Innovative & Cost-Effective Technology for Producing Low Sulfur Diesel

Transcription

1 Innovative & Cost-Effective Technology for Producing Low Sulfur Diesel Matthew Clingerman, DuPont Clean Technologies EGYPT DOWNSTREAM SUMMIT & EXHIBITION February 2016 Copyright 2016 DuPont. The DuPont Oval Logo, DuPont and The miracles of science are trademarks or registered trademarks of E. I. du Pont de Nemours and Company or its affiliates. All rights reserved.

2 Agenda 1 Introduction to DuPont Clean Technologies 2 Meeting Diesel Specifications 3 IsoTherming Hydroprocessing Technology 4 Case Studies 5 Summary Copyright 2016 DuPont. All rights reserved. 2

3 Our Purpose Through science and engineering, we solve some of the world s greatest challenges. DuPont has been bringing world-class science and engineering to the global marketplace in the form of innovative products, materials, and services since National Geographic Image Copyright 2016 DuPont. All rights reserved. 3

4 DuPont 2015 Segment Sales DuPont Agriculture ($9.8B) DuPont Nutrition & Health ($3.3B) Core Markets: Seeds Agricultural Chemicals Core Markets: Food & Nutrition Products DuPont Electronics & Communications ($2.1B) Core Markets: Photovoltaics Consumer Electronics Advanced Printing Displays $25B DuPont Industrial Biosciences ($1.2B) Core Markets: Industrial Enzymes BioBased Materials DuPont Performance Materials ($5.3B) DuPont Safety & Protection ($3.5B) Core Markets: Transportation Industrial Packaging Electrical/Electronics Core Markets: Industrial Construction Military & Law Enforcement Transportation Consumer Copyright 2016 DuPont. All rights reserved. 4

5 DuPont Clean Technologies IsoTherming Hydroprocessing Technology STRATCO Alkylation Technology MECS Sulfuric Acid Technology BELCO and DynaWave Scrubbing Technologies Text 1 Text 1 Text 1 Text 1 Improved hydroprocessing technology for the production of low sulfur diesel Leading technology for the production of lowsulfur, high octane gasoline blend stock Leading technology for the production of sulfuric acid and related high performance products Leading technologies for air emissions reduction in FCCs & SRUs for SOx, NOx, and particulates Copyright 2016 DuPont. All rights reserved. 5

6 Worldwide Fuel Specifications are Evolving USA <10ppm (2017) Brazil <50ppm (2014) Europe <10ppm (2009) South Africa <10ppm (2017) Russia <10ppm (2016) China <10ppm (2018) India <10ppm (2020) Thailand <50ppm (2012) Australia <10ppm (2012) Japan <10ppm (2007) Countries around the world are adopting low-sulfur diesel specifications that emulate Euro-V Copyright 2016 DuPont. All rights reserved. 6

7 Worldwide Fuel Specifications are Evolving Three key issues: satisfy global demand meet regional specifications maximize return on investment Refiners must ensure that the fuel meets local market specifications plus any specifications for pipelines and at the pump. Increasingly stringent legislation means that diesel sulfur levels will continue to fall. Copyright 2016 DuPont. All rights reserved. 7

8 IsoTherming Hydroprocessing Technology Straightforward, Flexible Design Versatile reactor design and unit configuration Customized revamp applications Cost Effective Reduced OpEx / decreased utilities consumption Capital cost savings Maximum usage of existing equipment Copyright 2016 DuPont. All rights reserved. 8

9 IsoTherming Hydroprocessing Technology Proven Experience 25 Licenses Grassroots: 20 Revamps: 5 Operating: Startups: 5 Applications Diesel Hydrotreating Kerosene Hydrotreating FCC Pretreat / Mild Hydrocracking VGO & LCO Mild Hydrocracking Dewaxing Gas-to-Liquids Upgrading Heavy Oil Upgrading Copyright 2016 DuPont. All rights reserved. 9

10 Conventional Hydrotreating Process Make-up Hydrogen Product M M Blended Feed Lean Amine Rich Amine Stripper Off Gas HHPS CHPS Naphtha Product STEAM Copyright 2016 DuPont. All rights reserved. 10

11 IsoTherming Hydroprocessing Technology Make-up Hydrogen Product Blended Feed M Liquid Phase Reactor Liquid Recycle Hydrogen in solution within the catalyst bed Distribution less critical Stripper Off Gas HLPS CLPS Naphtha Product STEAM Copyright 2016 DuPont. All rights reserved. 11

12 Major Equipment Comparison CONVENTIONAL Recycle Gas Compressor HP Lube and Seal Systems HP Surge/Recycle Controls HP Suction Knockout Drum Continuous Vibration Monitoring Vibration Control Foundation Hot HP Separator HP Condenser Cold HP Separator HP Amine Scrubber Lean Amine Pump Larger Feed/Effluent Exchanger Larger Reactor Charge Heater ISOTHERMING Reactor Recycle Pump Hot LP Separator Smaller Feed/Effluent Exchanger Smaller Reactor Charge Heater Copyright 2016 DuPont. All rights reserved. 12

