LCO Processing Solutions - ERTC 20th Annual · PDF fileLCO Processing Solutions ... Source: Axens & other sources Market Structure 2010 vs. 2020 ... g B o il n gi Po in t B Ts ba nds

1

LCO Processing Solutions

Antoine Fournier

2ERTC Annual Meeting - November 2011

Outline

• Market trends and driving factors

• The light cycle oil• Feedstock characteristics

• Hydroprocessing challenges

• Main option for LCO upgrading• Catalyst update

• Revamping and grassroots options

• Case Study • Single stage versus 2-stage configuration


-0.50.00.51.01.52.02.53.03.54.04.5

Source: Axens & other sources

Market Structure2010 vs. 2020

Oil Products DemandWorld

Other* = Kerosene (≠ Jet Kerosene), Refinery Gas, Petroleum Coke, NGL, Lubricants, Bitumen, Paraffin Wax, Refinery Losses, …

-0.1%0.9%2.5%2.5%1.1%2.6%1.1%1.4%

2010-2020 AAGR

Jet KeroseneOn-road dieselOff-road diesel

Fuel Oil

Motor GasolineNaphtha

LPGOther*

Mbdoe

Main Products Incremental Demand

2010-2020

9.7%

12.5%

16.1%5.3%

27.1%

7.3%8.7%

13.3%

8.3%11.8%

17.9%

5.8%

26.3%

8.1%8.5%13.2%

0%

20%

40%

60%

80%

100%

2010 202088.2

Mbdoe99.8

Mbdoe2010-2020 AAGR

1.2%


-0.6-0.5-0.4-0.3-0.2-0.10.00.10.20.30.40.50.60.7

9.7%

13.9%

28.1%

6.6%

16.4%

8.1%7.1%10.1%

8.3%11.9%

32.5%

7.7%13.4%

8.8%7.3%10.1%

0%

20%

40%

60%

80%

100%

2010 2020

Main Products Incremental Demand

2010-2020

Source: Axens & other sources

Market Structure2010 vs. 2020

Oil Products DemandEurope

Other* = Kerosene (≠ Jet Kerosene), Refinery Gas, Petroleum Coke, NGL, Lubricants, Bitumen, Paraffin Wax, Refinery Losses, …

-1.6%-1.7%1.4%1.5%-2.1%0.8%0.1%-0.1%

2010-2020 AAGR

Jet KeroseneOn-road dieselOff-road diesel

Fuel Oil

Motor GasolineNaphtha

LPGOther*

Mbdoe

14.8 Mbdoe

14.6Mbdoe

2010-2020 AAGR-0.1%


LCO vs SR Diesel

51

36 Min

0.845 max

11 wt%

10 wppm

Euro V

15 - 30

13 – 26

0.900 – 0.980

40 – 70

65 – 90

200 – 1200

30 – 70

0.2 - 2.5

LCO

5 – 15Di-Aro+, wt%

15 – 30S as DBTs, wt%

31 – 39API

45 - 60Cetane Number

0.830 – 0.870Density

20 – 30Total Aro, wt%

50 – 300N, wppm

0.5 – 2.0 S, wt%

SR Diesel


Bands of sulfides & thiophenes

DBT bands

BTs bands

Intensity Polarity

SR Diesel

Increasing Boiling Point

BTs bands

Polarity

Intensity

DBT bands

4,6-DiMeDBT

BT C1BT C2BT C3BT C4BT

Increasing Boiling Point

DBTC1DBT

C2DBTC3DBT

C4DBT

Bands of sulfides & thiophenes

LCO

Sulfur SpeciationLCO & SR Diesel

Very low amount of sulfides / thiophenes in LCOsHigh proportion of very refractory sulfur in LCO feedstocks


LCO Feed

Average Cetane Numbers

Paraffins

Iso-Paraffins

Naphthenes

Aromatics

Euro V Spec

0

20

40

60

80

100

120

5 10 15 20 25Carbon Number

Cetane Number


LCO Hydroprocessing Challenges

• High proportion of refractory species • More severe operating conditions• Lower catalyst cycle length if processed in existing units

