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Optimization of the Feedstock Blend for the New H-Oil-RC™ Ebullated Bed Resid Upgrading Unit at Lukoil Neftochim Burgas

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Optimization of the Feedstock Blend for the New H-Oil-RC™ Ebullated Bed Resid Upgrading Unit at Lukoil Neftochim Burgas Optimization of the feedstock blend for the new Presented by: H-Oil-RC™ ebullated bed Dr. Dicho Stratiev LukOil - Burgas resid upgrading unit Wessel IJlstra Criterion - Amsterdam at LukOil Neftochim Burgas, Co-authors: to maximize the conversion Dr. Ilshat Sharafutdinov LukOil - Burgas and yields of the on-site FCC Dr. Georgi Argirov LukOil – Burgas Dr. Magdalena Mitkova Burgas University unit Radoslava Nikolova Burgas University Dr. David E. Sherwood Jr. Criterion - Houston Burgas University Disclaimer Criterion, LukOil, and Burgas University are the trade names of independent entities. Where an entitity is identified by its trade name, the reference is used for convenience, or may be used where no useful purpose is served in referring to the entity by name. The services and products of these entities may not be available in certain countries or political subdivisions thereof. The information contained in this presentation is provided for general information purposes only and must not be relied on as specific advice in connection with any decisions you may make. No representations or warranties, express or implied, are made by the entity or entities presenting these materials, or their affiliates, concerning the applicability, suitability, accuracy or completeness of the information contained herein and these entities do not accept any responsibility whatsoever for the use of this information. The entities presenting these materials, and their affiliates, are not liable for any action you may take as a result of you relying on such material or for any loss or damage suffered by you as a result of you taking this action. Furthermore, these materials do not in any way constitute an offer to provide specific services. Copyright ©2015 Shell Oil Company. All rights reserved. No part of this publication may be reproduced or transmitted in any form or by any means, electronic or mechanical including by photocopy, recording or information storage and retrieval system, without permission in writing from Shell Oil Company or Criterion Catalysts & Technologies L.P. Always moving forward Program - Introduction to LukOil Neftochim, refinery Burgas and the new H-Oil-RC™ unit licensed by Axens - Study objectives for this presentation - Introduction to ebullated bed pilot plant testing - Pilot plant test plan - Pilot plant test results - Experimental and theoretical estimates FCC yields - Refinery scheduling - Conclusions 3 «ЛУКОЙЛ Нефтохим Бургас» АД Always moving forward Process Diagram of LUKOIL Neftohim Burgas Fuel gas AGFU CGFU B n-С4 LPG Naphtha Isomerization Hydrotreater Reformer L SRU-2 SRU-3 E Naphtha 2015 SRU-4 N Premium gasoline HDS-1 HDS-2 D HDS-3 (A-95H) Alkylatio I HDS-5 n Super Crude oil SMR FCC MTBE 1 700 N Gasoline AD-4 хил.т./г Pre- FCCU 6.5 MM t/y treate + 1.5 MM t/y r (А-98Н) Prime-G G Atm. Residue Jet A-1 VDU-2 H-Oil residue hydrocracking Euro diesel AVD-1 SMR 2015 2015 Road VBU Bitumen Fuel oil S<1% Bitumen unit Sulphur - Existing units - New units - Units out of operation - Gasoline - VGO - C1-C4 gas - Heavy residue - Kerosene - Diesel fuel - Н2S - Fuel oil 18 Always moving forward Program Problem definition: • Commissioning of the new H-Oil-RC™ unit at LukOil Burgas will allow for rescheduling of the refinery to optimize product yields. • At start-up, not enough vacuum resid will be available to fully utilize the capacity of the new unit, but alternative heavy feed components (AR, VGO) can be rerouted to H-Oil-RC™ unit. Study objectives: Screen possible feed blends for the H-Oil-RC™ unit. • Use yields- and product quality results from H-Oil pilot-plant study to estimate/test FCC unit performance. • Use conclusions in site scheduling program to optimize refinery margins. 5 Introduction ebullated bed pilot plant testing FRESH CATALYST PRODUCT LIQUID/GAS Level instrument EXPANDED CATALYST Example of a commercial LEVEL Ebullated Bed Reactor LIQUID/GAS Defining characteristics: SETTLED CATALYST LIQUID LEVEL * Back-mixing of liquid and CATALYST/ catalyst LIQUID/GAS - Little temperature and concentration gradient - Uniform catalyst activity GRID PLATE WITH MULTIPLE * Continues catalyst replacement HYDROGEN and DISTRIBUTION CAPS - Stable performance of FEED OIL catalyst inventory USED CATALYST EBULLATION PUMP RECYCLE OIL Introduction to Ebullated Bed pilot plant testing Criterion uses autoclave reactors equipped with Robinson-Mahoney type internals. Back-mixed (CSTR) kinetics are assumed to evaluate Ebullated Bed Catalyst Performance • Fixed annular catalyst basket with baffles inside and outside the basket to prevent vortexing. • Rotating