hardware and catalyst solutions for increasing middle ... · 6 refinery modernization project :...

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1 CONFIDENTIAL PROPERTY OF ADVANCED REFINING TECHNOLOGIES TO BE REPRODUCED, AND USED, ONLY IN ACCORDANCE WITH WRITTEN PERMISSION OF ADVANCED REFINING TECHNOLOGIES Hardware and Catalyst Solutions for Increasing Middle Distillate Yields SAMIR Hydrocracker Project African Refiners Association Marrakech, 24-28 March 2014

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1

CONFIDENTIAL

PROPERTY OF ADVANCED REFINING TECHNOLOGIES

TO BE REPRODUCED, AND USED, ONLY IN ACCORDANCE WITH

WRITTEN PERMISSION OF ADVANCED REFINING TECHNOLOGIES

Hardware and Catalyst Solutions for

Increasing Middle Distillate Yields

SAMIR Hydrocracker Project

African Refiners Association

Marrakech, 24-28 March 2014

2

TECHNOLOGY MARKETING

International Technical Services (ITS)

Upstream Global Manufacturing

Trading Shipping

Marketing ETC

Downstream Technology Lubes

Hydroprocessing Catalysts for

RDS EB-Resid

VRDS OCR

ULSD UFR

DHT Hydrocracking

MHC Lube Processing

Gas

ART JV

Formed

2001

CLG JV

Formed 2000

Process Technology Licensing

ISOCRACKING®

ISODEWAXING®

ISOFINISHING

RDS OCR

UFR VRDS

LC-FINING™

ART Partner Relationships

3

ART: Leader in Hydroprocessing Catalysts

ART, 23%

Comp A

Comp B

Comp C

Others

Global

Hydroprocessing

Market: over 350M LBS

Strong position for ART

#1 fixed bed resid

(FBR) segment

#1 ebullating bed

resid (EBR) segment

#2 hydrocracking

(HCR) segment

Growing technology

position in distillate

(DHT) segment

ART

All

Others

ART

All

Others

ART

All

Others

FBR EBR DHT HCR

All

Others

ART

World’s Largest

Hydrocracking Units

Designed by CLG

4

All unit configurations achieve unmatched industry performance with ART Catalyst Systems

Configuration Single Stage

Two Stage,

tail end

distillation

Two Stage,

intermediate

distillation

Two Stage,

intermediate

distillation

Process single stage

only

mainly

hydrotreating

then hydrocracking

mainly hydrotreating

then clean

hydrocracking

mainly hydrotreating

then sour

hydrocracking

Run length Short Intermediate Long Long

Hydrogen

consumption Low Intermediate High High

Contribution of

pretreat catalyst to

unit objectives

High High Intermediate High

Hydrocracking

catalyst system mostly crystalline

optimum

crystalline /

amorphous system

mostly amorphous optimum crystalline /

amorphous system

Application of ISOCRACKING® Catalyst Systems

5

Corporate Name: «Société Anonyme Marocaine de l’Industrie du Raffinage »

Web address: www.samir.ma Creation Date: 1959

Main shareholders: Corral Morocco Holding

Capital Share 1.189. 966. 500 MAD

Activities: • Crude Oil Refining • Base Oils

• Supply & Trading • Logistics & Distrib

Products: • Propane • Butane • Naphtha • Unleaded Gasoline • Jet • Gasoil 50

ppm • Fuel Oil • Base Oils • Bitumen • Waxes • Sulphur

Refining Capacity: 10 Million T/Y

Configuration: Complex refinery with Hydrocracking and Lube Complex

Nelson Complexity Index: 12, 8

Installed Power: 40 MW

Storage capacity: 2 million m3

SAMIR Refinery

6

REFINERY MODERNIZATION PROJECT :

Considered as the greatest Refining achievement in the country

since the creation of LUBE OIL in 1984.

SAMIR refinery modernization project is part of the general program

subject of the investment agreement signed on December 20, 2004

between the Moroccan Government and SAMIR.

The overall budget is more than 1,2 billion US Dollars.

POST REFINERY UPGRADE

Domestic market impact:

Reduction of FO sales

Increase of Diesel demand

New Spec for Diesel and gasoline

Refinery Modernization Project

7

Refinery Products – Before and After

8

CDU’s

N°1

N°2

N°3

Platforming

1&2

Gas Plant

Merox Unit

HDS2

Crude oil

gasoline

Propane

Butane

Butane/ Naphta

Jet Fuel

Jet Fuel

Gasoil

R. Atm

H2

H2S to SRU

HDS 3 Gasoil 50 ppm

Amine regen

Unit

Unit

SRU

H2S

Liquid Sulfure

H2 plant H2

Gaz Naturel

Process support:

Utilities & Off sites

Lube oil Base oil

Bitumes / Paraffines

Fuel oil

DSV

HCU

H2

H2S to SRU

Propane / Butane

Naphta / Gazoline

Jet A1

Diesel <10 ppm

VGO

KTU

CDU4

Process Units: Mohammedia Refinery

9

Positive impact on the national economy and SAMIR refinery:

Configuration of the refinery to the structure of the domestic demand by

increasing the production of diesel fuel.