• High aromatic and polyaromatic content• Higher hydrogen consumption• Higher exotherm in existing reactors• Feed API to be adjusted

• In particular when vegetable oil is blended in the diesel pool

• Low feed cetane• Need for cetane improvement (Euro V specification)


0 5 10 15 20 25 30 35 40 45 50

LCO in Feed, LV%

0153045607590105120

Main Impacts of LCO Co-processing

WABT adjustment

Rel. cycle

• When 35% LCO is co-processed with SR• SOR WABT typically increased by ~ 15°C• Catalyst cycle length typically reduced by 55%

°C Rel. Cycle Length (%)

02.85.68.3

11.113.916.719.422.2








Impact of LCO on H2 Consumption

The H2 consumption can be doubled with 35% LCO co-processed with SR Diesel (as opposed to 100% SR)

100

125

150

175

200

225

250

0 5 10 15 20 25 30 35 40 45 50LCO in Feed, LV%

Rel. H2 Consumption, %








Aromatic Hydrogenation Equilibrium Thermodynamic Limitations

Thermo Limitation at Ref ppH2

Thermo Limitation at 1.4 x Ref ppH2

HDA Target

340 350 360 370 380 390 400 410

HDAro (%)LHSV = 0.6 x Base

LHSV = 1.2 x Base

LHSV = Base

LHSV = 1.2 x Base

LHSV = 0.6 x Base

°C


Options for LCO Upgrading

NiMo

• Med. to high pres.

• Med. to high aro sat.

• Medium pressure

• Max aromatic sat.

• High pressure

• High aromatic sat.

• Ring opening

CoMoNiMo

Noble Metal

NiMo

Cracking Catalyst

Stage 1 Stage 2 Application

• ULSD

• Med. to high ∆ cetane

• ULSD

• Very High ∆ cetane

• Max. diesel yield

• ULSD

• Maximum ∆ cetane

• Low diesel incentive


The Right Catalyst Choice

CoMoHR 626

NiMoHR 648


HR 500 Series Industrial Feedback: First Case Study (1)

HR 648 Main Features

• HR 648 is a NiMo catalyst for cetane improvement based on further improvement of the well-mastered ACE™technology

• New technology for carrier• Improved surface area with an optimized pore distribution• Higher active phase concentration and dispersion

• Improved active phase impregnation technology• Higher activity without booster or organic coating• Optimum interaction between the metals and the catalyst

support• Conventional regeneration / in-situ sulfiding

• 95% activity recovery after single step ex-situ regeneration• Significant regeneration cost savings (similar to HR 626)


HR 548HR 648

6°C

0

50

100

150

200

330 340 350 360

Product Sulfur content, ppm

HR 648 Sample 1HR 648 Sample 2HR 648 Sample 3HR 548

Temperature, °C

>10°C

2.0

2.5

3.0

3.5

4.0

330 335 340 345 350 355 360

Temperature, °C

Delta API

HR 648 Sample 1HR 648 Sample 2HR 648 Sample 3HR 548

HR 548

HR 648

HR 648 is at 6°C more active than HR 548 on HDS

HR 648Improved Hydrogenation activity for

• higher cetane boost• higher volume swell

HR 648 is at 10°C more active than HR 548 on HDA

New NiMo HR 648 Activity Gain


Revamp Options for LCO Processing

• Co-processing in existing HDS• Reactor volume increase required to maintain the unit cycle

length unchanged• Bed distribution to be confirmed for optimum exotherm control• Low pressure unit thermodynamically limited for cetane

improvement / density reduction

• Addition of a second stage with noble metal• Well suited for max cetane improvement / density reduction• Adjustment of the first stage section could be needed to

maintain the unit cycle length unchanged

• Integration of a diesel HDS section into a CFHT• The HyC-10+TM technology


LCO

Prime-DSection

HyC-10+ TM Configuration

10 ppm Sulfur Diesel

VGO

H2 Low SFCC feed

Fuel gas,Naphtha

DieselS<400 wppm

Produces low sulfur FCC feed + Max ULSD simultaneously


HyC-10+ Benefits

• Minimum operating cost• Reduced system pressure• Optimized hydrogen level in the FCC feed (no giveaway)• Low Sulfur Gasoil for ULSG production