shaft with agitator, creating flow through the basket to the reactor wall for upward and downward deflection. • Liquid level controlled by overflow tube • Gas hold-up controlled by mixer speed • Multi-phase gradientless reactor. From: http://www.autoclave-france.fr/english/cata.html Two of the four Criterion CSTR Pilot Plants located in the Houston R&D laboratory Test plan • Three independent tests were done in the same Criterion pilot- plant at Shell Technology Center, Houston (STCH) to simulate the new H-Oil-RC™ unit at LukOil Burgas. • Each test used one of 3 feed blends as specified and supplied by LukOil: A. 100% VR B. 75% VR + 25% heavy VGO C. 50% VR + 50% heavy AR (All feed blends were additionally blended with FCCUHCO + FCCU Slurry Oil [diluents], as specified and supplied by LukOil) • Each test was done at equal conditions. The feed rates were kept constant, but, to allow for interpolation to the target conversion level, the evaluations were done at 2 different conversion levels. Test plan --- Feed Blends A, B and C (after diluent addition) VR VR/VGO VR/AR Analysis Unit 100% 75%/25% 50%/50% (+diluents) (+diluents) (+diluents) Density kg/l 1.010 0.984 0.978 Sulphur wt-% 2.73 2.38 2.03 Nitrogen wt-% 0.4964 0.4051 0.3679 Carbon residue, MCR wt-% 16.0 11.0 11.0 Ni ppm 82 53 48 V ppm 258 175 143 SimDis 538 oC+ wt-% 82.1 65.5 58.6 565 oC+ wt-% 75.2 55.5 52.1 Test Results • For each test, 2 (or 4) test-periods were selected for complete analysis (fractionation + product quality analysis). • All samples of the VGO and VR products were shipped to LukOil Burgas for further evaluation by LukOil and Burgas University. Test Results • Net 540°C+ conversion appears higher for vacuum resid only feed, compared to the lighter blends. 80.0 75.0 70.0 Target Conversion 65.0 60.0 55.0 50.0[wt%] C conversion ° 45.0 40.0 Net 540 Net 35.0 406 408 Operating410 412 temperature414 416 [°C]418 420 Test Results • For each of the feed blends the yield pattern was determined. • This example is for the100% VR feed. 37.0 32.0 VGO 27.0 22.0 17.0 Target Conversion 12.0 7.0 [wt%]yields Product 2.0 50 52 54 56 58 60 62 64 66 68 70 72 74 76 78 80 Net 540°C+ conversion [wt%] Test Results • The yield patterns can be directly compared for the different feed blends. • Lighter feed blends, containing more VGO, give higher VGO yields at equal 540°C+ conversion. 47.0 42.0 75/25 VR/VGO 37.0 32.0 100% VR 27.0 VGO yields [wt%] yields VGO 22.0 Target 17.0 Conversion 12.0 50 52 54 56 58 60 62 64 66 68 70 72 74 76 78 80 Net 540°C+ conversion [wt%] Test Results • Lighter feed blends, containing more diesel, result in higher diesel yields at equal 540°C+ conversion. 37.0 32.0 27.0 22.0 17.0 12.0 Target Conversion Diesel yields [wt%] yields Diesel 7.0 2.0 50 52 54 56 58 60 62 64 66 68 70 72 74 76 78 80 Net 540°C+ conversion [wt%] Test Results • Hydrogenation performance and product quality data were interpolated to the target 540°C+ conversion level. Feed blend VR VR/VGO VR/AR Blending ratio 100 75/25 50/50 540°C+ Conversion Base Same Same Sulfur in unconverted resid wt% Base -0.2 -0.2 HDS wt% Base +4 +4 HDN wt% Base +5 Same HDMCR wt% Base +5 +6 HDMetals wt% Base +4 +2 Always moving forward H-Oil-RC™ products from 3 different feed blends were separated and analyzed for product quality H-Oil-RC(TM) Product Density Feed blends 100% VR 75/25 VR/VGO 50/50 VR/AR Diesel VGO VR H-Oil-RC(TM) Product Sulfur Feed blends 100% VR 75/25 VR/VGO 50/50 VR/AR Diesel VGO VR H-Oil-RC(TM) Product Nitrogen Feed blends 100% VR 75/25 VR/VGO 50/50 VR/AR Diesel VGO 17 Always moving forward Specific properties of the H-Oil-RC™ products, needed for predicting the FCC unit performance were analyzed in the LukOil laboratory FCC feed specific properties for VGO product Feed blends 100% VR 75/25 VR/VGO 50/50 VR/AR Kw Saturates light middle heavy Resins Aromatics Specific properties for the unconverted product Feed blends 100% VR 75/25 VR/VGO 50/50 VR/AR Kw Saturates Aromatics Resins Asphaltenes 18 Always moving forward H-Oil-RC™ pilot-plant products were used as feed for Micro Laboratory FCC pilot units VGO product 100% VR 75/25 VR/HVGO 50/50 VR/AR drygas LPG gasoline LCO HCO Coke conversion FCC yield patterns simulated at max gasoline yield, when using H-Oil-RC™ VGO products neat from different feed blends 19 Always moving forward In addition, Micro Laboratory FCC simulations were performed for blends of H-Oil-RC™ products with straight-run HVGO VGO blends 100% SR HVGO 50% SR HVGO + 50% H-Oil VGO (100% VR) 50% SR HVGO + 50% H-Oil VGO (75/25 VR/HVGO) drygas LPG gasoline LCO HCO Coke conversion FCC yield patterns simulated at max gasoline yield, when using blends of SR HVGO and H-Oil-RC™ VGO products Compared to the blend 50%/50% blend with VGO product from 100% VR run, the 50%/50% blend with VGO product from the 75%/25% VR/VGO run gave ~+4% gasoline + LPG at the expense of ~-4% cycle oils.
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