H-Oil technology description

Alexandre Javidi
Jean-Philippe
Delphine Toupance
LE BARS

VCMStudy.ir
Teheran - November 2017 1
Oil Refining

REFINERY GASES

FOSSIL & LPG

RENEWABLE CDU TOP OF NAPHTHA
FEEDSTOCKS
THE GASOLINE
BARREL
JET FUEL / KEROSENE
DIESEL / GASOIL

FCC post- HEATING OILS

treatment
FUEL OILS
BOTTOM VGO/Res.
OF THE conversion LUBE OILS
VDU BARREL ASPHALT
Lube Oils
SYNCRUDE
SULFUR

S SULFUR RECOVERY

ACID GAS REMOVAL CLAUS TGT SULFUR

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Bottom of the Barrel
Axens Offer

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Axens Residue HydroCracking Offer

Objective: Conversion of Vacuum Residue (VR)

Feedstock into Valuable Products

 Fixed Bed Technology

• Limited conversion level

 Ebullated Bed Technology

• Deep conversion level possible

Deep Conversion

High Flexibility

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Axens H-Oil®RC Residue HydroCracking Feedstock

Vacuum Residue (VR) Feedstock

 Conversion into valuable products
› Naphtha, Diesel, VGO

 Unconverted Residue (UCO)

› Low Sulfur & Stable Fuel Oil
› Feed for Coker, SDA, Boilers or Gasification

High Value Products

UCO is a Liquid Fuel

Various Options for UCO Outlet
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 VCMStudy.ir

Axens H-Oil RC – Residue HydroCracking

 Vacuum Residue (VR) Feedstock
Catalyst Addition
Gas / Liquid • 40 - 85% VR conversion
Separator

Recycle Cup  Unconverted residue application

Expanded Catalyst • Low sulfur (up to S< 1%) & stable fuel oil
Level • Feed for coker, SDA or gasification units
Settled Catalyst Level
 On-line Addition/Withdrawal of
Ebullated Bed
catalyst
Distributor • Fully Automated System
Hydrogen and Grid • Constant product quality
Feed Slurry Feed
Plate • APC from Axens used to control catalyst
Ebullating Pump bed expansion

Catalyst Withdrawal Recycle Oil

 Availability > 96%
• 2 to 6 years cycle
• No shutdown for catalyst required

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Axens H-Oil Process - Flexibility
Design Feedstock of Motiva unit
• 70% Arabian Light
• 30% Arabian Medium

Feedstock of Motiva Refinery

• Arabian Light
• Arabian Medium
• Arabian Heavy
• Basrah
• Bonny Light, Brass River
• Brent, Ekofish and Escravos
• Iranian Light
• Kirkuk
• Maya
• Alaskan North Slope
• Eugene Island
• …

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Axens H-Oil®RC – Simplified scheme overview

Make-Up 1st 2nd 3rd

H2 Stage Stage Stage HP Mem PSA Fuel Gas

HP Abs
Inter-Stage
REACTION AND H2 Separator
COMPRESSION HP LT
SECTION Separator
HP HT
Heater Separator MP Abs
Used
Catalyst
H-Oil MP LT
CATALYST MP HT
Reactors Separator
Separator
SECTION

Resid Feed Gas

Fresh
Naphtha
Atmospheric
Heater Catalyst & Vacuum Diesel
Fractionation
VGO
Temperature 400 – 430°C Conversion 40 – 90 %
VR
Pressure 120 – 190 bar HDS 65 – 85 %
LHSV 0.1 – 1.3 hr-1 HDCCR 40 – 80 %
CRR 0.35 – 2.1 kg/t HDM 70 – 90 % FRACTIONATION SECTION

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H-Oil Overall Block Flow Diagram

UCO

 Outstanding catalytic system

 H-Oil ACS

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 H-Oil Catalyst

 Type: NiMo/Alumina 1.0-mm Extrudate. (Hydrotreatment catalyst type)

 Catalyst replacement rate : metals in feed & objectives depend.