• Minimum capital cost• Minimum operating pressure• Equipment count savings

• 2 compressors• 1 HP amine scrubber• 1 HP air cooler

• Maximum flexibility• ULSD processing decoupled from CFHT operation

• Minimum risk of off spec diesel production• Maximum diesel production

• No undercutting of the CFHT diesel product needed• Possibility to co-process additional diesel streams (LCO)


HyC-10+ Commercial Reference

Unit: Europe

Start-up: Nov 2005

Feedstocks:MHC: SRVGO+ aro extractPolishing: Diesel ex MHC +

LCO + AGO + VB Naph

Products:FCC Feed: S < 350 wtppmDiesel: S < 10 wtppm

CI > 51

Overall conversion to FCC feed: 20 - 30 wt%


Scheme Selection Mapping

CetaneNumber (CN)

H2 cons., %wt

ULS

D S

pec

2-Stages HDT / HDA

Single Stage HDTDiesel yields, %vol

100%

Max Diesel yield100% HDA

Lower Diesel yields with

HDK

Max CN withHCK catalystMax CN withHDT catalyst(100%HDA)

HDK area


2- Optimum scheme selection?• One-Stage HDT with Deep HDA• Two-Stage Unit - HDT + HDA

ULSD&

CetaneImprovement

&Max Diesel Production

Prime-D – 40,000 BPSD

1- Deep hydrogenation : 70% HDA from SOR to EOR

EconomicEvaluation

SR Diesel

LCO

Case Study 1/4: Unit Objectives & Preliminary Scheme Selection

+ 2 H2+ 3 H2+ 2 H2+ 3 H2


Case Study 2/4Scheme Comparison – Unit Performances

Base - 0.2%BaseNaphtha yields, vol%

0.7 x BaseBaseUnit pressure

BaseBaseChemical H2consumption, wt%

1.1 x BaseBaseElectric cons.

Base + 0.2%BaseDiesel yields, vol%

0.5 x BaseBaseHydrogen solutionlosses, wt%

Two-StageSingle Stage

Noble metal catalyst for an operation at low temp / low pressure without thermodynamic limitations

Same HDA : identical chemical H2 consumption

Dissolved H2 could be recovered downstream

Slightly better yields in favor of the two-stage configuration (lower operating temp)

Single stage requires a larger make-up compressor & feed pump but a smaller recycle gas compressor


Case Study 3/4Economics Cost Basis

• Reference: 2010 USGC Prices• WTI : 79.9 US$ / bbl• Diesel: 87.6 US$ / bbl• Naphtha: 84.7 US$ / bbl• Natural Gas: 4.4 US$ / MMBtu

• Operating Years: 20 Years

• Discount Rate: 10%

• TCI includes• ISBL investment• Off sites• Engineering fees• Contractor fees• Interest on construction loan• Start-up costs• Initial catalyst cost• Working capital needs

(Noble metal)


Case Study 4/4Scheme Comparison – Economics

Base x 1.09

Two-Stage

Base

Single Stage

Total Capital Investment

Economics are very similar for this case studyA customer specific study is needed for an optimum scheme selection

Base x 1.01BaseNet Present Value @ 10%

Base - 1%BaseInternal Rate of Return, %


Summary

• Covering every type of applications& process objectives

• For Revamp & Grassroot Units• Enabling Energy Optimization and

Scheme Tuning for maximumbenefits

A complete portfolio of process configurations tuned for LCO hydroprocessing

& a new generation of NiMo catalysts

28

LCO Processing Solutions

Documents

LCO Processing Solutions - ERTC 20th Annual · PDF fileLCO Processing Solutions ... Source: Axens & other sources Market Structure 2010 vs. 2020 ... g B o il n gi Po in t B Ts ba nds