Protection of the environment and improvement of the quality of the air by the

production of cleaner fuels:

Diesel 50 and 10 ppm, (Euro 4 and 5)

Super unleaded, (Euro 3).

Allow to reach a level of competitiveness in line with that of the modern

European refineries.

Upgrade Project Interest

10

HIGH LEVEL OF REFINING TECHNOLOGY

Hydrocracker: Chevron Lummus lobal

Gasoil deep Hydro-Treating: UOP

HYDROGEN Plant: Technip KTI

Sulfure recovery: Parsons

CONTRACTANTS :

PMC For FEED and Construction: FOSTER WHEELER

EPCM Service: SNAMPROGETTI

Construction: TEKFEN

PROJECT STEPS

Phase1: Diesel 50 ppm in July 2009.

Phase2: Hydrocracking Complex in march 2010.

The Project realization was conducted over a period of 40 months and required

25 million hours of work and 50 thousand tons of material and equipment.

25 Millions Working Hour without accident.

Project Execution

11

PROJECT CONSTRUCTION HIGHLIGHTS

The construction of the project started effectively on March 2006 with the

signature of the EPCM contract with SAIPEM and the ordering of the first

stage reactor.

DETAIL ENGINEERING

The project required more than 1.5 million working hours for the detail

engineering, and the procurement services carried out by the Italian company

SAIPEM.

PROCUREMENT

The company proceeded with the purchase of 760 equipments with a total

weight of 50,000 Tons.

Engineering, Procurement and Construction

12

The construction works totalized 25 million working hour without record of lost

time accident, major accidents or injuries.

Main key indicators:

Structural Concrete: 112 000 m3

Steel structure erection: 11 180 T

A/G Piping installation: 12 320 T

LV & MV cables pulling: 850 Km

Instruments erection: 9 135 U

Insulation: 161 000 m²

Painting: 131 000 m²

The number of the manpower reached 4 500 persons during the peak period.

Construction

13

Pictures of Upgrade Project

Photos: Courtesy of SAMIR

14

Design capacity : 5350 MT/D

Conversion rate : 99 %

Effective unit start up was on March 2010.

The performance test was carried out with the assistance of Licensor

Chevron on June 2010.

The unit performances were above the performances required by the

contract guaranties.

2013: TEST 107% capacity successful.

Hydrocracker Unit

15

Hydrocracker Configuration

16

Photo: Courtesy of SAMIR

Reactors

17

Photo: Courtesy of SAMIR

18

SAMIR Hydrocracker Salient Features

Largest Full Conversion Hydrocracking Unit in Africa

Licensed by CLG

Utilizes CLG ISOCRACKING technology

Two-Stage with Recycle Configuration

Designed for 36,000 BPSD of Arab Light and Arab Medium Crudes but capability to handle Opportunity Crudes

Designed for 99% Conversion to Middle Distillates

Foster Wheeler was original PMC Contractor. SnamProgetti FEED/EPC Contractor.

Plant was commissioned in 2010.

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Design Current

Capacity 36,000 37,000-38,500

Crude Blend Arab Light/Arab

Medium

AL/Basrah

Light/Kirkuk/Urals/Belayim

Feed Type VGO VGO from

refinery/Imported

VGO/Extract/Wax..

Nitrogen, wppm 1500 ~1500

Sulfur, wt.% 2.86 2.4

Metals, wppm <2 3-4

Asphaltenes, wppm 100-200 > 500

Feed HPNA Content Base Higher than Base

Current Operation vs. Design

20

Design Actual

Conversion, wt.% 99.1 99.5

Diesel Yield, wt.% Base Base + 0.8

Diesel Sulfur, wppm < 10 6-8

Diesel Cetane > 55 58

Unit Operation After ~1200 Days of Operation

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Summary

Successful Start-Up and Operation of CLG Hydrocracker at SAMIR through close collaboration:

Keys to Success:

Strong knowledgeable and experienced SAMIR Team

Strong CLG Team with Design and Operating Experience

State-of-the-art hydrocracking catalyst provided by ART

Close Cooperation Between All Parties:

SAMIR

CLG

Foster Wheeler

Snamprogetti

Tefken

Sharing Operational Knowhow (Chevron Best Practices)

Comprehensive Training