Quenching Our Thirst for Clean Fuels - fipi.org.in Session/James... · Jim Rekoske Quenching Our Thirst for Clean Fuels ... 22 April 2016 Petrofed Smart Refineries New Delhi,

© 2016 UOP LLC. A Honeywell Company All rights reserved.

Quenching Our Thirst for Clean FuelsJim RekoskeVP & Chief Technology Officer

Honeywell UOP

22 April 2016 Petrofed Smart Refineries New Delhi, IndiaUOP 7200-0

India’s Demand for Clean Gasoline1

Drivers Trends- Improved economic outlook –

higher spending on Fuels and Plastics – 7.6% annual GDP growth possible over next 5 years

- Need for air quality Improvement – regulations for Fuel specs upgrade

- Dependence on imported crude

- Refinery utilization at or near 100% (nominal basis) for many units

- Demand has caught up with supply – need for new investment planning

- Nationwide upgrade to BS IV fuel by Q1’17 and EBSVI by 2020

- Maximize value from crude imports through efficiency, upgrading

- Automobile sales growth of ~10%

- Gasoline growth outpaces diesel

A Balancing Act: Bharat VI Specs with Maximum Profit

Many constraints – optimal solution?

2

UOP Solutions EtherMax™ unit InAlk™ Unit AlkyPlus™ Unit Hydrotreating Platforming™ Unit Penex™ Unit IsomEx™ Unit Par-Isom™ Unit Selectfining™ Unit


More Oxygenates

More Oxygenates

Remove before or after reformer


Limit on C4s & C5s in IsomerateLimit on C4s &

C5s in Isomerate

Limit on FCC Gasoline


Limit on FCC Gasoline or Increase Desulfurization

Severity


SeverityLimit on ReformateLimit on

Reformate

Limit on “lights”Limit on “lights”

Benzene1 vol%

RVP60 kPa

Olefins18 vol%

Sulfur10

wt-ppm

Aromatics35 vol%

Oxygenates2.7 vol%

DistillationE70/E100

How can I blend more FCC Gasoline and control olefins and sulfur?

How do I drive octane yield and aromatics to the limit?

Where is the rest of my octane going to come from?



3



More Oxygenates

More Oxygenates




C5s in Isomerate




Severity



Reformate


Benzene1 vol%

RVP60 kPa

Olefins18 vol%

Sulfur10

wt-ppm

Aromatics35 vol%

Oxygenates2.7 vol%







4



More Oxygenates

More Oxygenates




C5s in Isomerate




Severity



Reformate


Benzene1 vol%

RVP60 kPa

Olefins18 vol%

Sulfur10

wt-ppm

Aromatics35 vol%

Oxygenates2.7 vol%





Indian Refiner Gasoline Pool Requirements

How do we manage both S and olefins in FCC gasoline?

5

BS III BS IV BS VI

Density @ 15 °C kg/m3 720-775 720-775 720-775

E-70E-100E-150

% vol% vol% vol min

10-4540-70

75

10-4540-70

75

10-4540-70

75

FBP °C 210 210 210

Sulfur ppm max 150 50 10

RON Min 91 91 91

MON Min 81 81 81

RVP @ 38 °C kPa 60 60 60

Benzene vol % max 1 1 1

Aromatics vol % max 42 35 35

Olefin vol % max 21 21 18

Oxygen wt% max 2.7 2.7 2.7

Coker Naphtha

Coker Naphtha

OtherOther

FCC NaphthaFCC Naphtha

Sources of sulfur in typical gasoline pool

• FCC naphtha represents ~40% of the volume of the typical refinery’s gasoline pool

UOP Confidential Information

UOP’s Portfolio of FCC Naphtha Desulfurization Technologies

•MeroxTM process- extraction or sweetening of mercaptan components of

FCC Light Naphtha (LCN) and Mid-cut Naphtha (MCN)- Does not remove thiophenes

•SelectFiningTM process- desulfurization and octane retention for FCC FBR,

MCN or HCN

Technology choice is based on octane requirements, feedstock composition, product values and required desulfurization.


SelectFining Technology Overview

Optimum Flowscheme and Catalysts for particular needs

7

• Achieve low S target in Gasoline Pool• Can achieve <10 wt-ppm S in FCC Gasoline

• Maximum Octane Retention to Meet Specifications• Lowest Hydrogen Consumption

• Flowschemes for Various Feedstocks Optimized for Maximum Economical Value

• One Stage for low sulfur feedstock (or 90% HDS)• Two Stage for high sulfur feedstock and 90% HDS• Depends on feed characteristics and product requirements

• High Stability Specialized Catalysts• Specialized Co/Mo catalyst with optimized metals levels and distribution• Suitable for all FCC naphtha hydrotreating applications where selectivity to

favor desulfurization over olefin saturation is required


Issues Relating to Hydrotreating FCC Naphtha

Sulfur RemovalSulfur Removal

+ 6H2+ 6H2 H2S +H2S + + Heat+ HeatSS

DesirableDesirableSulfurSulfur

Olefin SaturationOlefin Saturation

+ H2+ H2

CH3CH3

CH3 – CH = C – CH3CH3 – CH = C – CH3

––

CH3CH3

CH3 – CH2 – CH – CH3CH3 – CH2 – CH – CH3

––

UndesirableUndesirableOctaneOctane

Octane loss is dependant on feed/product sulfur contents, and quantity/types of naphtha’s sulfur and olefin species!


