New Residue Up-grading Complex at European Refinery Achieves Euro 5 Specifications

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1 New Residue Up-grading Complex at European Refinery Achieves Euro 5 Specifications Presented by: Gert Meijburg Technical Manager - Criterion Co-author: John Baric - Licensing Technology Manager - Shell Global Solutions BV

2 AGENDA HDT 1,2,3 Hydrocracker margin and Feed selection Case Study: SDA and Hydrocracking at Grupa Lotos Gdansk Refinery, Poland Conclusions

3 Hydrocracker margin Margin is created by upgrading relatively low value feedstocks into high value clean products Low value feedstocks, e.g.: Heavy VGO Heavy Coker Gas Oil Heavy Cycle Oil De-asphalted Oil High value products, e.g.: Middle distillates (Euro V Diesel, jet A-1 kero) Naphtha (gasoline blending stock) Unconverted oil (for lubes or chemical feedstock)

4 How to improve Margin? Maximize utilization Increase throughput, Improve reliability Optimizing yield to favorable products In Europe: maximize Diesel and Kerosene Processing lower value feeds Deep Cut HVGO Products from bottoms conversion processes De-asphalted oils Heavy Coker gas oils FCC cycle oils Opportunity crudes

5 The Price of Processing Low Value Feeds Low value feeds challenge the catalyst system: High levels of metals such as Ni and V irreversible poison the catalyst system and can cause pressure drop problems High levels of Coke precursors cause increased deactivation of catalysts and possible limit cycle length Refractive molecules require higher operating severity and affects cycle length

6 Key to processing Low Value Feeds in the hydrocracker is the catalyst system A well designed demetallization catalyst system will protect the pretreat catalyst protecting cycle length A stable high activity pretreat catalyst will be maintain activity during the cycle and allow for a low nitrogen and aromatics slip to the hydrocracking catalyst Properly selected Demet and Pretreat catalyst will allow the use of selective cracking catalysts that will give a high yield in Diesel and kero during a viable cycle length

7 GRUPA LOTOS, GDANSK REFINERY, POLAND 7

8 GRUPA LOTOS: RESIDUE UPGRADING PROJECT Primary Objective: To a make a step change in the long-term profitability of the refinery by installation of major upgrading facilities Key Strategic Drivers: Enhance Financial Performance Meet future product specs Reduce Emissions Reduce HSFO exports Expand employment/business

9 GRUPA LOTOS: RESIDUE UPGRADING PROJECT LOTOS Post 10+ Program Refinery Configuration Naphtha HMU Hydrogen Atmospheric residue HVU VGO HCU Jet Diesel DAO Vacuum residue ROSE Asphaltenes

10 GRUPA LOTOS: SHELL DAO HYDROCRACKER Fresh feed H 2 H 2 H 2 Gas + LPG LN HN HDM Jet DSL Hydrowax R-01 R-02 R-03 Demet Pretreat Cracking

11 GRUPA LOTOS: SHELL DAO HYDROCRACKER Sustained performance: All Shell guarantees met Product quality still at SOR levels First cycle, 3+ years, in progress Demet reactor catalyst change Ongoing optimisation TWO KEY SUCCESS FACTORS: 1. Understanding DAO feed 2. Understanding process variables Property (Urals) VGO DAO Specific gravity Sulphur, %wt Nitrogen, ppmw 1,573 2,664 Total Ni + V, ppmw <1/<1 6/11 Conradson carbon, %wt C7 Asphaltenes, wppm <500 <200 T95%, C

12 GRUPA LOTOS HYDROCRACKER SUSTAINED PERFORMANCE Average Ni+V content in Demet effluent <0.5ppmw HDM efficiency >99.4%

13 GRUPA LOTOS HYDROCRACKER SUSTAINED PERFORMANCE DEMET Catalyst activity HDN HDS HDCCR

14 GRUPA LOTOS HYDROCRACKER SUSTAINED PERFORMANCE

15 GRUPA LOTOS HYDROCRACKER SUSTAINED PERFORMANCE Stable temperature performance for both pretreat and cracking catalysts.

16 GRUPA LOTOS HYDROCRACKER SUSTAINED PERFORMANCE

17 GRUPA LOTOS HYDROCRACKER SUSTAINED PERFORMANCE

18 GRUPA LOTOS HYDROCRACKER SUSTAINED PERFORMANCE

19 Grupa LOTOS Hydrocracker - Conclusion Proven performance from combination of SDA and hydrocracking KBR + Shell proposed configuration deliverssustained operating performance and product specs for over 3 years single-run time

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