WORLDWIDE REFINERY PROCESSING REVIEW. Third Quarter 2013

Transcription

1 WORLDWIDE REFINERY PROCESSING REVIEW Monitoring Technology Development and Competition in One Single Source Third Quarter 2013 Hydrotreating, and Product Treating and Blending Plus Latest Refining Technology Developments & Licensing HYDROCARBON PUBLISHING COMPANY Translating Knowledge into Profitability SM P.O. Box 661 Southeastern, PA (U.S.A.) Phone: (610) / Fax: (610)

2 Review Hydrotreating, and Product Treating and Blending 1. Introduction Hydrotreating MARKET/TECHNOLOGY TRENDS & OPPORTUNITIES Introduction Market Conditions and Outlook Refined Products Legislation Transportation Fuels Bunker Fuels Refined Products Demand Increasing Middle Distillate Production Diesel Supply and Demand United States European Union Russia Middle East Asia-Pacific Renewable and Bio-based Diesel and Jet Fuel Renewable Diesel and Bio-based Diesel Renewable Jet Fuel and Bio-based Jet Fuel Shifting Crude Slate Opportunity Crudes Tight or Shale Oil Hydrotreating Capacity Expansion Construction Projects and Unit Revamps Hydrogen Demand Hydrotreating Catalysts Market Technology Competition, Directions, and Future Prospects Conventional Hydrotreating Heavy Oil/Resid Hydrotreating Renewable Feed Hydrotreating Conclusion STATE-OF-THE-ART TECHNOLOGY Introduction Commercial Catalysts and Guard Materials Advanced Refining Technologies SmART ApART StART Albemarle STARS Series NEBULA Series Combined Implementation KF 901, KF 902, KF 905, KF KF Guard Catalysts i

3 Axens Impulse HR 400 Series HR 500 Series HR 600 Series HR 900 Series AX 740 Hydrogenation Catalysts ACT Grading Materials BASF Chevron Lummus Global Clariant Cosmo Oil Criterion Catalysts & Technologies CENTINEL CENTINEL GOLD ASCENT CENTERA SDD-800/SDD Selective Hydrogenation Catalysts Guard Catalysts Crystaphase Products ExxonMobil RT OCTGAIN Catalysts Haldor Topsøe Coker Naphtha Hydrotreating Naphtha and Kerosene Production FCC Feed Pretreat ULSD Production Reduction of Diesel Density and Aromatics Hydrocracker Pretreating Graded Bed Products for Pressure Drop Control JGC Catalysts & Chemicals Industries Johnson Matthey Catalysts Nippon Oil Sinopec Saint Gobain NorPro TRICAT UOP Summary of Commercially Available Hydrotreating Catalysts Auxiliary Catalyst Technology Advanced Refining Technologies PHOENIX Albemarle EasyActive React Stax Axens Criterion Catalysts & Technologies Eurecat Sulficat Totsucat Haldor Topsøe ii

4 Orient Catalyst/Advanced Refining Technologies Oxford Catalysts TRICAT Inc TRICAT Regeneration Process XpresS Commercial Process Technology Albemarle UD-HDS HDAr Cold Flow Improvement PLEX Reactor Internals Axens Prime-G Prime-D Benzene Saturation Coker Naphtha Hydrotreating EquiFlow Reactor Internals Chevron Lummus Global DuPont Clean Technologies ExxonMobil Research & Engineering/KBR GO-Fining HYDROFINING SCANfining EXOMER OCTGAIN MIDW Fushun Research Institute of Petroleum and Petrochemicals (Sinopec) FHI Diesel Hydro-upgrading/Isodewaxing Process FRS OTA OCT-M GTC Technology Haldor Topsøe Conventional Hydrotreating Coker Naphtha Hydrotreating Diesel Dewaxing Distillate HDS/HDA Aroshift Reactor Internals Instituto Mexicano del Petróleo JGC Catalysts & Chemicals JUST Refinery Gas Oil Ultra Deep Desulfurization GEFINERY LCO Upgrading Lummus Technology, a CB&I Company Conventional Hydrotreating Benzene CDHydro LCN CDHydro/CDHDS and CDHDS MOL Neste Jacobs Nippon Oil RIPP/Sinopec iii

5 SK Corp Shaw Group/BASF Shell Global Solutions Hydrotreating Process SMDH Pyrolysis Hydrogenation Unit Reactor Internals UOP MQD Unionfining VGO Unionfining ISAL SelectFining BenSat Unisar Unicracking/DW UltraMix Reactor Internals Summary of Hydrotreating Process Technologies Commercially Available Advanced Control and Optimization Systems Aspen Technology Axens KBC Advanced Technologies Repsol YPF Resid Hydrotreating Coprocessing of Renewable Feed with Conventional Petroleum Feed Advanced Refining Technologies Albemarle Axens BP ConocoPhillips Haldor Topsøe Green Diesel Coprocessing Unit Standalone Renewable Diesel Hydrotreater Neste Oil Petrobras Repsol YPF UOP/Eni UPM Summary of Renewable Feed Hydrotreating PLANT OPERATIONS AND PRACTICES General Hydrotreating Operations Feed Considerations, Process Configuration, and Hardware Feedstock Characterization Pre-hydrotreated Feeds Upgrading Tight Oil Feed Drum Blanketing Gas Reactor Configuration Minimize Fouling of Reactor Internals Twisted Tube Exchanger Bundles for Preheat Service Thermal Enhancement System to Improve Heat Recovery iv

