Raising the Bar Premium Base Oils Produced by the All-Hydroprocessing Route

Transcription

1 Raising the Bar Premium Base Oils Produced by the All-Hydroprocessing Route Presented at ARTC 7 th Annual Meeting April 2004 Singapore Srinivasan

2 Dr. Ashok Krishna Managing Director Chevron Lummus Global LLC and ChevronTexaco's Technology Marketing Mr. Sook-Hyung (Sam) Kwon Vice President and Project Director SK Corporation

3 Raising the Bar Through Partnership The Past History of Hydroprocessing at SK, ChevronTexaco, the partnership begins The Present Influence of SK, CLG on base oil market, development of technology and catalyst, the partnership evolves The Future Extending the hydroprocessing chain for further improvement, the bar is raised, the partnership innovates

4 The Past Hydroprocessing at ChevronTexaco 1963: Pascagoula ISOCRACKING Unit #1 1966: Richmond ISOCRACKING Plant : Pascagoula ISOCRACKING Unit #2 and El Segundo ISOCRACKING Unit Mid-1970 s and Early 1980 s: LSFO projects (diesel, VGO, RDS and VRDS Hydrotreaters) in all three refineries 1984: Richmond Lube Oil Plant (RLOP), world s first all-hydroprocessing route to base oils Srinivasan

5 Development of ISODEWAXING/ Hydrofinishing : Invention, development and commercialization of ISODEWAXING Catalyst 1993: First generation, ICR 404, installed at RLOP 1993-Now: Multiple industry awards, licensing takes off 1996: Second generation ISODEWAXING Catalyst commercialized, ICR 408 ChevronTexaco ISODEWAXING/Hydrofinishing become industry leaders Base Oil Market driven by supply and demand from finished lubricants evolving specifications Srinivasan

6 Licensing of ISODEWAXING/ Hydrofinishing Operator Plant Location Design Capacity, BPSD Unit Startup Chevron California 1993 PetroCanada Canada 1996 Excel Paralubes Louisiana 1996 SK Corp. Korea 1997 Fortum Finland 1997 Motiva Texas 1998 Chevron, 2 nd Train California 1998 Daqing China 1999 Motiva 2 Texas 2000 Lukoil Russia 2002 Total (Operating) 106,000 SK Corp. Asia 2004 Glimar Poland 2004 Gaoqiao, China Asia 2004 BPCL, India Asia 2005 Petrobras Brazil 2007 Total 45,000 (Design/Construction) Three Projects Asia, Europe On Hold Total 22, Srinivasan

7 1993 ISODEWAXING Application at RLOP Light & Heavy VGO Light HCR ISODE- WAXING Unit Hydrofinishing Unit Light Neutral Medium Neutral Heavy VGO Heavy HCR Solvent Dewax - Shut Down Hydrofinishing Unit Heavy Neutral Srinivasan

8 Pre RLOP Light & Heavy VGO Light HCR Catalytic Dewaxer Hydrofinishing Unit Light Neutral Medium Neutral Heavy VGO Heavy HCR Solvent Dewax Hydrofinishing Unit Heavy Neutral Srinivasan

9 Present, All- Hydroprocessing Light & Heavy VGO Light HCR ISODE- WAXING Unit Hydrofinishing Unit Light Neutral Medium Neutral Heavy VGO Heavy HCR ISODE- WAXING Unit Hydrofinishing Unit Heavy Neutral Srinivasan

10 Marketplace Evolution % of Paraffinic Base Oil Market In North America Now Classification None API Group II/III Market Share (North America) 10% > 50 % Premium Over Group I None Yes Srinivasan

11 Current Events SK challenges CLG to improve lube quality/yield further CLG s catalyst development program results in next-generation ISODEWAXING and ISOFINISHING Catalysts SK and CLG do joint testing, validation -- ICR 422 currently operating in LBO #1 ICR 418 selected for new plant LBO #2, to be started up in 3Q Srinivasan

12 Yield and V.I. Improvements on LN Feed (Group II, 150N) Srinivasan

13 100N Performance (Feed-Normalized) CDW ICR 408 ICR 422 Yield, LV % Base Viscosity Index Base Srinivasan

