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

Agenda

• Development of Enhanced

Two-Stage Unicracking

Process

• Feedback on Operation

of First Units

• Recent Innovations

UOP 7304-1

1

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

2 UOP 7304-2

2

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

3 UOP 7304-3

3

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

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

5

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

6

Second unit in Asia now successfully started up

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

UOP 7304-7

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

UOP 7304-8

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

9

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

UOP 7304-9

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

10

Profitability Reliability

Capital Cost Operating Cost

UOP 7304-10

11

UOP 7116-11 UOP 7304-11