6 Catalyst Management Measuring Hydrotreating Catalyst Activity Protecting HT Catalysts from Contamination Determining and Mitigating HDS Catalyst Deactivation Minimizing HDS Activity Loss from Low Sulfur Feed In situ Catalyst Sulfiding vs. Ex situ Presulfiding Comparison of Various Sulfiding Agents Using Regenerated Catalyst Dry Dump vs. Wet Dump Catalyst Change-out Procedures Catalyst Dense Loading Operating Conditions and Hydrogen Consumption Effect of Process Severity/Variables on Hydrotreater Performance Using High-purity Hydrogen and/or Adjusting Hydrogen Partial Pressure Optimizing the Hydrogen-to-oil Ratio Mitigating High Temperature Hydrogen Attack Accurately Measuring Hydrogen Consumption in Hydrotreaters Membranes for H 2 Recovery from Hydrotreaters Operational Monitoring and Upset Detection Process Analyzer Placement Reactor Effluent Sampling Accurate Level Measurements in a Cold High Pressure Separator Maldistribution in Hydrotreaters Reactor Pressure Drop Buildup: Causes and Remedies Detecting and Mitigating Leaks in Equipment Fouling in Feed/Effluent Exchangers Ammonium Chloride Fouling in Effluent Exchangers and H 2 Gas Compressors Best Practices and Troubleshooting Reviewing and Updating Unit Operating Procedures Criteria for Selecting Remote Manual and/or Auto Depressuring Equipment and Instrumentation Interruption of Operations (Emergency or Planned) and Recommended Actions Minimizing Exposure Risks during Reactor Shutdowns Preventing Flaring during Unit Startup or Shutdown Procedures Distillate Hydrotreating Diesel Quality Requirements Cetane ULSD Cold Flow Properties ULSD Haze Point Minimizing Diesel Color Degradation Logistics Hardware Considerations Adjusting Hydrotreater Internals to Improve Diesel Production Limitations of Single Bed or Undersized ULSD Reactors Determining Sufficient Reserve Quench in ULSD Hydrotreaters Using Advanced-phase Separation Techniques Fouling on Disposable Feed Filters Improving Energy Efficiency Catalyst Management Feed Considerations Options for Converting FCC LCO to ULSD Processing Distillate and Naphtha Blends in a Diesel Hydrotreater Coprocessing Renewable Feedstocks v

7 Process Monitoring Calculating Diesel Cetane Number from a Diesel Hydrotreater Revamps for ULSD Production Case Study Case Study Case Study Case Study Case Study Case Study Case Study Ultra-low Sulfur Kerosene Production Naphtha Hydrotreating Processing Coker and Visbreaker Naphtha Measuring Silicon Content in Coker Naphtha Hydrotreating FCC Naphtha Octane Loss and Other Problems Minimizing Fouling to Increase Catalyst Run Length Separating Stripping and Splitting Applications Gas Oil Hydrotreating Modifying a FCC Feed Pretreater to Increase Yield of Diesel Impact of Feed Hydrotreatment on FCC Product Aromatics Content FCC Feed Pretreatment vs. FCC Gasoline HDS Impact of Tier III Gasoline Standards on FCC Feed Pretreaters Reducing the Endpoint in Gas Oil Hydrotreaters Hydrotreating Heavy Coker Gas Oil Predicting the Yield Pattern When Coprocessing LCGO in a VGO FCCU Improved Operation of a VGO Hydrotreater Operating a VGO Hydrotreater in Blocked Mode REFINING R&D ALERT! Introduction General Hydrotreating Process Designs Stripping and/or Fractionation Process Integration Miscellaneous Process Schemes Catalyst Formulation and Preparation Phosphorus-modified Carrier Supports Patents Research Literature Metal Oxides Carrier Supports Patents Research Literature Promoters Transition Metal Sulfides Zeolites Patents Research Literature NiP-containing Catalysts Miscellaneous Catalyst Innovations Patents Research Literature vi

