Application: An ebullated-bed process H-OilDC is used for hydrocon-version (hydrocracking and hydrotreating) of heavy vacuum gasoil and DAO having high Conradson carbon residue and metal contents and low asphaltene content. It is best suited for high severity operations and applications requiring long run lengths.
Description: The flow diagram includes integrated mid-distillate hydro- treating for an ultra-low-sulfur-diesel product. The typical battery limits scheme includes oil- and hydrogen-fired heaters, an advanced design hot high-pressure separator and ebullating pump recycle system, a re-cycle gas scrubber and product separation and fractionation.
Catalyst in the reactor is replaced periodically without shutdown and, for cases of feeds with low metal contents, the catalyst can be re-generated onsite to reduce catalyst consumption.
Various catalysts are available as a function of the feedstock and the required objectives. An H-OilDC unit can operate for four-year run lengths at constant catalyst activity with conversion in the 20-80%
range in once-through mode and to more than 95% in recycle mode with up to 99% hydrodesulfurization.
Operating conditions:
Temperature 750– 820°F/400–438°C
Hydrogen partial pressure 600 –1,500 psi/40_45 bar
LHSV, hr –1 0.5 –3.0
Conversion, wt% 20 –80 in once-through mode Example: VGO + DAO feed: a blend of heavy VGO and C5 DAO con-taining close to 100 ppm metals is processed at 80% conversion at an overall desulfurization rate of over 96%.
Economics: Basis—2008 US Gulf Coast
Investment in $ per bpsd 2,800–4,500 Utilities, per bbl of feed
Fuel, 103 Btu 60
Power, kWh 3
Catalyst makeup, lb 0.01–0.3
Installation: The H-OilDC process has four references, three in operation, with a total cumulative capacity of 11.45 metric tpy. This technology has been commercially demonstrated based on the ebullated bed reactor making a total of 13 references for residue and VGO hydroconversion.
Licensor: Axens contact
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HYDROCARBON PROCESSING
®2011 refining Processes Handbook
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Hydrocracking
Application: Upgrade vacuum gas oil alone or blended with various feedstocks (light-cycle oil, deasphalted oil, visbreaker or coker gasoil).
Products: Jet fuel, diesel, very-low-sulfur fuel oil, extra-quality FCC feed with limited or no FCC gasoline post-treatment or high VI lube base stocks.
Description: This process uses a refining catalyst usually followed by hydrocracking catalyst. Main features of this process are:
• High tolerance toward feedstock nitrogen
• High selectivity toward middle distillates
• High activity of the cracking catalyst, allowing for 3–4 year cycle lengths and products with low aromatics content until end of cycle.
Three different process arrangements are available: single-step/
once-through; single-step/total conversion with liquid recycle; and two-step hydrocracking. The process consists of: reaction section (1, 2), gas separator (3), stripper (4) and product fractionator (5).
Product quality: Typical for HVGO (50/50 Arabian light/heavy):
Feed, Jet
HVGO fuel Diesel UCO
Sp. gr. 0.932 0.800 0.826 0.835
TBP cut point, °C 405–565 140–225 225–360 360+
Sulfur, ppm 31,700 < 10 < 10 < 20 Nitrogen, ppm 853 < 5 < 5 < 5
Metals, ppm < 2 – – –
Cetane index – – 62 –
Flash pt., °C – 40 125 –
Smoke pt., mm, EOR – 26–28 – –
Aromatics, vol%, EOR – < 12 < 8 –
Viscosity @ 38°C, cSt 110 – 5.3 4–5
PAH, wt%, EOR < 2 –
Viscosity Index – – – > 125
Reference:
Copyright © 2011 Gulf Publishing Company. All rights reserved.
Hydrocracking
Application: Convert naphthas, AGO, VGO, DAO, cracked oils from FCC units, delayed cokers and visbreakers, intermediate products from residue hydroprocessing units and synthetic gasoils and shale oil using the Chevron Lummus Global ISOCRACKING Process.
Products: Lighter, high-quality, more valuable products: LPG, gasoline, catalytic reformer feed, jet fuel, kerosene, diesel and feeds for FCC, eth-ylene cracker or lube oil units.
Description: A broad range of both amorphous/zeolite and zeolitic catalysts, including noble-metal zeolitic catalysts, are used to tailor the ISOCRACKING Process exactly to the refiner’s objectives. In general, the process involves a staged reactor system with an initial stage of hydrotreating and partially hydrocracking the feed, and a subsequent stage continuing the conversion or product upgrade process in a more favorable environment.
Feeds can be introduced in between stages using Chevron Lum-mus Global (CLG) patented split-feed injection technology, or efflu-ent flow paths can be arranged to best utilize hydrogen and minimize quench-gas requirements using proprietary SSRS (single-stage reaction sequenced) technology.
Most modern large-capacity flow schemes involving heavy sour gas oils require two reactors (1, 4) and one high-pressure separation system (2) with an optional recycle gas scrubber (5) and one recycle-gas com-pressor (8). The low-pressure separators (3), product stripper (6) and fractionator (7) provide the flexibility to fractionate products either in between reaction stages or at the tail-end, depending on desired prod-uct slate and selectivity requirements.
Single-stage options are used in once-through mode typically for mild hydrocracking or when a significant quantity of unconverted oil is required for FCC, lubes, or ethylene units. The single-stage recycle option is used for lower capacity units when economical. The reactors use pat-ented internals technology called ISOMIX for near-flawless mixing and re-distribution. For feeds that are high in nitrogen and other contaminants, CLG recommends the Optimized Partial Conversion (OPC) scheme that achieves gravity targets of the unconverted oil (typical FCC feed) and de-sired conversion at much lower capital cost and hydrogen consumption.
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Yields: Typical from various feeds:
Feed VGO VGO VGO VGO
Gravity, API 24.1 24.1 24.1 21.3
TBP range, °F 700–1,100 700–1,100 700–1,100 700–1,100
Nitrogen, wppm 2,500 2,500 2,500 900
Sulfur, wt % 1.9 1.9 1.9 2.5
Mode Max. Diesel Max. Jet Max. Max. Mid-Distillate Mid-Distillate
+ Lubes Yields, vol %
Naphtha 22.8 30.8 14.0 18
Jet/kerosine – 79.7 22.0 50
Diesel 85.5 – 73.0 35
UCO – – – 10
Feed VGO VGO VGO VGO
Product quality
Kerosine smoke, mm 29–32 29–32 29–32
Diesel cetane number 58–64 58–64 58–64
UCO BMCI 6–8
UCO Waxy V.I. 143–150
UCO Dewaxed V.I. 131–133
Economics: ISBL total installed cost of 50,000-bpsd unit at 100% con-version to middle distillates using Middle Eastern VGO feed (USGC, 2010 basis): $342 million.
Process fuel (absorbed), MMBtu/hr 180
Electricity, MW 10
CW, gpm 2,500
Steam (export at 150 psig), M lb/hr 22
Installation: More than 100 units worldwide with over three million-bpsd total capacity.
Reference: Dahlberg, A., U. Mukherjee and C. W. Olsen, “Consider using integrated hydroprocessing methods for processing clean fuels,”
Hydrocarbon Processing, September 2007, pp. 111–120.
Mukherjee, U., J. Mayer and B. Srinivasan, “Hydroprocessing In-novation—Some Recent Applications, Petroleum Technology Quarterly, Summer 2004.
Bridge, A. G. and U. Mukherjee, “ISOCRACKING—Hydrocracking for Superior Fuels and Lubes Production,” Handbook of Petroleum Re-fining Processes, McGraw Hill, Third Edition.
Licensor: Chevron Lummus Global LLC contact