uop uniflex heavy oil upgrading paper
TRANSCRIPT
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Maximize Conversion and Flexibility
The UOP UniflexTM Process
Maximize Conversion and Flexibility
The UOP UniflexTM ProcessRobert Haizmann
UOP LLC
Robert Haizmann
UOP LLC
2011 UOP LLC. All rights reserved.
6th Russia & CIS BBTC Conference April 13-14, 2011Moscow, Russia
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2Maximize Conversion and Flexibility With the UOP Uniflex Process
Market Factors
Technology Summary
Capital Savings Through Integration
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3Product Demand, Specifications, and Prices are ChangingIncremental Fuel Demand 2010-2020
Source: Purvin & Gertz, 2010 GPMO
Common goal: Maximize residue conversion to distillatesCommon goal: Maximize residue conversion to distillates
-2.0
0.0
2.0
4.0
6.0
8.0
Gasoline Diesel Kerosene/Jet Residue Fuel Oil
M
M
B
P
D
Bunker Fuel Oil Sulfur Specifications
0.0
1.0
2.0
3.0
4.0
5.0
2005 2010 2015 2020 2025 2030
S
u
l
f
u
r
,
W
t
%
m
a
x
GlobalGlobal DelayedECA
NW European Product Differentials to Brent, Forecast in Constant 2010 $/Bbl
Source: Purvin & Gertz, 2010 GPMO
-30
-20
-10
0
10
20
30
40
2000 2005 2010 2015 2020
Euro UnleadedDiesel EN590RFO, 1%SRFO, 3.5%S
Diesel Price Premium over Coke
0
200
400
600
800
20 (2000) 40 (2004) 60 (2009) 80 (Future)
Crude Price, $/bbl (year)
P
r
o
d
u
c
t
V
a
l
u
e
(
$
/
M
T
)
CokeDiesel
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4TransportationFuels:
Gasoline, Jet Fuel, Diesel
D
i
s
t
i
l
l
a
t
i
o
n
Naphtha
Crude Oil
VacuumResidue
VacuumGas Oil
Distillates
Residues:Heavy Fuel Oil, Pitch,
Coke
NaphthaHydrotreating & Reforming
FCC orHydrocracking
DistillateHydrotreating
UOPs Heavy Oil Upgrading Processes
ResidueConversion
UOP/FWUSASolvent
DeasphaltingFWUSA SYDECTMDelayed Coking
ProcessUOP/FWUSAVisbreaking
UOP RCDUnionfiningTM
Process
UOP SolutionsUOP/FWUSA
SolventDeasphalting
FWUSA SYDECTMDelayed Coking
ProcessUOP/FWUSAVisbreaking
UOP RCDUnionfiningTM
Process
UOP Solutions for Residue ConversionUOP UNIFLEXUOP UNIFLEX
ProcessProcess
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5UOP Uniflex Process
VacuumResidue
Catalyst
Gasoline
Diesel
VGO
MakeupHydrogen
Pitch
Reactor Slurry hydrocracking technology
High conversion to desired products
Contains elements of proven processes
CANMET Hydrocracking Process
UOP UnionfiningTM and UOP UnicrackingTM Processes
Uniflex Process has >25% yield Uniflex Process has >25% yield advantage over Delayed Cokingadvantage over Delayed Coking
-35
-15
5
25
45
65
85
105
Delayed Coking Uniflex Process
V
o
l
u
m
e
%
o
f
F
e
e
d
VGOVGO
DistillateDistillate
Naphtha
Naphtha
Coke(wt.%)
Pitch(wt.%)Pitch(wt.%)
Typical Yields
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6Uniflex Process Extensive Commercial ExperienceExtensive Commercial Experience
Petro-Canada Montreal Unit25 years R&D15 years commercial
operation Variety of feedstocks High conversion 97%+ availability
Many UOP improvements in the last 5 yearsMany UOP improvements in the last 5 years-20
0
20
40
60
80
100
Y
i
e
l
d
,
v
o
l
%
Naphtha
Distillate
VGO
Pitch
85% 94%90%Commercial Performance
Conversion
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7Uniflex Process Proven Flowscheme with ImprovementsProven Flowscheme with Improvements
UniflexReactor
Vacuum Residue Feed
HotSeparator
Stripper/Product
Fractionator
Catalyst
Recycle H2
Naphtha
Diesel
C4 -
MakeupH2
Pitch
LVGO
Cold Separator
HVGO Recycle
Flash Gas
HotFlashDrum
ColdFlashDrum
VacuumFractionator
FeedHeater
RecycleGas
Heater
FractionatorHeater
Large Unit CapacitiesLarge Unit Capacities
Capital Cost Savings Through Process IntegrationCapital Cost Savings Through Process Integration
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8-40
-20
0
20
40
60
80
100W
t
.
