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UOP 7304-0 © 2016 UOP LLC. A Honeywell Company All rights reserved.
Innovations in Hydrocracking Technology
UOP UnicrackingTM Process Kevin Whitehead
15 February 2016 Egypt Downstream Summit & Exhibition 2016 Cairo
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Agenda
• Development of Enhanced
Two-Stage Unicracking
Process
• Feedback on Operation
of First Units
• Recent Innovations
UOP 7304-1
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Development of Enhanced Two-Stage Unicracking Process
• Two-stage configuration is favoured for full conversion, maximum middle distillate units
– Higher yields
– Very cost effective for today’s higher capacity units
– Highly flexible
• UOP conducted an extensive R&D program to advance two-stage hydrocracking covering
– Process technology
– Catalysts
• Result was a step-out increase in value to our customers
1st Stage Reactors
Feed
H2
Separator
Recycle Oil
2nd Stage Reactor
To Fractionation
HT HC
HC
Recycle Gas
Scrubber
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1st Stage Reactors
Feed
H2
Recycle Oil
2nd Stage Reactor
To Fractionation
HT HC
HC
How was this Achieved?
• First stage
– Optimized operating conditions, catalyst system and first stage conversion
• Second stage
– Optimized operating conditions and conversion per pass
– Developed high selectivity catalyst designed for unique second stage environment
– New 2nd stage catalysts with even higher distillate yields now available
• Process Design
– Higher energy efficiency
– Fractionation improvements to allow highest possible conversion & product yield
Recycle Gas
Scrubber
Separator
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Enhanced Two-Stage Unicracking Process
• Advancements delivered
– Diesel yields increased by up to 7 Wt-%
– Full conversion, constant throughout cycle
– Hydrogen consumption reduced
– Catalyst volumes reduced significantly
– Lower energy consumption
• Improvements launched in late 2008
• Strong commercial interest shown
– First license signed in April 2009
• 13 units licensed since launch
4
HIG
H Q
UA
LIT
Y
DIS
TIL
LA
TE
DE
MA
ND
UOP 7304-4 First units now operating
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First Commercial Operation
Tüpraş Izmit Refinery
• Residue Upgrading Project
– New hydrocracking – delayed
coking complex
– Heavy opportunity crudes
– Maximize high quality distillates
(Jet A-1, Euro V diesel)
• Conversion Technologies
– Enhanced Two-Stage Unicracking Process with integrated diesel hydrotreating and coker naphtha hydrotreating
– Amec-Foster Wheeler SYDECTM
Delayed Coking Process
UOP 7090H-5 UOP 7304-5
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Commercial Results
• Hydrocracking unit in operation
with products on grade in
May 2015
• All performance tests passed
High middle distillate yield
achieved
All product quality guarantees met
Excellent energy performance
• Unit successfully operating above
design throughput
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Second unit in Asia now successfully started up
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Example: Installed in 5-bed HC reactor in
Nov, 2014. Unit operating at 32% higher
feed rate compared to previous cycle.
• New design offering a step change in performance & speed of installation
• First sale in 2013
• Sold into 16 units (new and revamp) with 6 already operating successfully
7 Improved Distribution with
UOP Uniflow Reactor Internals
Customer Feedback: “We would never have been able to operate this unit where it is today
without these new internals. This is a step change for UOP”
Hydrocracking
Bed
Radial Spread (ºF)
New Cycle
Radial Spread (ºF)
Previous Cycle
Bed 1 Top: 1
Bottom: 1
Top: 3
Bottom: 18
Bed 2 Top: 4
Bottom: 3
Top: 2
Bottom: 6
Bed 3 Top: 4
Bottom: 2
Top: 5
Bottom: 6
Bed 4 Top: 4
Bottom: 3
Top: 12
Bottom: 36
Bed 5 Top: 4
Bottom: 4
Top: 11
Bottom: 45
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Column
Feed
LP Steam
Unconverted
Oil Recycle Oil
• Patented split shell design in Product Fractionator
• Concentrates HPNAs in unconverted oil purge from unit
• Permits operation at very high conversion levels that are constant throughout the cycle
– Higher product revenues
• Total steam requirement is reduced
• Diesel/recycle oil separation is improved
Higher Unit Conversion Enabled By HPNA Management
• Operating experience demonstrates effectiveness of HPNA rejection in purge
– Sample on left is clean recycle oil
– Sample on right is HPNA contaminated purge oil
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Traditional Single Stripper Design
Optimised Fractionation Design Reduces Capital and Operating Costs
Fractionator
Feed Heater
Stripper
Cold
Feed
Steam
Off Gas
Product
Fractionator
• Separation accomplished in hot and cold separators/flash drums is further optimized in the dual zone stripper
Hot
Feed
Unconverted
Oil
Improvement over traditional
design (for 50kbpsd unit):
• 75% decrease in utilities (FOE)
• Heater fuel reduced by 79% (savings of 128 MM BTU/h)
• $5.5 Million savings in capital cost for new equipment
• Higher diesel yield
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Optimised Fractionation Design
Cold
Stripper
Hot
Stripper
Cold
Feed
Hot
Feed Steam
Steam
Off Gas
Light
Fractionator
Heavy
Fractionator
Heavy Fractionator
Feed Heater
Unconverted
Oil
Steam
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Summary
• UOP has a long history of successful development and
commercialisation of hydrocracking technology and catalysts
– Over 220 units licensed to date
– More than 60 full conversion units, many with difficult feeds (HCGO, DAO)
• Enhanced Two-Stage Unicracking Process is UOP’s latest maximum
middle distillate technology
– Provides highest proven yields and conversion in market
– Two units already operating well
• UOP continues to innovate and has introduced over 40 process
improvements in the last 10 years
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Profitability Reliability
Capital Cost Operating Cost
UOP 7304-10
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