 Vendor : Axens

 Spent Catalyst Re-Processing

• Worldwide based companies which process spent catalyst for metals reclamation
(Mo/Ni/V) – 15 references all around the world.
Additional revenue for customer from reclaimed metals

 Catalyst Cascading: spent 2nd stage catalyst is used as replacement

catalyst for 1st stage reactor

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Catalyst Handling Section Overall Scheme

Fresh Catalyst
Provision
Catalyst Wash/Cooling
Oil Drum Diesel from
Measuring
hopper Fractionation

Reactor 1

Reactor 2
Fresh Catalyst
Pneumatic Spent
Transport System Fresh Catalyst Catalyst
Storage Cooling
Hopper Drum

Spent Catalyst
Catalyst Storage
Addition/ Hopper
Withdrawal
Transport/
Wash Oil
Drum
HVGO from Drum
Fractionation
Catalyst
Vapor
Separator
Drum Spent Catalyst Dump

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Why an H-Oil is not impacted by metals
content in the feed?
Case 1

Feed UCO
250 ppm of metals H-Oil unit 90 ppm of metals

Fresh catalyst HDM ~90% Eq. catalyst

~0.85 kg/t of feed 23% of V
5% of Ni
Case 2

Feed UCO
520 ppm of metals H-Oil unit 200 ppm of metals
Fresh catalyst HDM ~90% Eq. catalyst
~1.4kg/t of feed 23% of V
5% of Ni

Catalyst Addition Rate Adjustment maintains constant

catalyst activity irrespective of metals in the VR feed
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 H-Oil Pilot Scale Experience
 Origin of the crudes
Canadian (Athabasca mined, Athabasca SAGD, Athabasca PFT, Lloydminster,
Cold Lake, ...)
Middle East (Safaniya, Buzurgan, Arabian Heavy, ...)
South-American (Zuata, Morichal, Cerro Negro, Boscan, Chichimene, ...)
Russian (Ural, Siberian, ...)
Chinese (Tahe)…
Metals: 0 to 1500 ppm, S: 0.2 to 6wt%, CCR: 0.1 to 35wt%, N: 10 to 8000 ppm
Feedstock origin Metals content, ppm % conversion

Athabasca 431 58 to 78
Maya-Ismuth 566 45 to 50
Focus on high metals feed Maya-Ismuth 688 45 to 50
Tahe 447 40 to 50
Athabasca/Cold lake 540 50 to 75
Maya/Ismuth 1040 54 to 65

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 H-Oil Industrial Scale experience
CONTENIDO DE NIQUEL, CARGA NEGRA
200 CONTENIDO DE VANADIO, CARGA NEGRA
950
180
850
160 750
140 650
550
120
450
VALOR

%w
100 VALOR 350
%W

DISEÑO
80 250
DISEÑO
150
60
50

01/01/2004
15/01/2004
29/01/2004
12/02/2004
26/02/2004
11/03/2004
25/03/2004
08/04/2004
22/04/2004
06/05/2004
20/05/2004
03/06/2004
17/06/2004
01/07/2004
15/07/2004
29/07/2004
12/08/2004
26/08/2004
09/09/2004
23/09/2004
07/10/2004
40
20
0
01/0…
15/0…
29/0…
12/0…
26/0…
11/0…
25/0…
08/0…
22/0…
06/0…
20/0…
03/0…
17/0…
01/0…
15/0…
29/0…
12/0…
26/0…
09/0…
23/0…
07/1…
ENE-AGO 2004
ENE-AGO 2004
500
450
 More than 430 ppm of V+Ni is 400

contained in the feed. 350

 Design was made for 670 ppm in the 300

250 VANADIO
feed 200 NIQUEL

 Quantity of vanadium in the feed 150

100
varies a lot : no issue 50

Flexibility of the H-Oil towards metals 0

0 5 10 15 20 25 30

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H-Oil Overall Block Flow Diagram

UCO

 Safe and robust

 Superior Internals
design

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 Axens H-Oil®RC Ebullating pump

 Safety “H-Oil®” Ebullating Pump

(External: case mounted)
• Easy leak detection when external
• Should a fire occur, risk to the reactor is
minimal when external

 Maintenance
• Direct access to the pump (easier & safer)

