UOP Unicracking TM Process Innovations in Hydrocracking Technology

Transcription

1 Kevin Whitehead UOP Unicracking TM Process Innovations in Hydrocracking Technology 15 February 2016 Egypt Downstream Summit & Exhibition 2016 Cairo 2016 UOP LLC. A Honeywell Company All rights reserved. UOP

2 Agenda 1 Development of Enhanced Two-Stage Unicracking Process back on Operation of First Units Recent Innovations UOP

3 Development of Enhanced Two-Stage Unicracking Process 2 1 st Stage Reactors HT HC Recycle Gas Scrubber Two-stage configuration is favoured for full conversion, maximum middle distillate units Higher yields Very cost effective for today s higher capacity units Highly flexible H 2 2 nd Stage Reactor Separator UOP conducted an extensive R&D program to advance two-stage hydrocracking covering Process technology HC To Fractionation Catalysts Result was a step-out increase in value to our customers Recycle Oil 2 UOP

4 How was this Achieved? 3 H 2 1 st Stage Reactors HT 2 nd Stage Reactor HC HC Recycle Oil Recycle Gas Scrubber Separator To Fractionation First stage Optimized operating conditions, catalyst system and first stage conversion Second stage Optimized operating conditions and conversion per pass Developed high selectivity catalyst designed for unique second stage environment New 2 nd stage catalysts with even higher distillate yields now available Process Design Higher energy efficiency Fractionation improvements to allow highest possible conversion & product yield 3 UOP

5 HIGH QUALITY DISTILLATE DEMAND 4 Enhanced Two-Stage Unicracking Process Advancements delivered Diesel yields increased by up to 7 Wt-% Full conversion, constant throughout cycle Hydrogen consumption reduced Catalyst volumes reduced significantly Lower energy consumption Improvements launched in late 2008 Strong commercial interest shown First license signed in April units licensed since launch UOP First units now operating

6 First Commercial Operation Tüpraş Izmit Refinery 5 Residue Upgrading Project New hydrocracking delayed coking complex Heavy opportunity crudes Maximize high quality distillates (Jet A-1, Euro V diesel) Conversion Technologies Enhanced Two-Stage Unicracking Process with integrated diesel hydrotreating and coker naphtha hydrotreating Amec-Foster Wheeler SYDEC TM Delayed Coking Process UOP UOP 7090H-5

7 6 Commercial Results Hydrocracking unit in operation with products on grade in May 2015 All performance tests passed High middle distillate yield achieved All product quality guarantees met Excellent energy performance Unit successfully operating above design throughput Second unit in Asia now successfully started up

8 Improved Distribution with UOP Uniflow Reactor Internals 7 New design offering a step change in performance & speed of installation First sale in 2013 Sold into 16 units (new and revamp) with 6 already operating successfully Example: Installed in 5-bed HC reactor in Nov, Unit operating at 32% higher feed rate compared to previous cycle. Hydrocracking Bed Bed 1 Bed 2 Bed 3 Bed 4 Bed 5 Radial Spread (ºF) New Cycle Top: 1 Bottom: 1 Top: 4 Bottom: 3 Top: 4 Bottom: 2 Top: 4 Bottom: 3 Top: 4 Bottom: 4 Radial Spread (ºF) Previous Cycle Top: 3 Bottom: 18 Top: 2 Bottom: 6 Top: 5 Bottom: 6 Top: 12 Bottom: 36 Top: 11 Bottom: 45 Customer back: We would never have been able to operate this unit where it is today without these new internals. This is a step change for UOP UOP

9 Higher Unit Conversion Enabled By HPNA Management Column LP Steam Recycle Oil Unconverted Oil Patented split shell design in Product Fractionator Concentrates HPNAs in unconverted oil purge from unit Permits operation at very high conversion levels that are constant throughout the cycle Higher product revenues Total steam requirement is reduced Diesel/recycle oil separation is improved Operating experience demonstrates effectiveness of HPNA rejection in purge Sample on left is clean recycle oil Sample on right is HPNA contaminated purge oil UOP

10 Optimised Fractionation Design Reduces Capital and Operating Costs 9 Separation accomplished in hot and cold separators/flash drums is further optimized in the dual zone stripper Cold Traditional Single Stripper Design Stripper Off Gas Product Fractionator Optimised Fractionation Design Hot Fractionator Heater Off Gas Steam Cold Hot Cold Stripper Steam Hot Stripper Steam Light Fractionator Steam Heavy Fractionator Heater Heavy Fractionator Unconverted Oil Unconverted Oil Improvement over traditional design (for 50kbpsd unit): 75% decrease in utilities (FOE) Heater fuel reduced by 79% (savings of 128 MM BTU/h) $5.5 Million savings in capital cost for new equipment Higher diesel yield UOP

11 10 Summary UOP has a long history of successful development and commercialisation of hydrocracking technology and catalysts Over 220 units licensed to date More than 60 full conversion units, many with difficult feeds (HCGO, DAO) Enhanced Two-Stage Unicracking Process is UOP s latest maximum middle distillate technology Provides highest proven yields and conversion in market Two units already operating well UOP continues to innovate and has introduced over 40 process improvements in the last 10 years Profitability Reliability Capital Cost Operating Cost UOP

12 11 UOP UOP