14 Higher Performing Lubricants Are Required for Future Automotive Applications Passenger Car GF-4 and Euro-IV 2004 Fuel Economy, Volatility Oxidation Resistance Heavy Duty PC-10 and Euro-IV Soot Handling, Volatility Oxidation Resistance Group II/II+/III Base oil Required Transmission Fluid DEXRON-IIIH New Factory Fill Specs Group III for Oxidation Resistance Srinivasan

15 Premium Base Oil Capacity Continues to Grow SK Leading the Way Refineries throughout Asia are actively seeking ways to upgrade to group II/II+/III Market Share of Premium Base Oils Global Asia North America % Today % 2006

16 Future Success Through Partnership Finished lubricants specifications will continue to drive base oil demand towards Group II, II+, III, GTLbased SK/CLG drive to continually improve base oil yield, qualities are now extending upstream of ISODEWAXING/Hydrofinishing Unit to the hydrocracking step Collaboration on studying feasibility of revamping existing hydrocracker for greater capacity, improved performance AND better base oil yields and qualities Process and catalyst developments are keys to Raising the Bar on Performance

17 Feasibility Case - Configuration, CLG Catalysts HCR debottleneck by >30%, using CLG s Optimized Partial Conversion ( OPC ) concept. Increase amount of high quality feedstock for ISODEWAXING/Hydrofinishing Unit by >60% Minimal modification to H.P. loop, downtime for modifications reduced Better catalyst life, despite higher throughput Flexibility to select different viscosity grades Can segregate low viscosity, high V.I. material, SK s primary product New CLG catalysts improve base oil V.I. for low viscosity material HCR bottoms enhance yields, V.I. in ISODEWAXING Process SK has done PP tests along with CLG to validate the concept Srinivasan

18 ICR 240 CLG s Latest Catalyst, Uniquely Suited to SK s Primary Product Objective Srinivasan

19 Partnership in Action SK and CLG have demonstrated the synergy and impact of a partnership in allhydroprocessing base oil production Separately we have innovated, and profoundly influenced the base oil market Together we have raised the bar Srinivasan

20 The Past SK s Growth 1962: Korea Oil Corporation established 1964: No. 1 Crude Distillation Unit commenced operation, 35 KBD 1992: Heavy Oil Upgrading (HOU) Plant commenced, including VRDS 1995: Lubricating Base Oils Plant (LBO #1) commenced, Hydroprocessing-based, included UCO Lube Process 1996: RFCC Plant commenced, also pre-treat RDS 1996: No. 5 Crude Distillation Unit 1997: LBO #1 commenced as ISODEWAXING/ Hydrofinishing Unit, with ICR 408/407 Currently, second largest refinery in the world (OGJ) Major manufacturer/marketer of Group III base oils

21 Application of SK UCO Technology Original HCK Design 30,000 FF +5,000 35,000 50,000 50,000 Unit : B/D R1 R2 Fs Diesel 5,000 15,000 20,000 VDU #2 VDU 35,000 35,000 FF 50,000 50,000 R1 R2 Fs After SK UCO Technology 15,000 20,000 Application VDU VDU CDW #2 VD U Diesel Unit : B/D

22 Application of SK UCO Technology Process Integration Scheme VG O HT HC Recycle Oil Surge Drum Excess Distillates 70D 100D UCO 150/250D Existing HCK Reactors Fractionator Distillation Intermediate Storage

23 SK s UCO Lube Process, Properties Test Item Test Method Solvent Refining Lube Hydrocracking SK UCO Lube Process (Old) 100 C, cst ASTM D Viscosity Index ASTM D Pour Point, C ASTM D CCS -20 C, cp ASTM D2602 2,100 2,000 1,650 Flash Point, C ASTM D Noack Volatility, Wt % DIN Aromatics, Wt % ASTM D Sulfur Content, Wt % ANTEC

24 ISODEWAXING/Hydrofinishing SK s Project Result Description IDW CDW Dewaxing Isomerization Cracking Pour Point -12 C -12 C VI N Case REMARK Flash Point 250 C 232 C Noack Vol Naph. 10.5% 33.8% Yield Dist 4.5% 6.0% Lube 85.5% 64.5% M/U H2 1,900Nm3/hr 4,500Nm3/hr - 2,600

25 YIELD (%) Catalyst Conversion Lube Product Yield 95.0% 90.0% 85.0% 80.0% 75.0% 70.0% 65.0% 60.0% 70N 100N 150N CDW ISODEWAXING OPERATION DAYS