8 Catalyst Activation Procedures Catalyst Regeneration Naphtha and Pyrolysis Gasoline Hydrotreating Middle Distillate Hydrotreating (Including ULSD Production) Process Patents Research Literature Catalyst Patents Research Literature LCO and Light Gas Oils Hydrotreating Process Catalyst Heavy Oil Hydrotreating Process Patents Research Literature Catalyst Patents Research Literature Resid Hydrotreating Patents Research Literature Renewable Feed Hydrotreating Process Patents Research Literature Catalyst Patents Research Literature WORLDWIDE INSTALLED CAPACITY CONSTRUCTION Recent Construction Activity Completed Construction Projects REFERENCES Product Treating & Blending MARKET/TECHNOLOGY TRENDS & OPPORTUNITIES Introduction Market Conditions and Outlook Technology Competition, Directions, and Future Prospects Product Treating Commercial and Near-commercial Technologies Trends in R&D Adsorptive Desulfurization Oxidative Desulfurization Membrane Desulfurization Ionic Liquid Extraction Benzene Removal vii

9 Product Blending Commercial Technologies Trends in R&D Conclusion STATE-OF-THE-ART TECHNOLOGY Introduction Product Treating Commercial Processes Axens Sulfrex Sweetening Sweetn'K OATS ExxonMobil GTC Technology Inc Hielscher Ultrasonics Indian Oil Corp Merichem Chemicals & Refinery Services Jet Fuel Treating Gasoline and LPG Treating Reformer and Alkylation Products Treating Petreco Process Systems Sinopec UOP Merox Extraction Sweetening Fixed-bed Minalk Caustic Free Merox Liquid-liquid Sweetening Sulfur-X Catalysts, Adsorbents, and Other Technologies Axens Chemical Products Industries, Inc CSIR-Indian Institute of Petroleum Gas Technology Products No Heat Resources UOP Emerging Technologies Alternative Petroleum Technologies Grace LyondellBasell Industries RTI SulphCo UniPure Energy Summary of Commercial Product Treating Processes Product Blending PLANT OPERATIONS AND PRACTICES General Non-hydrogen Product Treating Predicting Sulfur Type, Levels in FCC Products Methods of Removing Sulfur Compounds Without Hydrogen Analyzing Product Streams for Sulfur and Aromatics viii

10 LPG Treating Minimizing Caustic Consumption in Product Treating Effects of H 2 S Content on Deethanizer Mercury Removal Commercial Methods of Removing COS from Propane/Propylene Streams Gasoline Treating Meeting 10 ppm Sulfur in Gasoline Liquid-Liquid Coalescence to Obtain On-spec FCC Gasoline Utilizing Octane-enhancing FCC Additives in Product Treating Applications Natural Gasoline Processing Problems Minimizing Gasoline Color Degradation Middle Distillates Treating Meeting Cloud Point and CFPP Specifications with Additives Meeting Jet Fuel Specifications Minimizing Jet Fuel Color Degradation Product Blending Systematic Approach to Upgrading Refinery Blending Operations Benefits of Inline Blending over Storage Use of Process Analyzers and Models FTIR vs. Raman Spectroscopy for Inline Blending Accurately Predicting Cetane Improver Impact Gasoline Blending Optimal Gasoline Blending Effect of RVP on Gasoline Loss During Blending Summer Management of RVP and Butanes Blending Opportunities for Heavy Naphtha Online Analyzers Used for Gasoline Blending Accurately Predicting Gasoline Octane Using ANN Models Bunker Fuels Blending Biofuels Blending Flexible Fuel Terminals for Biofuels Blending European Union Measuring Instruments Directive Ethanol Blending into the Gasoline Pool Increasing Ethanol Blending Corrosion Gasoline Blendstocks Gasoline Pool Components Isobutanol as an Alternative to Ethanol Biodiesel Blending into the Diesel Pool Predicting Viscosity for Heavy Blends Incorporating Logistics in Blending Optimizations Systems REFINING R&D ALERT! Introduction Product Treating Adsorptive Desulfurization Gasoline Patents Research Literature Diesel Patents Research Literature Multiple fuel application Patents ix

11 Research Literature Oxidative Desulfurization Catalysts Patents Research Literature Process Patents Research Literature Ionic Liquid Extraction Patents Research Literature Membrane Desulfurization Process Patents Research Literature Novel material Patents Research Literature Benzene Removal Reactive Patents Research Literature Non-reactive Patent Miscellaneous Scavengers Patents Other Patent Research Literature Other contaminants Research Literature Product Blending Blending and Process Control Patents Research Literature Components/Additives Patents Research Literature CONSTRUCTION Recent Construction Activity Completed Construction Projects REFERENCES Latest Refining Technology Developments & Licensing FLUID CATALYTIC CRACKING HYDROCRACKING CRUDE DISTILLATION DEASPHALTING HYDROGEN PRODUCTION AND PURIFICATION GAS CONCENTRATION PLANT/VAPOR RECOVERY x

12 4.7 LUBE PRODUCTION AROMATICS, LIGHT OLEFINS, AND ETHANOL PRODUCTION PROCESS CONTROLS AND SIMULATION XTL (BIOMASS-, GAS-, AND COAL-TO-LIQUID) BIOFUELS PRODUCTION CO 2 CAPTURE AND CONVERSION PLANT SAFETY REFERENCES xi

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