Jim Rekoske VP & Chief Technology Officer Honeywell UOP Quenching Our Thirst for Clean Fuels 22 April 2016 Petrofed Smart Refineries New Delhi, India UOP 7200-0 2016 UOP LLC. A Honeywell Company All rights reserved.
India s Demand for Clean Gasoline 1 Drivers - Improved economic outlook higher spending on Fuels and Plastics 7.6% annual GDP growth possible over next 5 years - Need for air quality Improvement regulations for Fuel specs upgrade - Dependence on imported crude - Refinery utilization at or near 100% (nominal basis) for many units Trends - Demand has caught up with supply need for new investment planning - Nationwide upgrade to BS IV fuel by Q1 17 and EBSVI by 2020 - Maximize value from crude imports through efficiency, upgrading - Automobile sales growth of ~10% - Gasoline growth outpaces diesel
A Balancing Act: Bharat VI Specs with Maximum Profit 2 Limit on lights Distillation E70/E100 Oxygenates 2.7 vol% More Oxygenates Remove before or after reformer Benzene 1 vol% RVP UOP Solutions 60 kpa EtherMax unit Limit on C4s & InAlk Unit C5s in Isomerate AlkyPlus Unit Hydrotreating Limit on FCC Platforming Unit Gasoline Penex Unit Olefins IsomEx Unit 18 vol% Par-Isom Unit Selectfining Unit How can I blend more FCC Gasoline and control olefins and sulfur? How do I drive octane yield and aromatics to the limit? Where is the rest of my octane going to come from? Limit on Reformate Aromatics 35 vol% Sulfur 10 wt-ppm Limit on FCC Gasoline or Increase Desulfurization Severity Many constraints optimal solution?
A Balancing Act: Bharat VI Specs with Maximum Profit 3 Limit on lights Distillation E70/E100 Oxygenates 2.7 vol% More Oxygenates Remove before or after reformer Benzene 1 vol% RVP UOP Solutions 60 kpa EtherMax unit Limit on C4s & InAlk Unit C5s in Isomerate AlkyPlus Unit Hydrotreating Limit on FCC Platforming Unit Gasoline Penex Unit Olefins IsomEx Unit 18 vol% Par-Isom Unit Selectfining Unit How can I blend more FCC Gasoline and control olefins and sulfur? How do I drive octane yield and aromatics to the limit? Where is the rest of my octane going to come from? Limit on Reformate Aromatics 35 vol% Sulfur 10 wt-ppm Limit on FCC Gasoline or Increase Desulfurization Severity Many constraints optimal solution?
A Balancing Act: Bharat VI Specs with Maximum Profit 4 Limit on lights Distillation E70/E100 Oxygenates 2.7 vol% More Oxygenates Remove before or after reformer Benzene 1 vol% RVP UOP Solutions 60 kpa EtherMax unit Limit on C4s & InAlk Unit C5s in Isomerate AlkyPlus Unit Hydrotreating Limit on FCC Platforming Unit Gasoline Penex Unit Olefins IsomEx Unit 18 vol% Par-Isom Unit Selectfining Unit How can I blend more FCC Gasoline and control olefins and sulfur? How do I drive octane yield and aromatics to the limit? Where is the rest of my octane going to come from? Limit on Reformate Aromatics 35 vol% Sulfur 10 wt-ppm Limit on FCC Gasoline or Increase Desulfurization Severity Many constraints optimal solution?
Indian Refiner Gasoline Pool Requirements 5 BS III BS IV BS VI Density @ 15 C kg/m3 720-775 720-775 720-775 E-70 E-100 E-150 % vol % vol % vol min 10-45 40-70 75 10-45 40-70 75 10-45 40-70 75 FBP C 210 210 210 Sources of sulfur in typical gasoline pool FCC Naphtha Sulfur ppm max 150 50 10 RON Min 91 91 91 MON Min 81 81 81 RVP @ 38 C kpa 60 60 60 Benzene vol % max 1 1 1 Aromatics vol % max 42 35 35 Olefin vol % max 21 21 18 Oxygen wt% max 2.7 2.7 2.7 Other Coker Naphtha FCC naphtha represents ~40% of the volume of the typical refinery s gasoline pool UOP Confidential Information How do we manage both S and olefins in FCC gasoline?