Relative Reactivity of S and Olefins in FCC Gasoline

Incr

easi

ng R

eact

ivity

Increasing Molecular Weight

R-SH

Olefins

C5

C6

C7

C8

SulfurR-S-S-R

C9

S

S

S

S


UOP One-Stage SelectFining Process

Typical for low sulfur feeds and/or 90% HDS Flowscheme and operating

conditions are similar to NHTs

Steam

ChargeHeater

SelectFiningReactor

MakeupHydrogen

LeanAmine

Debutanizer

LightEnds

Low SulfurNaphtha

Feed

Recycle GasScrubber

RichAmine

ProductSeparator

RecycleCompressor

DieneSaturation

ReactorHYT-2117

N-200 HYT-2018 (S-200)HYT-2118

10


Impact of % Desulfurization on Olefin SaturationSingle-Stage SelectFining Performance

% O

lefin

Sat

urat

ion

10095 96 98 99

100

20

60

80

97% Desulfurization

FBR FCC NaphthaSulfur = 1800 wppm

Single-Stage SelectFining Unit

40

18 ppm36 ppm54 ppm72 ppm90 ppmTypical Product S


H2S Impacts Olefin Retention

18.5

19.5

20.5

21.5

0.0% 0.4% 0.8% 1.2%

Tota

l Pro

duct

Ole

fins,

wt%

Volume Percent H2S

Understanding recombination is critical as it directly impacts olefin retention

Feedstock23.8 wt-% Olefins2206 wt ppm Sulfur


12

• Mitigate with two HDS stages – strip out H2S between stages, as dictated by feed sulfur and product sulfur and octane targets

• Mitigate with polishing reactor downstream of SHDS

H2S

+ H2S

H3CCH3

H3C

H3CCH3

H3CH3C

CH3H3C

SH

+ H2+ H2

Octane

Mercaptan Recombination


13

UOP Two-Stage SelectFining Process14

Steam

ChargeHeater

First StageReactor

RecycleCompressor

LeanAmine

Debutanizer

LightEnds

Low SulfurNaphtha

Feed

Recycle GasScrubber

RichAmine

ProductSeparator

Second StageReactor

InterstageSeparator

MakeupHydrogen

DieneSaturation

Reactor

Typical for high sulfur feeds with 90% HDS Interstage H2S Stripping Mitigates Recombination

HYT-2117HYT-2018HYT-2118

HYT-2119


Impact of % Desulfurization on Olefin SaturationSingle-Stage vs Two-Stage SelectFining Performance

% O

lefin

Sat

urat

ion

10095 96 98 99

100

20

60

80

97

Two-Stage SelectFining Unit

% Desulfurization

FBR FCC NaphthaSulfur = 1800 wppm

Single-Stage SelectFining Unit

~ 2 RONC

~ 1 RONC40

18 ppm36 ppm54 ppm72 ppm90 ppmTypical Product S


SelectFining – Gasoline Desulfurization Optimized, Simply

• Flexible configurations to meet the most demanding challenges of octane retention and sulfur removal

• State-of-the-art, commercially proven catalysts with best-in-class performance

• Configurations in combinations with UOP Merox™ sweetening technology- Enables “molecule management” – directing the sulfur species to the most

efficient conversion process- Unique offerings which can lower both capital and operating costs



17



More Oxygenates

More Oxygenates




C5s in Isomerate




Severity



Reformate


Benzene1 vol%

RVP60 kPa

Olefins18 vol%

Sulfur10

wt-ppm

Aromatics35 vol%

Oxygenates2.7 vol%





UOP’s Recent Platforming Innovations18

UOP 7299-18 Project IRR improved by 2 - 6 %

Naphtha Feed

CFE

Convective Charge Heater

Modified CatMax™ Internals

Recycle Gas

Reactor Effluent

Cyclemax™ III CCR

Convective Charge Heater19

UOP 7299-19 Estimated savings is $5MM for 50,000 BPSD UnitUOP Confidential Information

Conventional Conventional Convective Charge Heater

Convection

Product Condenser

Recycle Gas

To Separator

Naphtha CFE

To Stack

Stabilizer Preheat

Steam Convection Bank

Charge Heater

IH #1 IH #2 IH #3 To RX4

To RX1

• Features – Charge heater moved to convection section

displacing portion of steam generation – Temperature control achieved by stack gas recycle– Radiant section fouling reduced with stainless

steel tubes– 1 less heater box

• Benefits: – Lower capital cost – Reduced plot space – Less fuel fired – Lower emissions*