26 VI NOACK Catalyst Conversion Lube Product Quality VI NOACK wt % CDW ISODEWAXING OPERATION DAYS

27 History of SK HCK & Lube Process Original Design (HCK Only) 30,000 FF +5,000 35,000 50,000 50,000 Unit : B/D R1 R2 Fs Diesel 5,000 15,000 20,000 VDU #2 VDU Combination of HCK and #1 LBO 35,000 FF 35,000 50,000 50,000 R1 R2 Fs #2 VD U VDU 15,000 20,000 Unit : B/D Diesel VDU CDW

28 History of SK HCK & Lube Process HCK Capa. Increase #1 40,000 FF 40,000 50,000 50,000 R1 R2 Fs 10,000 VDU #2 VD U VDU Diesel IDW HCK Capa. Increase #2 42,000 FF #2 VD U VDU 42,000 52,000 52,000 Unit : B/D R1 R2 Fs Diesel 10,000 VDU IDW

29 History of SK HCK & Lube Process 45,000 FF 45,000 55,000 55,000 R1 R2 Fs Diesel HCK Revamp + # 1 LBO + # 2 LBO #2 VD U VDU 10,000 VDU #1 IDW VRDS/Asphalt UCO VDU #2 IDW

30 Feasibility Study Modified Two-Stage HCK 1. Main Objectives of Feasibility Study Maximization of UCO for Lube Products Maximization of Premium Lube Base Oil (100N Product ) Upgrading Lube Quality (VI, CCS, Noack,etc)

31 Feasibility Study Modified Two-Stage HCK 2. Study Concept 60,000 FF 60,000 R1 R2 Fs Diesel 2-Stage HCK Modification + #1 LBO + #2 LBO #2 VD U VDU New VDU 35,000 5,000 30,000 New Fs 25,000 VDU VDU #1 IDW #2 IDW

32 Feasibility Study Modified Two-Stage HCK 3. Study Basis Sub-items Base Feasibility Study Case Hydrocracker Type Single Stage Hydrocracker Capa., B/D 45,000 Lube Production, B/D Base Two-Stage 60, ,000 Recycle Oil Rate, B/D 10,500 35,000 1st Stage Conversion, % Fract Bottom fr 1 st Stage, B/D 2 nd Stage Conversion, % , Fract Bottom fr 2nd Stage, B/D Waxy Distillate, B/D ,000 20,000

33 Feasibility Study Modified Two-Stage HCK 4. Feedstock of HCK Typical Crude Slate : Middle East Feed type : Mixture of SR VGO (85%) plus HGO (15%) Feed Properties Feed Type Unit Typical Feed Type Unit Typical API 21.5 Metal Sulfur wt% Ni wppm Total Nitrogen wppm 1,100 - V wppm less than 1 Vis (40C) cst Fe wppm Vis (100C) cst 6.75 Distillation VI 80 0/5%LV Deg C 301/359 Pour Point Deg.C /30 Deg C 378/417 CCR wt% /70 Deg C 442/455 Aniline Pt Deg.C 79 90/95 Deg C 513/532

34 Feasibility Study Modified Two-Stage HCK 5. Scheme developed 60,000 FF Naph Unit : B/D VDU 35,000 RF Kero Diesel 20,000 HHPS HLPS 30,000 New VDU HHPS 25,000 HLPS 5,000

35 Feasibility Study Modified Two-Stage HCK 6. Result of Feasibility Study Feasibility Study Result Lube Product Description Base From New Scheme Delta 70N Yield, vol% Vis. VI 10% 3.0 cst % 3.0 cst N Yield, vol% Vis. (@100C) VI 10% 4.3 cst % 4.3 cst % N Yield, vol% Vis. (@100C) VI 11% 7.6 cst % 7.6 cst Total Lube Product 100N Product B/D Base + 6,000 B/D Base + 7,500

36 Feasibility Study Modified Two-Stage HCK 7. Summary FUELS HYDROCRACKER NAPHTHA, KEROSENE, DIESEL UCO PROJECT VHVI BASE OILS SK UCO TECHNOLOGY YUBASE UPGRADING VI, LUBE YIELD,WHITE OIL SK UCO TECHNOLOGY + ISODEWAXING HYDROCRACKER REVAMP SINGLE TWO STAGE - MORE PREMIUM LUBE - BETTER QUALITY - MORE PRODUCTION SK UCO TECHNOLOGY + CLG OPC HCK + ISODEWAXING