UOP s Portfolio of FCC Naphtha Desulfurization Technologies Merox TM process - extraction or sweetening of mercaptan components of FCC Light Naphtha (LCN) and Mid-cut Naphtha (MCN) - Does not remove thiophenes SelectFining TM process - desulfurization and octane retention for FCC FBR, MCN or HCN Technology choice is based on octane requirements, feedstock composition, product values and required desulfurization. UOP Confidential Information
SelectFining Technology Overview 7 Achieve low S target in Gasoline Pool Can achieve <10 wt-ppm S in FCC Gasoline Maximum Octane Retention to Meet Specifications Lowest Hydrogen Consumption Flowschemes for Various Feedstocks Optimized for Maximum Economical Value One Stage for low sulfur feedstock (or 90% HDS) Two Stage for high sulfur feedstock and 90% HDS Depends on feed characteristics and product requirements High Stability Specialized Catalysts Specialized Co/Mo catalyst with optimized metals levels and distribution Suitable for all FCC naphtha hydrotreating applications where selectivity to favor desulfurization over olefin saturation is required UOP Confidential Information Optimum Flowscheme and Catalysts for particular needs
Issues Relating to Hydrotreating FCC Naphtha Desirable S Sulfur Removal + 6H 2 H 2 S + + Heat Sulfur Undesirable CH 3 Olefin Saturation CH 3 Octane CH 3 CH = C CH 3 + H 2 CH 3 CH 2 CH CH 3 Octane loss is dependant on feed/product sulfur contents, and quantity/types of naphtha s sulfur and olefin species! UOP Confidential Information
Relative Reactivity of S and Olefins in FCC Gasoline R-SH Increasing Reactivity R-S-S-R Sulfur S S C 6 C 7 Olefins S C 8 C 9 C 5 Increasing Molecular Weight S UOP Confidential Information
UOP One-Stage SelectFining Process 10 Makeup Hydrogen Charge Heater SelectFining Reactor Recycle Compressor Lean Amine Recycle Gas Scrubber Steam Feed Diene Saturation Reactor HYT-2117 N-200 HYT-2018 (S-200) HYT-2118 Rich Amine Light Ends Debutanizer Typical for low sulfur feeds and/or 90% HDS Flowscheme and operating conditions are similar to NHTs Product Separator Low Sulfur Naphtha UOP Confidential Information
Impact of % Desulfurization on Olefin Saturation Single-Stage SelectFining Performance 100 FBR FCC Naphtha Sulfur = 1800 wppm % Olefin Saturation 80 60 40 Single-Stage SelectFining Unit Typical Product S 20 95 96 97 98 % Desulfurization 99 90 ppm 72 ppm 54 ppm 36 ppm 18 ppm 100 UOP Confidential Information
H 2 S Impacts Olefin Retention 12 Total Product Olefins, wt% 21.5 20.5 19.5 Feedstock 23.8 wt-% Olefins 2206 wt ppm Sulfur 18.5 0.0% 0.4% 0.8% 1.2% Volume Percent H 2 S Understanding recombination is critical as it directly impacts olefin retention UOP Confidential Information
Mercaptan Recombination 13 H 3 C H 3 C CH 3 Octane H 2 S H 3 C H 3 C H 3 C CH 3 + H 2 H 3 C CH 3 + H 2 S SH Mitigate with two HDS stages strip out H 2 S between stages, as dictated by feed sulfur and product sulfur and octane targets Mitigate with polishing reactor downstream of SHDS UOP Confidential Information
UOP Two-Stage SelectFining Process Steam Charge Heater First Stage Reactor Makeup Hydrogen Recycle Compressor Lean Amine Second Stage Reactor Recycle Gas Scrubber 14 Feed Diene Saturation Reactor HYT-2117 HYT-2018 HYT-2118 HYT-2119 Rich Amine Light Ends Debutanizer Interstage Separator Product Separator Low Sulfur Naphtha Typical for high sulfur feeds with 90% HDS Interstage H 2 S Stripping Mitigates Recombination UOP Confidential Information
Impact of % Desulfurization on Olefin Saturation Single-Stage vs Two-Stage SelectFining Performance 100 FBR FCC Naphtha Sulfur = 1800 wppm % Olefin Saturation Typical Product S 80 60 40 ~ 1 RONC Single-Stage SelectFining Unit Two-Stage SelectFining Unit 20 95 96 97 98 % Desulfurization 99 90 ppm 72 ppm 54 ppm 36 ppm ~ 2 RONC 18 ppm 100 UOP Confidential Information