%
o
f
F
e
e
d
Pitch/Coke 524+ Gasoil 343-524C Distillate 204-343CNaphtha C5-204C Fuel Gas + LPG
Uniflex Process Uniflex Process HVGO Recycle Improves Yields and QualityHVGO Recycle Improves Yields and Quality
IncreasedNaphtha &Distillate
Yields
Lighter VGO, easier
to process
Delayed Coking
Uniflex Uniflex + HVGO Recycle
Maximum naphtha and diesel yield from vacuum residueMaximum naphtha and diesel yield from vacuum residue
VGO conversion without a separate Mild Hydrocracking UnitVGO conversion without a separate Mild Hydrocracking Unit
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9-50
-30
-10
10
30
50
70
90
110
V
o
l
.
%
o
f
F
e
e
d
DelayedCoking
UniflexProcessSDA
EBEDHC
Base Case: Uniflex Process Compared to Other VR Conversion ProcessesUniflex Process Compared to Other VR Conversion Processes
Uniflex Process Benefits:
High liquid yields on vacuum residue feed, especially distillates
Minimum residue by-products
Significantly increases margins
Residue Conversion Yields
30
40
50
60
70
80
90
V
o
l
.
%
o
f
F
e
e
d
Distillate Yield(After Hydrocracking)
DelayedCoking
UniflexProcessSDA
EBEDHC
Upgrading MarginsWith Hydrocracking
DelayedCoking
UniflexProcessSDA
EBEDHC 60%
Arab Light Vacuum Residue
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10
SDAPitch
Uniflex Pitch
Uniflex Naphtha and Distillate
To New or Existing HDT
Unicracking UCO (to FCC)
DAO
Vacuum Gas Oil
Uniflex VGO
Uniflex Process Integrated with UOP/FW Solvent Deasphalting & Unicracking ProcessUOP/FW Solvent Deasphalting & Unicracking Process
UOPUniflexProcess
UOP/FWUSASolvent
DeasphaltingProcess
Vacuum Residue UOPUnicracking
Process
Unicracking Naphtha and Distillate
Maximum Distillate Production Maximum Distillate Production -- 95% Vacuum Residue Conversion with Uniflex and SDA95% Vacuum Residue Conversion with Uniflex and SDA-- 99+% VGO conversion with Unicracking Process99+% VGO conversion with Unicracking Process
Low Capital Cost Upgrading ComplexLow Capital Cost Upgrading Complex-- Low capital cost SDALow capital cost SDA-- Small, moderate reactor pressure Uniflex Process UnitSmall, moderate reactor pressure Uniflex Process Unit
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11
Integrated Case: Solvent Deasphalting/Uniflex/Unicracking ProcessesSolvent Deasphalting/Uniflex/Unicracking Processes
-50
-30
-10
10
30
50
70
90
110
V
o
l
.
