WORLDWIDE REFINERY PROCESSING REVIEW. Second Quarter 2016

Transcription

1 WORLDWIDE REFINERY PROCESSING REVIEW Monitoring Technology Development and Competition in One Single Source Second Quarter 2016 Hydrocracking, and Lube Oil Production Plus Latest Refining Technology Developments & Licensing HYDROCARBON PUBLISHING COMPANY Translating Knowledge into Profitability P.O. Box 815, Paoli, PA (U.S.A.) Phone: (610) / Fax: (610)

2 1Q 2016

3 WORLDWIDE REFINERY PROCESSING REVIEW Monitoring Technology Development and Competition in a Single Source Second Quarter 2016 Hydrocracking, and Lube Oil Production Plus Latest Refining Technology Developments & Licensing WORLDWIDE REFINERY PROCESSING REVIEW is published by Hydrocarbon Publishing Co. every quarter. Copyright All rights reserved. No part of this publication may be reproduced, stored in a retrieval system or transmitted in any form or translated into any language or by any means electronic, mechanical, photocopying, recording or otherwise without prior written permission of Hydrocarbon Publishing Company. P.O. Box 815, Paoli, PA (USA). Tel: (610) , Fax: (610) review@hydrocarbonpublishing.com

4 1Q, 2Q, 3Q, 4Q..(the) first, second, third, and fourth quarters, respectively AAA... American Automobile Association (US) ANS... Alaskan North Slope crude API... American Petroleum Institute (US) ARA... Antwerp, Rotterdam, Amsterdam ASTM... American Society for Testing & Materials b or bbl... barrel(s) B... billion boe... barrel(s) of oil equivalent CA... California CAA... Clean Air Act (US) CARB... California Air Resources Board cf... cubic foot, cubic feet cfr... cost and freight cif... cost, insurance, and freight Concawe... Conservation of Clean Air and Water Europe CIS... Commonwealth of Independent States CNG... compressed natural gas cst... centistoke d... day DOE... Department of Energy EEC... European Economic Community EIA... US Energy Information Administration EPA... US Environmental Protection Agency EPC(M)... engineering, procurement, and construction (management) EU original EU members EU25... EU15 and the 10 new members admitted in May 2004 EUROPIA... European Petroleum Industry Association (Brussels) FCV... fuel cell vehicle fd... free delivered FEED... front-end engineering design fob... free on board gal... gallon GTL... gas to liquid(s) h... hour H1 or H2... first or second half of the year ICE... Int'l Commodity Exchange (UK formerly Int'l Petroleum Exchange) IEA... Int'l Energy Agency (Paris-based) IPAA... Independent Petr. Assoc. of America IPO... initial public offering j.v.... joint venture LPG... liquefied petroleum gas K... thousand kl... kiloliter lb... pound(s) METI... Ministry of Economy, Trade and Industry (Japan) MM... million MOU... memorandum of understanding mpg... miles per gallon mt... metric ton MW... megawatt N.A.... not applicable or not available NAAQS... national ambient air quality standards NESCAUM... Northeast States for Coordinated Air Use Management NG... natural gas NGL... natural gas liquid NPRA... National Petrochemical & Refiners Association (US) NWE... Northwest Europe NYMEX... New York Mercantile Exchange (US) OECD... Organization for Economic Cooperation & Development OPEC... Organization of the Petroleum Exporting Countries OSHA... Occupational, Safety and Health Administration (US) PC... petrochemical(s) PM... particulate matter RBOB... RFG before oxygenate blending RFG... reformulated gasoline RMT... refining, marketing, and transportation RVP... Reid vapor pressure SCAQMD... South Coast Air Quality Management District (California) VLCC... very large crude carrier WTI... West Texas Intermediate y... year... US cent(s)... EU euro(s)... UK pound(s) $... US dollar(s)... Japanese yen Please note that other international currencies are abbreviated using International Standards Organization codes, which can be found at