*Applicability for individual units to be evaluated

Meeting the Expansion Challenge:Example Max Throughput Revamp

20

UOP 7299-20 Convective heater was a key part of this revampUOP Confidential Information

Capacity raised to 190% nameplate– Unit met / exceeded guaranteed

revamp performance

Key features:– R-264 catalyst– Reactor Bypasses with Rx Addition– CCR expanded 1500 to 3250 lb/hr– Radiant–Convection fired heater– Add a 4th Net Gas Compressor – which also

supplies additional recycle gas

UOP’s revamp experience:– Over 50 CCR Platforming Units and over

25 Regenerator revamp designs

Platforming Innovations Summary• UOP continues to improve best-in-class naphtha reforming technology

• Innovations include all critical sections of the process:- Regeneration- Catalyst- Reactor / Internals- Heaters

• Innovations drive substantial incremental customer value

• Innovations enabled because of unique R&D / Engineering / Equipment interaction



22



More Oxygenates

More Oxygenates




C5s in Isomerate




Severity



Reformate


Benzene1 vol%

RVP60 kPa

Olefins18 vol%

Sulfur10

wt-ppm

Aromatics35 vol%

Oxygenates2.7 vol%





Where should your C7s go?23

UOP 7299-23C7 Management is critical for meeting BS VI specs

C5 - C6

82

92

RONC

Gasoline Blending

Isomerization330 Units

PI-242PI-244 Feed

To Separation

Makeup Gas

Par-Isom Unit

Light Naphtha

Cl

Make-Up Gas

Stabilizer

Dryers

Penex ReactorsDryers

To Scrubber

To Gasoline or DIH

I-122

I-82I-84

Penex Unit

• None• Once Through

OT

•DIHRecycle

•DIP•Super DIHRecycle

Hydrocarbon Recycle Option

C6 – C11

106+

93

Gasoline Blending

BTX and Gasoline Blending

Reforming304 units

R-264R-284

R-234R-254

Platforming Unit with Cyclemax™ III CCR

CCR

Naphtha Feed

RXs

SEP

Heaters CFE

R-334

C7s?

Processing Feed with Low Light to Heavy Naphtha Ratio in Naphtha Complex

24

UOP 7299-24 Naphtha Complex achieves 92 RONC pool without MTBE

Total Gasoline Yield = 90 Wt-%Meeting EURO V specNo MTBE added

100% Feed

Platforming Unit

95 RONC

100%92 RONC

65% Feed

35% Feed

C4s

NHT

Penex Unit 89+ RONCN

ap S

plit

DIP

SDIH

Naphtha Complex with Penex/IsomEx Process Maximizes Gasoline Yield

25

UOP 7299-25 IsomEx™ achieves higher yield and RONC gasoline without MTBE

Gasoline Yield ~ 95 Wt-%Meeting EURO V specNo MTBE added

CCR Unit

Penex Unit

44%92 RONC

55% Feed

C4s

89+ RONCIsomEx Unit

89-91 RONC

92+ RONC

56%95 RONC

80+ RONC

95 - 102 RONC

DIP

SDIH

DIH

p

15% Feed

DIP

Nap

Spl

it

30% Feed

Nap

Spl

it

NHT

Alternative schemes are available

UOP IsomEx: C7 Solutions for Octane Challenges• Simultaneous increase of gasoline yield and quality

- Meets stringent Euro V specifications without MTBE addition

- Increases naphtha block gasoline yield from 90 to 95%

- Upgrades 56% of the product to premium gasoline (95 RONC)

• Built on generations of paraffin isomerizationexperience

- Proven process configuration- Proven catalysts, yields and stability

• Molecule management: direct the molecules to the perfect technology.

26

27.0 27.825.2

14.3 16.2 16.6

05

101520

2530

3540

4550

2007 2008 2009 2010 2011 2012C

7+ in

Rea

ctor

Fee

d, W

t-%


UOP has the proven, commercialized solutions

27



More Oxygenates

More Oxygenates




C5s in Isomerate




Severity



Reformate


Benzene1 vol%

RVP60 kPa

Olefins18 vol%

Sulfur10

wt-ppm

Aromatics35 vol%

Oxygenates2.7 vol%


UOP technologies can help refiners meet the rigorous specifications of Bharat VI while maintaining or increasing profit

The principle of Molecule Management – directing molecules to the most efficient, advanced technology – provides real benefits

Complex processing / blending solutions require a strong partner with broad experience…

28

UOP 7200-28

Documents

Quenching Our Thirst for Clean Fuels - fipi.org.in Session/James... · Jim Rekoske Quenching Our Thirst for Clean Fuels ... 22 April 2016 Petrofed Smart Refineries New Delhi,