Flexible produc.on of refining products

Transcription

1 Flexible produc.on of refining products The European Fuels Conference 13th Annual Mee.ng Paris, France 14th March 2012 András HOLLÓ a, István VALKAI b, Pavol FEHÉR c, Jenő HANCSÓK d, Márton KRÁR e, Richárd SÁGI f a MOL Group, Product Development manager Hungary b MOL Group, Refinery Technology Development manager - Hungary c Slovnaft, Product Development manager Slovakia d University of Pannonia, Head of MOL Department Hungary e MOL, Product Development engineer - Hungary f MOL, Technology Development engineer - Hungary

2 Agenda! Environment! Role of product por3olio,! Refining produc8on flexibility! Dis8lla8on! FCC! HCK! Conclusions 2

3 Vola.le environment Source: PlaV's and ARGUS 3

4 CEE region Source: Woodmac and MOL data 4

5 ! Produc.on alterna.ves! Naphtha (C 2 =, C 3 =) vs. Aroma.cs! Aroma.cs vs. Gasoline! Naphtha vs. Solvents! JET vs. Solvents! Diesel vs. Hea.ng oil! Bitumen vs. Fuel oil! VGO/Residues vs. fuel oil/bitumen + base oil/paraffin! Blending alterna.ves! LPG vs. Gasoline or Pyrolysis feed! Naphtha vs. Gasoline! JET vs. Diesel! Hea.ng oil components selec.on! Selec.on Fuel oil cuver stocks Role of product poryolio,! Flexible planning/scheduling are key factors in the whole value chain 5

6 Simplified flow diagram of a refinery Gas HDS. and fract. Naphtha HDS Naphtha isom. Cat. reformer Gasoline C3-C4 Naphtha Gasoline AVD JET HDS FCC feed pretreater (HDS/MHC) FCC Gas oil HDS Alkylation/ ETBE Gasoil JET Gasoil Oligomerisation RHCK / Coker VGO HCK Fuel oil Fuel oil Bitumen 6

7 Crude oil AV Distillation Dis.lla.on flexibility Case study Δ ~ 1.2 % Δ ~ 1.5 % Δ ~ 1.6 % Δ ~ 2.0 % Δ ~ 3.0 % LPG Naphtha Jet Gasoil VGO Residue Source: MOL data 7

8 T95 increase of AV s gasoil - Case Study Gasoil surplus in winter + Change of Cold Flow Improvers, critical parameter: CFPP + up to 150 t diesel/ day ( summer cut ) Unit Before the change Aler the change T 95, C Dis8lla8on Unit Dis8lla8on Unit D350, v/v % Dis8lla8on Unit Dis8lla8on Unit Yields, m/m % +0.9% Dis8lla8on Unit Dis8lla8on Unit % Source: Slovnaft data 8

9 Diesel/naphtha flexibility: Flexibility in Gasoil HDS unit Case study! Changes the opera8on parameters in the Stabiliza8on (dis8lla8on) Sec8on (Products Stripper + Vacuum Dryer) of Gasoil Hydrotreater Unit! Cri8cal parameter: flash point, EBP Unit Before the change Aler the change Yield, m/m % +0.7% Diesel Naphtha Diesel / naphtha flexibility + 45 t diesel/day or + 45 t naphtha/day - 0.7% Source: MOL data 9

10 Flexibility in VGO HDS- MHC unit Gas HDS. and fract. Naphtha HDS Naphtha isom. Cat. reformer Gasoline C3-C4 Naphtha Gasoline AVD JET HDS FCC feed pretreater (HDS/MHC) FCC Gas oil HDS Alkylation/ ETBE Gasoil JET Gasoil Oligomerisation RHCK / Coker VGO HCK Fuel oil Fuel oil Bitumen 10

11 Revamp of HDS- MHC unit! Replace/update the reactors internals! increasing the number of used distributor elements! improving their spraying func8on! sta8c mixing elements for mixing of quench gas and reactants! New hot, high pressure separator! Upgrade of furnace! Further reactors (with compressors, heat exchangers, etc.)! Selec8ve catalysts +2-4% conversion Yields: C3-C4 Naphtha Gasoil Bottoms % conversion 11