%
o
f
F
e
e
d
Residue, wt% DAO VGO Distillate Naphtha
SDA +Uniflex
DelayedCoking
SDA +Coking
UniflexProcessSDA/Uniflex/Unicracking Benefits:
Very high vacuum residue conversion
Maximum distillate yields on vacuum residue feed
Highest margins
Capital cost reduced
Increased operating flexibility
Distillate Yield(After Hydrocracking)
SDA +Uniflex
DelayedCoking
SDA +Coking
UniflexProcess
Upgrading MarginsWith Hydrocracking
SDA +Uniflex
DelayedCoking
SDA +Coking
UniflexProcess
Arab Light Vacuum Residue
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12
UOP/FWUSA SDA Process Commercial ExperienceCommercial Experience
UOP/FWUSA Combined Experience Over 70 units licensed (500 to 50000 BPD) Proven scale-up between pilot plant and
commercial operations
Recent Selection in 6 Projects
All units won in competitive bidding Utilizing features from both UOP and FW
technologies
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UOP Unicracking Process Commercial ExperienceCommercial Experience
Proven Experience >60% of the Worlds Licensed Hydrocracking
Units 195 Licensed Units in 40 Countries >100 Operating Units 54 Licenses Since 2000 Experience with all flow scheme options and
DAO processing
Experience IS the differenceExperience IS the difference
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Coke
Uniflex Process Integrated with Existing Delayed Coking UnitExisting Delayed Coking Unit
Increased Naphtha and Distillate yieldIncreased Naphtha and Distillate yield
Heavy Coker Gas Oil converted in UniflexHeavy Coker Gas Oil converted in Uniflex
Uniflex Pitch converted in CokerUniflex Pitch converted in Coker
Debottleneck Coker and Coker Heavy Gas Oil Debottleneck Coker and Coker Heavy Gas Oil HydrotreaterHydrotreater
Vacuum Residue
Feed
Delayed Coking
ProductsUniflexProcess
Pitch Products
HCGO
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15
TransportationFuels:
Gasoline, Jet Fuel, Diesel
D
i
s
t
i
l
l
a
t
i
o
n
Naphtha
Crude Oil
VacuumResidue
VacuumGas Oil
Distillates
Residues:Heavy Fuel Oil, Pitch,
Coke
NaphthaHydrotreating
Hydrocracking
DistillateHydrotreating
Integration of Hydroprocessing Units
UOP UniflexProcess
Integration Drivers Integration Drivers --Capital Cost Reduction and Energy EfficiencyCapital Cost Reduction and Energy Efficiency
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Slurry Hydrocracking and Hydroprocessing Issues that impact optimal degree of integrationIssues that impact optimal degree of integration
Economics Capital cost savings Utilities savings
Design and operating flexibility Operating pressures and relative flowrates of units Future changes in crudes and product slate Catalyst performance in HC and HDT Timing of catalyst and inspection turn-arounds Start-up, shut-down, emergency procedures
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17
Full Process Integration Challenges
Features
Combines slurry hydrocracking and Hydroprocessing in one hydrogen gas loop
Requires both sour and sweet fractionation systems products fractionated twice
Slurry HC and Hydroprocessing sections require same high reactor pressure
Challenges
Moderate effect on overall capital and operating costs
H2 S and NH3 depress catalytic activity and selectivity
Diesel yield loss via cracking
Straight Run Diesel and VGO
VacuumResidue
Slurry HCRx
HydroprocessingRx
RecycleGas
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Selective Integration Benefits
UOP offers many integration options to meet refiners varied requirements
Examples Common H2 recovery and compression systems for make-up gas
and off-gas Parallel recycle gas systems Uniflex products integrated directly to UOP Unicracking and UOP
Distillate Unionfining
Benefits >10% capital savings for Uniflex, Unicracking, Distillate
Unionfining Heavy Oils Complex Performance optimized of each unit
Reduced contamination in catalytic process units Unicracking: >99% VGO conversion Distillate Unionfining - Maximum diesel yield, quality and cycle length
at minimum reactor pressure
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UOP Uniflex Process Will Meet Your Future Transportation Fuel Requirements
Ideal Process for Maximizing Transportation Fuels from Vacuum Residue
Unique Solutions for Maximizing Distillate
Extensive Commercial Operations Background
UOP Development Program Assures Future Units Success
Optimization and Integration Solutions will Maximize Benefits for your Refinery
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Maximize Conversion and Flexibility The UOP UniflexTM ProcessMaximize Conversion and FlexibilityWith the UOP Uniflex ProcessProduct Demand, Specifications,and Prices are ChangingUOPs Heavy Oil Upgrading ProcessesUOP Uniflex ProcessUniflex Process Extensive Commercial Experience Uniflex Process Proven Flowscheme with ImprovementsUniflex Process HVGO Recycle Improves Yields and QualityBase Case:Uniflex Process Compared to Other VR Conversion ProcessesUniflex Process Integrated withUOP/FW Solvent Deasphalting & Unicracking ProcessIntegrated Case:Solvent Deasphalting/Uniflex/Unicracking ProcessesUOP/FWUSA SDA Process Commercial ExperienceUOP Unicracking ProcessCommercial ExperienceUniflex Process Integrated withExisting Delayed Coking UnitIntegration of Hydroprocessing UnitsSlurry Hydrocracking and HydroprocessingIssues that impact optimal degree of integrationFull Process Integration ChallengesSelective Integration BenefitsUOP Uniflex Process Will Meet YourFuture Transportation Fuel RequirementsSlide Number 20