WORLDWIDE REFINERY PROCESSING REVIEW. Third Quarter Hydrotreating

Transcription

1 WORLDWIDE REFINERY PROCESSING REVIEW Monitoring Technology Development and Competition in One Single Source Third Quarter 2014 Hydrotreating HYDROCARBON PUBLISHING COMPANY Translating Knowledge into Profitability SM P.O. Box 661 Southeastern, PA (U.S.A.) Phone: (610) / Fax: (610)

2 Review - Hydrotreating 1. Hydrotreating MARKET/TECHNOLOGY TRENDS & OPPORTUNITIES Introduction Market Conditions and Outlook Refined Products Legislation Transportation Fuels Bunker Fuels Refined Products Demand Renewable and Bio-based Diesel and Jet Fuel Shifting Crude Slate Hydrotreating Capacity Contraction Construction Projects and Unit Revamps Hydrotreating Catalysts Market Technology Competition, Directions, and Future Prospects Conventional Hydrotreating Diesel Hydrotreating Gasoline Hydrotreating Major Technology Offerings H 2 Consumption Advanced Process Control Process Integration 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 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 i

3 Cosmo Oil Criterion Catalysts & Technologies CENTINEL CENTINEL GOLD ASCENT CENTERA SDD-800/SDD Selective Hydrogenation Catalysts Guard Catalysts Crystaphase Products ExxonMobil RT 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 Albemarle EasyActive React Stax Axens Criterion Catalysts & Technologies Eurecat Sulficat Totsucat Haldor Topsøe HPA hte Orient Catalyst/Advanced Refining Technologies TRICAT Inc TRICAT Regeneration Process XpresS Velocys Commercial Process Technology Albemarle UD-HDS ii

4 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 Nippon Oil RIPP/Sinopec SK Corp Shaw Group/BASF Shell Global Solutions Hydrotreating Process SMDH Pyrolysis Hydrogenation Unit Reactor Internals UOP MQD Unionfining iii

5 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 Petrobras 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 Welded Supports on Reactor Walls Catalyst Management iv

6 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 Determining HDM Range Using Regenerated Catalyst Dry Dump vs. Wet Dump Catalyst Change-out Procedures Catalyst Removal for Non-free Flowing Catalysts Transportation and Disposal of Contaminant-laden Catalysts Catalyst Dense Loading Catalyst Short 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 Carbon Oxide Contamination 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 Temperature Monitoring During Startup and Shutdown Reactor Effluent Sampling Accurate Level Measurements in a Cold High Pressure Separator Maldistribution in Hydrotreaters Reactor Pressure Drop Buildup: Causes and Remedies Pressure Drop Issues Due to Catalyst Pressure Drop Issues Due to Plugging/Fouling 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 Irregularities in Sulfur Content Distillate Hydrotreating Diesel Quality Requirements Cetane ULSD Cold Flow Properties ULSD Haze Point Minimizing Diesel Color Degradation Logistics Increasing Diesel Output Maximizing Volume Swell of Distillate Feeds Increasing Distillates Fed into a Hydrotreater Hardware Considerations v

7 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 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 Off-Color Products Naphtha Hydrotreating Hydrotreating FCC Naphtha Processing Coker and Visbreaker Naphtha Processing Coker Naphtha for Hydrogen Production Measuring Silicon Content in Coker Naphtha 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 Impact of Tier III Gasoline Standards on FCC Feed Pretreaters FCC Feed Pretreatment vs. FCC Gasoline HDS 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 Patents Reduction of Refractory Aromatic Sulfur Compounds Dissolution of Hydrogen to Enhance Mass Transfer Other Process Innovations Research Catalyst Formulation and Preparation Alumina Carrier Supports Patents Research vi

8 Zeolite Carrier Supports Patents Research Titanium and Zirconium Carrier Supports Patents Research NiP-containing Catalysts Phosphorus-modified Carrier Supports Patents Research Transition Metal Sulfides Patents Research Noble Metal Catalysts Patents Research Unsupported Catalysts Use of Acids and/or Amines during Formulation and Preparation Patents Research Catalyst Regeneration Patents Research Catalyst Sulfidation Other Catalyst Innovations Patents Research Middle Distillate Hydrotreating (Including ULSD Production) Process Patents Integration of Hydrotreating and Hydrocracking Processes Aromatics Extraction to Improve Cetane Combined Hydrotreating and Oxidation Treatment Combined Hydrotreating and Dewaxing Other Process Schemes Research Catalyst Patents Metal Oxide Supports Patents Research Zeolites Bulk Catalysts Research General Catalyst Studies NiP Supported Catalyst Unsupported Catalysts Naphtha Hydrotreating Process Patents FCCU Posttreatment Other Innovations Catalyst vii

9 Patents FCCU Posttreatment Non-FCCU Naphtha Hydrotreating Research General Catalyst Studies Catalyst Supports Reaction Mechanism Tight Oil Processing Heavy Oil and Resid Hydrotreating Process Patents Integrated Processes Reactor Configuration Bunker Fuel Production Research Catalyst Patents Resid HDM Catalysts Resid HDS and/or HDN Catalysts Research Renewable Feed Hydrotreating Process Patents Process Integration Product Specific Processes Gasoline/Naphtha Kerosene/Jet Fuel Biodiesel Heavy Products Minimization of Coke Production Miscellaneous Process Schemes Research Catalyst Patents Noble Metal Phosphided Catalysts Metal Oxide Carrier Supports Miscellaneous Research WORLDWIDE INSTALLED CAPACITY CONSTRUCTION Recent Construction Activity Completed Construction Projects REFERENCES viii