12 Flexibility in FCC unit Gas HDS. and fract. Naphtha HDS Naphtha isom. Cat. reformer Gasoline C3-C4 Naphtha Gasoline AVD JET HDS FCC feed pretreater (HDS/MHC) FCC Gas oil HDS Alkylation/ ETBE Gasoil JET Gasoil Oligomerisation RHCK / Coker VGO HCK Fuel oil Fuel oil Bitumen 12

13 New LCO selec.ve catalyst! Lower zeolite/matrix (Z/M) ra8o results lower conversion, cracking! Lower amount of bodoms Source: Hunt, D. and co-authors, Catalagram 105, Spring 2009! Higher amount of LCO (1-5%)! (but higher amount of coke) Source: BASF Technical note, 13

14 FCC opera.on in Diesel mode (max. LCO yield)! Target! change of the operational parameters and the catalyst activity to realise higher LCO yield! Diesel mode! Higher feed preheating Lower reactor temperature and pressure Lower catalyst to oil ratio Lower MAT activity! Lower conversion!!! 14

15 Gasoline vs. diesel mode in FCC unit Case Study* -2.7% +5.7% Source: MOL data Diesel / gasoline flexibility t diesel/day or 110 t gasoline/day *9v/v% recycled MCB in feed 15

16 FCC opera.on in LLCO mode Before the change! Descrip8on:! LLCO: light LCO! change of the cut point in FCC dis8lla8on unit gasoline Aler the change gasoline LCO LLCO! Proper8es of FCC LCO/LLCO! ini8al boiling point, density! flash point! polyaroma8cs! cetane index! sulphur! Proper8es of FCC gasoline! final boiling point, density! sulphur! E100! aroma8cs! olefins! RON, MON, RVP Source: MOL data 16

17 FCC opera.on in LLCO mode Case Study Cri.cal parameter: flash point or EBP -4.1% Actual LLCO case 40 Yield, % % 10 0 Fuel gas C3+C4 Gasoline LCO / LLCO Source: MOL data HCO + MCB Coke Diesel / gasoline flexibility t diesel/day or 165 t gasoline/day 17

18 FCC bovoms recircula.on (& cracking) Source: Hunt, D. Catalagram 105, Spring 2009! Recircula8on of bodoms (e.g. HCO, MCB) can result higher conversion à higher LCO yield (4-6%) 18

19 FCC - Oligomerisation! Reac.ons: C3 olefin + C3 olefin C4 olefin + C4 olefin C3 olefin + + C3 olefin C4 olefin + + C4 olefin C6 olefin gasoline C8 olefin C9, C12, C15, C18 olefin JET, diesel C12, C16, C20 olefin! Parameters: C, bar! Catalyst:! Zeolite! Ionic liquids! Others (H 3 PO 4, resins)! Products (aier hydrogena8on): depend on feedstock, catalyst and process parameters! Gasoline: RON: 95-98; MON: 82-84! Kerosene: freezing point: <- 60 C; Smoke point: C! Diesel: CN > 48, aroma8cs <0.4% Sources: Sébastien Huchette: WRA Fuels Conference, 2011; US (Snamprogetti); J.G. Speight: The Chemistry and Technology of Petroleum, 4th edition 19

20 Flexibility in VGO HCK unit Gas HDS. and fract. Naphtha HDS Naphtha isom. Cat. reformer Gasoline C3-C4 Naphtha Gasoline AVD JET HDS FCC feed pretreater (HDS/MHC) FCC Gas oil HDS Alkylation/ ETBE Gasoil JET Gasoil Oligomerisation RHCK / Coker VGO HCK Fuel oil Fuel oil Bitumen 20

21 Flexibility in HCK unit Case study Revamp:! New reactor internals! Further catalyst beds! New high mid- dis8llate selec8ve catalyst! Revamp the high and low pressure separators Incremental diesel t mid- dis8llate/ day (capacity increase) Yield, % Before revamp - Naphtha mode After revamp - Naphtha mode After revamp - Diesel mode Diesel / gasoline flexibility + 60 t diesel/day or t gasoline/day Gases Naphtha Kerosene Gas oil UCO Source: Slovnaft data 21

22 Conclusions! Vola.le environment! Imbalance?! Flexible product poryolio! Possibili.es in refining units! Is it enough? 22

23 Thank you for your aden8on! 23