SelectFining Gasoline Desulfurization Optimized, Simply Flexible configurations to meet the most demanding challenges of octane retention and sulfur removal State-of-the-art, commercially proven catalysts with best-in-class performance Configurations in combinations with UOP Merox sweetening technology - Enables molecule management directing the sulfur species to the most efficient conversion process - Unique offerings which can lower both capital and operating costs
A Balancing Act: Bharat VI Specs with Maximum Profit 17 Limit on lights Distillation E70/E100 Oxygenates 2.7 vol% More Oxygenates Remove before or after reformer Benzene 1 vol% RVP UOP Solutions 60 kpa EtherMax unit Limit on C4s & InAlk Unit C5s in Isomerate AlkyPlus Unit Hydrotreating Limit on FCC Platforming Unit Gasoline Penex Unit Olefins IsomEx Unit 18 vol% Par-Isom Unit Selectfining Unit How can I blend more FCC Gasoline and control olefins and sulfur? How do I drive octane yield and aromatics to the limit? Where is the rest of my octane going to come from? Limit on Reformate Aromatics 35 vol% Sulfur 10 wt-ppm Limit on FCC Gasoline or Increase Desulfurization Severity Many constraints optimal solution?
UOP s Recent Platforming Innovations 18 Modified CatMax Internals Convective Charge Heater CFE Reactor Effluent Recycle Gas Cyclemax III CCR Naphtha Feed UOP 7299-18 Project IRR improved by 2-6 %
Convective Charge Heater 19 Features Charge heater moved to convection section displacing portion of steam generation Temperature control achieved by stack gas recycle Radiant section fouling reduced with stainless steel tubes 1 less heater box Conventional Conventional To Separator To Stack Convection Convective Charge Heater Benefits: Lower capital cost Reduced plot space Less fuel fired Lower emissions* Recycle Gas Naphtha Product Condenser CFE Stabilizer Preheat Steam Convection Bank Charge Heater IH #1 IH #2 IH #3 To RX1 To RX4 *Applicability for individual units to be evaluated UOP 7299-19 UOP Confidential Information Estimated savings is $5MM for 50,000 BPSD Unit
Meeting the Expansion Challenge: Example Max Throughput Revamp 20 Capacity raised to 190% nameplate Unit met / exceeded guaranteed revamp performance Key features: R-264 catalyst Reactor Bypasses with Rx Addition CCR expanded 1500 to 3250 lb/hr Radiant Convection fired heater Add a 4th Net Gas Compressor which also supplies additional recycle gas UOP s revamp experience: Over 50 CCR Platforming Units and over 25 Regenerator revamp designs UOP 7299-20 UOP Confidential Information Convective heater was a key part of this revamp
Platforming Innovations Summary UOP continues to improve best-in-class naphtha reforming technology Innovations include all critical sections of the process: - Regeneration - Catalyst - Reactor / Internals - Heaters Innovations drive substantial incremental customer value Innovations enabled because of unique R&D / Engineering / Equipment interaction
A Balancing Act: Bharat VI Specs with Maximum Profit 22 Limit on lights Distillation E70/E100 Oxygenates 2.7 vol% More Oxygenates Remove before or after reformer Benzene 1 vol% RVP UOP Solutions 60 kpa EtherMax unit Limit on C4s & InAlk Unit C5s in Isomerate AlkyPlus Unit Hydrotreating Limit on FCC Platforming Unit Gasoline Penex Unit Olefins IsomEx Unit 18 vol% Par-Isom Unit Selectfining Unit How can I blend more FCC Gasoline and control olefins and sulfur? How do I drive octane yield and aromatics to the limit? Where is the rest of my octane going to come from? Limit on Reformate Aromatics 35 vol% Sulfur 10 wt-ppm Limit on FCC Gasoline or Increase Desulfurization Severity Many constraints optimal solution?