 Operability / Reliability
• Direct flow measurement
• Butterfly valve on pump discharge
› Easy start up and shutdown
› Avoids reverse flow through pump and catalyst
bed collapsing in emergency situation

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Axens H-Oil®RC Ebullating Pump

 Axens H-Oil unit

design features an
external location for the
ebullating pump for:

 safety
 maintenance
 operability

Available Only from Axens

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Axens H-Oil®RC Ebullating Pump – Iran case
 Type of pump
• Pump flowrate in the middle range of existing pump in operation
(Typical sizing of reactor)

 Supplier
• Sulzer
› Relevant experience with “Isotherming” process
› Have been short listed by Hengli (China) for H-Oil unit

• Flowserve
› Leader in EB market
› Latest two EB pumps supplied and serviced 100% from EU base
› On-going Company business compliance process

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 H-Oil Overall Block Flow Diagram

UCO

 Optimal Vacuum Tower bottoms arrangement

 Energy efficient Spiral heat exchangers

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 How much conversion can you get with H-Oil?
Conversion
wt%

90 %

80 %

70
%

60
%

50 % Feed
Middle east Middle East Heavy Shengli Ural Athabasca Zuata Maya Difficult
Light
y

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H-Oil® : Assets & Values Streamline

H-Oil® reactor design leverage

Sequential Deasphalting
Coker Integration
- Maximize catalytic
performance for both
- Accommodate high
conversion and
capacity
hydrorefining - Maximize the use of
- Overcome stability
- Balance reactor existing assets
issues thanks to
size and operating - Unlock sediment
asphaltene rejection
conditions constraints for H-Oil® UCO
- Balance Hydrogen
- Control - Create value not only with
and/or utilities with
sedimentation high conversion but also
pitch valorisation with better coke quality

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Understanding Effluent Stability
Saturates / Aromatics / Resins / Asphaltenes Asphaltenes are:

MATRIX
the heaviest structures
 difficult to characterize
 difficult to convert
 potentially unstable

Conversion

When destabilized, Asphaltenes floculate and cause:

- Fouling & downtime for cleaning
- Sediment in products

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 How to Push the Conversion?
 Increase Temperature or Reduce space velocity?
LHSV Temperature Conversion
Case 1 Base Base Base
Case 2 Base Base + 14°C Base x 120%
Case 3 Base/3 Base - 18°C Base
Case 4 Base /3 Base Base x 120%

• From Pilot Test Results with true EB pilot testing unit

140
200

120 180
160
100
Case 1 140
120
80
Case 2 Target good stability
100
60 80
Case 3
60
40 Case 4 40

20 20
0
0 % Sediments vs Stability Limit
Conversion HD Asphaltenes HDCCR HDS

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 How to Push the Conversion?
 Temperature Increase
• Conversion increase driven by thermal cracking: compromises
operability (sediments, fouling)

 Reduce LHSV
• Lower LHSV is favorable towards sediment control at iso
conversion
• At same temperature, lower LHSV is a powerful way to boost
conversion and hydrogenation reactions
• Effluent quality is improved
• Catalytically driven conversion increase: delivers higher
performance in HDCCR and HDAsph. Unlocks sedimentation
barrier

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 H-Oil® Suite
Conversion To Capacity Effect
40% VR availability
reduction

 Lower capacity operation

Up to 15% of
industrial demonstration conversion
• Higher conversion
• Less sediment production Conversio
• Enhanced refining n
performance

 LHSV / WABT prove

powerful to break
conversion ceiling
Four-fold sediment
reduction
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H-Oil® : Assets & Values Streamline

H-Oil® reactor design leverage

Sequential Deasphalting
Coker Integration
- Maximize catalytic
performance for both
conversion and - Accommodate high
hydrorefining capacity
- Maximize the use of
- Balance reactor size - Overcome stability existing assets
and operating issues thanks to
- Unlock sediment
conditions asphaltene rejection
constraints for H-Oil® UCO
- Control - Balance Hydrogen
and/or utilities with - Create value not only with
sedimentation high conversion but also
pitch valorisation with better coke quality

Teheran - November 2017

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