wt ppm LHSV: Jurong Year 2000 150N, 500N Feed S < 50 wt ppm Feed N < 20 wt ppm LHSV: Year 2004 Group II+ Feed S < 10 wt ppm Feed N < 2 wt ppm LHSV: Year 2002 100N,150N Group III Feed S < 7 wt ppm Feed N < 1 wt ppm LHSV: Cat: MSDW Year 2006 70N,150N Feed S < 30 wt ppm LHSV: LHSV: 100N, 150N, 600N Group II LHSV: Year 2007 LHSV:

21 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)

22 Catalytic Lube Application of EMRE’s Technologies ... Since 2000
Operating or in Design/Construction Lube Hydrocrackers 5 RHT or RHC 8 MSDW 23 MAXSAT 18

23 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!


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