Where should your C7s go? 23 Isomerization 330 Units C 5 -C 6 Par-Isom Unit I-122 PI-244 PI-242 Feed Dryers Makeup Gas To Separation Make-Up Gas Penex Reactors Stabilizer To Scrubber Hydrocarbon Recycle Option OT Recycle None Once Through DIH RONC 82 Gasoline Blending C 7 s? I-82 I-84 Penex Unit Dryers Cl Light Naphtha To Gasoline or DIH Recycle DIP Super DIH 92 93 Reforming 304 units C 6 C 11 CCR RXs Heaters CFE S E P R-254 R-234 R-334 Gasoline Blending Naphtha Feed R-264 R-284 Platforming Unit with Cyclemax III CCR 106+ BTX and Gasoline Blending UOP 7299-23 C 7 Management is critical for meeting BS VI specs
Processing Feed with Low Light to Heavy Naphtha Ratio in Naphtha Complex 24 Total Gasoline Yield = 90 Wt-% Meeting EURO V spec No MTBE added DIP Penex Unit SDIH 89+ RONC 35% Feed 100% Feed NHT Nap Split 100% 92 RONC 65% Feed Platforming Unit 95 RONC C 4 s UOP 7299-24 Naphtha Complex achieves 92 RONC pool without MTBE
Naphtha Complex with Penex/IsomEx Process Maximizes Gasoline Yield 25 Gasoline Yield ~ 95 Wt-% Meeting EURO V spec No MTBE added 92+ RONC Alternative schemes are available DIP Penex Unit IsomEx Unit SDIH 89-91 RONC 89+ RONC 56% 95 RONC 30% Feed NHT Nap Nap Split 15% Feed DIHp 80+ RONC 44% 92 RONC 55% Feed CCR Unit 95-102 RONC C 4 s UOP 7299-25 IsomEx achieves higher yield and RONC gasoline without MTBE
UOP IsomEx: C7 Solutions for Octane Challenges 26 Simultaneous increase of gasoline yield and quality - Meets stringent Euro V specifications without MTBE addition - Increases naphtha block gasoline yield from 90 to 95% 50 45 - Upgrades 56% of the product to premium gasoline (95 RONC) Built on generations of paraffin isomerization experience - Proven process configuration - Proven catalysts, yields and stability C 7 + in Reactor Feed, Wt-% 40 35 30 25 20 15 10 5 27.0 27.8 25.2 14.3 16.2 16.6 Molecule management: direct the molecules to the perfect technology. 0 2007 2008 2009 2010 2011 2012
A Balancing Act: Bharat VI Specs with Maximum Profit 27 Limit on lights More Oxygenates Distillation E70/E100 Oxygenates 2.7 vol% Limit on Reformate Aromatics 35 vol% Benzene 1 vol% UOP Solutions EtherMax unit InAlk Unit AlkyPlus Unit Hydrotreating Platforming Unit Penex Unit IsomEx Unit Par-Isom Unit Selectfining Unit Remove before or after reformer Sulfur 10 wt-ppm RVP 60 kpa Olefins 18 vol% Limit on C4s & C5s in Isomerate Limit on FCC Gasoline Limit on FCC Gasoline or Increase Desulfurization Severity UOP technologies can help refiners meet the rigorous specifications of Bharat VI while maintaining or increasing profit The principle of Molecule Management directing molecules to the most efficient, advanced technology provides real benefits Complex processing / blending solutions require a strong partner with broad experience UOP has the proven, commercialized solutions
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