5 Review Hydrocracking and Lube Oil Production 1. INTRODUCTION HYDROCRACKING MARKET/TECHNOLOGY TRENDS & OPPORTUNITIES Introduction Market Conditions and Outlook Global Transportation Fuels Specifications... 6 Global Refined Products Demand Diesel Demand in Decline in Parts of the World But Growth Opportunities Still Exist Shifting Crude Slate Opportunity Crudes Tight Oil Hydrogen Demand Capacity Expansion Construction Projects and Unit Revamps Hydrocracking Catalyst Market Technology Competition, Direction, and Future Prospects Market Layout and Strategic Alliances Recent Technology Developments Catalyst Developments Process and Hardware Developments Two phase Hydrocracking Reactor Internals HPNAs Removal Conventional and Mild Hydrocracking Resid Hydrocracking Alternative Feed Hydrocracking Revamp and Integration Options Process Modeling Latest R&D Trends Conclusion STATE OF THE ART TECHNOLOGY Introduction Commercial Process Technology Axens Mild Hydrocracking Mild HCK HyC 10/HyC H Oil DC Medium pressure Hydrocracking Conventional (High pressure) Hydrocracking HPNA Removal Reactor Internals Chevron Lummus Global ISOCRACKING Single stage Once Through and Single stage Recycle Two stage Recycle Optimized Partial Conversion Selective Staging Split feed Injection i

6 Single stage Reaction Sequencing ISOFLEX Reactor Internals DuPont Clean Technologies ExxonMobil Single stage MPHC MPHC PTU MPHC LCO Two stage MPHC MIDW Spider Vortex Reactor Internals Haldor Topsøe Mild Hydrocracking Staged Partial Conversion Hydrocracking Back End Shift (BES) Process Conventional (High pressure) Hydrocracking HPNA Trim Reactor Internals Shell Global Solutions Mild Hydrocracking Conventional Hydrocracking Reactor Internals Sinopec Flexible Hydrotreating/Mild Hydrocracking Medium pressure Hydro Upgrading Moderate pressure Hydrocracking High pressure Hydrocracking Single stage Hydrocracking Single stage in Series Hydrocracking Two stage Hydrocracking Flexible Hydrocracking UOP MHC Unicracking Unicracking Single stage Once Through or with Recycle Two stage Partial conversion Unicracking Dieselmax HyCycle Unicracking Advanced Partial Conversion Unicracking HPNA Removal Systems Reactor Internals Summary of Hydrocracking Process Technologies Commercial Catalysts Albemarle Axens Clariant Catalysts Chevron Lummus Global Criterion Catalysts & Technologies Haldor Topsøe JGC Catalysts & Chemicals Sinopec Catalyst Co UOP Summary of Commercially Available Hydrocracking Catalysts ii

7 2.2.4 Auxiliary Catalyst Technology Axens Crystaphase Products Eurecat TRICAT Control and Optimization Systems Resid Hydrocracking Renewable Hydrocracking PLANT OPERATIONS AND PRACTICES General Hydrocracking Operations Feed Considerations, Operational Variables, Process Configurations, and Hardware Feedstock Characterization Contaminant Metals Upgrading Tight Oil Increasing Conversion for Heavier Feedstocks Upgrading LCO and/or HCO in Hydrocrackers Undercutting LVGO to Increase Hydrocracker Utilization Optimizing Operational Variables Recycle Rate in Two stage Units Setting Operational Pressure Flow Control on Feeds from Coking Unit Reactor Configuration Optimized Hydrocracker Reactor Internals Removing Welded Attachments from Reactor Internals Changing Unit Configuration to Boost Yields and Process Alternative Feeds Large Single Process Train vs. Smaller Parallel Trains in Hydrocrackers Reactor Fabrication and Metallurgy Comparison of Quench Systems Revamping the Overhead Condenser of a Hydrocracker Hydrocracker Stripper Revamp: From Packing to Trays Designing Hydrocracker Charge Heater Hydrocracker Pump Selection Membranes for H 2 Recovery from Hydrocrackers Fouling, Particulate Deposition, and Corrosion Causes of Hydroprocesser Fouling and Possible Treatments Chlorides Fouling in Effluent Exchangers Elimination of Polynuclear Aromatics (PNA) Buildup Preventing Sedimentation in Ebullated bed Hydrocrackers Iron Sulfide Buildup in VGO Hydrocrackers Feed Filter Operation Mitigating High Temperature Hydrogen Attack Fouling in Furnace Tubes Corrosion in Overhead System Corrosion in Auxiliary Equipment Reducing Foaming in an Amine Scrubber Operational Problems Increased Yield Using Multivariable Predictive Control (MPC) Improving Hydrocracker Temperature Control Detecting Radial Temperature Spread and Preventing Reactor Runaway Hydrocracker Furnace Operations Causes of Overcracking Improving the Performance of a Debutanizer Preventing Off color Naphtha Product Reducing the Level of Sulfur in Naphtha at EOR Conditions Limiting Ammonia Concentration in the Cold High pressure Separator Overhead Inline Hydrocracker Cleaning System iii