13 Advantages of IsoTherming Technology Reduced Fuel Gas Usage 30 to 60% reduction Heat of reaction absorbed by liquid recycle and used to heat the feed Lower heater firing rates in normal operation Lower Power Consumption 30 to 40% reduction Reactor recycle pump vs. recycle gas compressor Better Energy Recovery 30 to 50% increase Optimized heat integration/heat recovery allowing for steam or power generation Reliable and Safe Quick recovery from unit upsets Minimal HP equipment & reduced hydrogen inventory No runaway reaction Lower greenhouse gas emissions Copyright 2016 DuPont. All rights reserved. 13

14 Revamping Existing Capacity Motivations Capacity Increases Product Quality Requirements Process More Difficult Feedstock Challenges Hydraulic limitations Existing catalyst volume Extensive modifications Increase Catalyst Cycle Length Major modifications require long shut downs to implement and can be very costly Copyright 2016 DuPont. All rights reserved. 14

15 Conventional Revamps Product M M Make-up Hydrogen Blended Feed NEW / MODIFIED EQUIPMENT IN RED Lean Amine Rich Amine Stripper Off Gas Naphtha Product STEAM Copyright 2016 DuPont. All rights reserved. 15

16 IsoTherming Revamp Solutions Integration of Conventional and IsoTherming Technologies Product M M Make-up Hydrogen Blended Feed NEW / MODIFIED EQUIPMENT IN RED Lean Amine Rich Amine Stripper Off Gas Naphtha Product STEAM Copyright 2016 DuPont. All rights reserved. 16

17 IsoTherming Revamp Solutions Conventional IsoTherming Reactors New Required May Retrofit Existing Recycle Gas Loop Recycle Gas Compressor Modify/Replace No Modification Reactor Recycle Pump Not Required Required High Pressure Gas Loop Charge Heater Modify/Replace No Modification Feed/Effluent Exchangers New Exchangers No Modification Gas-Liquid Separators Modify No Modification High Pressure Piping Modify/Replace Some Tie-Ins Project Timing Longer Shorter Plot Space Requirements Greater Lesser Project Cost Higher Lower Equipment Investment Higher Lower Copyright 2016 DuPont. All rights reserved. 17

18 Revamps with IsoTherming Technology Maximize Unit Throughput Improve Diesel Product Quality Process More Cracked Feedstock Increase Catalyst Cycle Length Minimize Capital Investment Reduce Operating Expenses Copyright 2016 DuPont. All rights reserved. 18

19 IsoTherming Technology Case Studies Grassroots Diesel Hydrotreater in China ULSD Revamp in India Full Conversion to IsoTherming Technology Copyright 2016 DuPont. All rights reserved. 19

20 IsoTherming for Grassroots DHT Units Production of China National IV Throughput: 0.6 MMTPA Product Target: S < 50 wppm (China IV) Project Execution: ~ two years From Process Design kickoff to fresh feed introduced into the unit Unit successfully achieved < 50 wppm S diesel specifications, per design, while at the following conditions: Throughput BPD 0.6 MMTPA (design) Reactor WABT o C Reactor Pressure kg/cm 2 65 Diesel Product Sulfur wppm Copyright 2016 DuPont. All rights reserved. 20

21 IsoTherming Revamp Solutions Benefits Achieved in a 37,000 BPSD Trickle Bed Unit 35% Capacity Increase with Minimal Modifications 2% Reduction in Charge Heater Duty 10% Reduction in Feed / Effluent Exchanger Duty Pre-Revamp Case Post-Revamp - Conventional Technology Post-Revamp - IsoTherming Technology Delta Capacity BPSD 37,000 50,000 50,000 Power consumption per barrel of feed Fuel gas consumption per barrel of feed Cooling water consumption per barrel of feed KWh/bbl % lb/bbl % ft 3 /bbl % Copyright 2016 DuPont. All rights reserved. 21

22 IsoTherming Revamp Solutions Trickle Bed Reactor Conversion Utilize Existing Nozzles All internal parts pre-fabricated and were installed through existing manway Reused supports No welding to the reactor 40 days from shutdown to beginning of startup Copyright 2016 DuPont. All rights reserved. 22

23 IsoTherming Revamp Solutions Full Conversion to IsoTherming Product Blended Feed DECOMMISSIONED EQUIPMENT M M Make-up Hydrogen Lean Amine Rich Amine Stripper Off Gas Unstabilized Naphtha Product Stabilized Naphtha Product STEAM Diesel Product STEAM Copyright 2016 DuPont. All rights reserved. 23

24 IsoTherming Hydroprocessing Technology Summary A reliable & robust process for Grassroots or Revamp HDT Units Simple & Straightforward Less equipment required Fewer modifications in revamps Cost Effective Lower capital cost High energy efficiency Shorter project schedules & implementation time Copyright 2016 DuPont. All rights reserved. 24

25 Thank You Copyright 2016 DuPont. All rights reserved. 25