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

PETROTECH 2010 New Delhi, India November 2010. Convert Bottom-of-the-Barrel to Diesel and Light Olefins. Dalip Soni Lummus Technology. Refining Business Drivers. Growth in diesel demand higher than gasoline

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

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

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

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

  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

  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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