8 Improving Recycle Gas Compressor Operation Catalyst Management Selection Process for Hydrocracking Catalysts Catalyst Testing on Different Scales Catalyst Loading Precautions Measuring Hydrocracking Catalyst Activity Catalysts for Processing Tight Oil Catalysts for Processing Various Feeds Replacing a Noble Metal Catalyst with a Base Metal Catalyst Catalyst Structure: Homogeneous vs. Stacked Ex Situ Sulfiding (Presulfiding) of Hydrocracking Catalysts Hydrocracking Catalyst Passivation Disproportionate Catalyst Deactivation in the First Bed of a Hydrocracker Designing a Posttreat Bed for Hydrocracking Reactors Asphaltene Contribution to Catalyst Deactivation Impact of HPNAs on Catalyst Activity and Stability Regenerated Hydrocracking Catalyst Use Catalyst Removal for Non free Flowing Catalysts Recovering Spent Hydroprocessing Catalysts and Metal Reclamation Reducing Hydrocracker Energy and Hydrogen Use Advanced Process Control and Modeling Cleaning Heat Integration Power Recovery Process Heaters Compressors Impact of Catalysts Hydrocracker Safety Hydrocracker Safety Incidents Emergency Depressurization: Triggering Criteria, Rates and Modes Operational Status of Emergency Depressurizing Valves and Interlocks Safely Performing Inter reactor Sampling in Hydrocrackers Sampling of Light Streams around High Pressure Equipment Mild Hydrocracking (MHC) Mild Hydrocracking: Feedstock, Conversion, and Product Quality Converting a Cat Feed or Distillate Hydrotreater to a Mild Hydrocracker Options for Improving the Cycle Length of Mild Hydrocrackers Distillate Hydrocracking Shifting from Maximum Naphtha to Maximum Middle Distillate Yields Maximizing Diesel Production in VGO Hydrocrackers Benefits of Moderate Pressure Hydrocracking (MPHC) in Clean Diesel Production Adjusting CAT to Maximize Diesel Production Reactor Revamp to Improve ULSD Production Optimizing Saturation and Volume Swell in ULSD Service Loading Hydrocracking Catalyst in the Last Bed of a ULSD Unit Process Revamp for Added H 2 S Removal to Meet ULSD Standards Improving Diesel Cetane from Hydrocrackers Hydrocracking Catalysts for Cold Flow Property Improvements Integrated Processing Schemes Delayed Coker with Hydrocracker Solvent Deasphalting with Hydrocracker Mild Hydrocracker with FCC Integrated Processes for Heavy Oil Upgrading iv

9 2.4 REFINING R&D ALERT! Introduction General Hydrocracking Process Catalyst Patents Novel Composition Preparation Method Research Novel Composition Preparation Method Hardware Patents Research Integrated Operations (Conventional Feeds) Mild Hydrocracking and Hydrotreating to Improve Cetane Process Modeling Patents Research Product Selective Hydrocracking Middle Distillates Process Catalyst Patents Support with Improved Porosity Catalysts Enhancing Aromatics Saturation Other Research Production of Aromatics rich, High octane Heavy Naphtha Patents Research Production of Gasoline Patents Research BTX Patents Research Resid Hydrocracking Ebullated bed Reactor Patents Research Slurry bed Reactor Process Patents Research Catalyst Patents Research Other Catalyst Hydrocracking Alternative Feedstocks Fischer Tropsch Liquids Process Catalyst Patents Research v

10 Renewable Feedstocks Coprocessing Hydrocarbon and Bio oil Feeds Production of Fuels Patents Research Making Bio chemicals Patents Research Other WORLDWIDE INSTALLED CAPACITY CONSTRUCTION Recent Construction Activity Completed Construction Projects REFERENCES LUBE OIL PRODUCTION MARKET/TECHNOLOGY TRENDS & OPPORTUNITIES Introduction Market Conditions and Outlook Base Oil Market In The Midst of Oversupply New Regulations, Overcapacity Drive Base Oil Switch Poor Economics Driving Out European Group I Lubes Vehicle Ownership to Contribute to Rise in Asian Lube Demand Middle East Refiners Add Base Oil Capacity Crude Feedstock Impacts Lubes Output Lube Prices Track Crude Higher Installed Capacity and Future Projects Technology Competition, Direction, and Future Prospects Hydroprocessing based Technology Hybrid Processes Alternative Feeds Converting from Solvent based to Hydroprocessing based Lubes Production Conclusion STATE OF THE ART TECHNOLOGY Introduction Commercial Processes Axens Solvent Refining Hydroprocessing Hydrorefining High Conversion Hydrocracking Lube Oil Hydrofinishing White Oils Hydrotreatment Wax Hydrotreatment (Wax HDT) Bechtel Solvent Refining MP Refining Furfural Refining Solvent Dewaxing Wax Fractionation Hydroprocessing Hy Raff Hy Finishing Hy Starting Wax Hy Finishing vi

11 White Oil Hy Finishing Chevron Lummus Global Hydroprocessing ISOCRACKING ISODEWAXING ISOFINISHING Integration Opportunities ExxonMobil Solvent Refining EXOL N Extraction DILCHILL Propane Dewaxing Hydroprocessing Lube HYDROFINING LHDC Raffinate Hydroconversion MSDW MLDW MWI Wax HYDROFINING MAXSAT Membrane Separation Integration Opportunities Process Dynamics Integrated Extraction/Dewaxing IsoTherming Shell Global Solutions Solvent Refining Hydroprocessing Pretreating/Hydrofinishing Hydrocracking Catalytic Dewaxing and Wax Isomerization Food Grade Oils and Wax Hybrid Process Suncor Energy HT Severe Hydrocracking HydroIsomerization Uhde Solvent Refining Solvent Dewaxing and Wax Deoiling Slack Wax Deoiling Liquid liquid Extraction Hydroprocessing Hydrofinishing White Oil and Wax Hydrotreating Washington Group Int./SK Innovation Summary of Commercial Lube Oil Manufacturing Processes Summary of Commercial Lube Oil Manufacturing Catalysts PLANT OPERATIONS AND PRACTICES Process Selecting a Lube Production Process Breakeven Cost Comparison Improvements in Plant Efficiency, Performance, and Profitability Converting Fuel Hydrocracking to Lube Hydrocracking Revamps to Existing Equipment Vacuum Distillation Unit vii

12 Solvent Extraction Unit Solvent Dewaxing Unit Optimization of Operating Conditions Vacuum Distillation Unit Solvent Extraction Unit Solvent Dewaxing Unit Lube and Wax Hydrofinishing Unit Retrofitting Solvent Extraction Unit Solvent Dewaxing Unit Hydrofinishing Unit Use of Additives and Aids Improvements to Additives and Lubricant Blending Dewaxing Aids Alternative Base Oil Sources Recycled Used Lubricants Bio lubricants and GTL Lubricants Other Chemicals Wax Production Waxes from Fischer Tropsch Hybrid Installations REFINING R&D ALERT! Introduction Fractionation Solvent based Lube Production Solvent Extraction Solvent Dewaxing Patents Research Hydroprocessing based Lube Production Hydrocracking Process Catalyst Patents Research Hydroisomerization/Dewaxing Process Catalyst Combined Hydrocracking and Dewaxing Process Process Catalyst Alternative Processes Oligomerization/Alkylation Alternative Feeds F T Wax Bio and Unconventional Feeds Process Patents Lube Grease Research Catalyst Miscellaneous Patents Research viii

13 3.5 WORLDWIDE INSTALLED CAPACITY CONSTRUCTION Recent Construction Activity Completed Construction Projects REFERENCES LATEST REFINING TECHNOLOGY DEVELOPMENTS & LICENSING FLUID CATALYTIC CRACKING HYDROTREATING (INCLUDING HDS) BENZENE REDUCTION AND REMOVAL ALKYLATION COKING SULFUR PLANT GAS CONCENTRATION PLANT/VAPOR RECOVERY AROMATICS AND LIGHT OLEFINS PRODUCTION PROCESS CONTROLS AND SIMULATION XTL (BIOMASS, COAL, AND GAS TO LIQUID) BIOFUELS PRODUCTION ENERGY MANAGEMENT CO 2 EMISSIONS (CARBON CAPTURE AND SEQUESTRATION) SITE AIR POLLUTION AND WASTE DISCHARGE REFERENCES ix

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