10_latest developments in hydrocracking catalysts proceedings.pdf

7/23/2019 10_Latest developments in Hydrocracking catalysts Proceedings.pdf

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Latest Developments in

Hydrocracking Catalysts

Bertrand Carruette


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References in Hydrocracking catalysts

In the world

Focus in India

Axens Catalysts Offer

Hydrotreatment Catalyst portfolio

Hydrocracking Catalyst portfolio

Industrial Case Study

Axens technical services offer

Agenda

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2 Hydrocrackers Operating in India

Refinery 1 (Axens design)

Started-up in 2010

Capacity 1.7 MMTPA

Feed origin 100% SRVGO

Catalyst combination : HR 448 HYC 652

Pretreatment catalyst replacement with HRK 558 in 2012

Refinery 2 (Competitor design)

Started-up in 2009 (with Axens catalysts)

Capacity 1.35 MMTPA Feed origin 100% SRVGO

Catalyst combination : HR 448 HYC 652

Pretreatment catalyst replacement with HRK 658 in mid 2013

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In the world

Focus in India






Agenda

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Increasing HDA Activity

Increasing HDN Activity

HRK 658

HRK 558

HRK 1448

HR 448

Axens Pretreatment Catalyst Portfolio

Launched in 2012

Impulse

Technology

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The cycle length of hydrocracking units is generally limitedbythe activity of the pretreating catalyst

HRK 1448

The challenge in catalyst engineering is to

maximize the HDN activity of the pretreating

catalyst while maintaining our benchmark

catalyst stability

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ImpulseTM Technology

Maximum promotion

Maximum active phase dispersion

Optimized support characteristics

including metal-support interactions

Combination ofmaximal activity with

maintained superior stability

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HRK 1448 Relative HDN Activity Gain

HRK

558

Impulse

HRK

1448

Relative Volume Activity(%)

Significant HDN activity improvements

observed for Impulse catalysts 8


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Impulse Technology - Summary

A breakthrough technology for

maximum refinery profits

Complete high performance

Can process more difficult feedstock

without cycle penalty

Additional Flexibility

Maximum Throughput with higher EBP Opportunity Feed

Longer Cycles

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In the world

Focus in India






Agenda

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HDK 786

Increasing Middle Distillate Selectivity

Increasing Conversion Activity

HYK 762

HYK 752

HYK 742

HYK 732

HDK 776

HDK 766

HYK 743

HYC 642

HYC 652

More active in conversion

More selective towards Middle Distillate

Diesel cold flow properties improvement

Hydrocracking Catalyst Portfolio

Launched in 2013

Axens offers the most adapted catalysts required cycle length

required middle distillate yield

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350

360

370

380

390

400

410

420

430

0 100 200 300 400 500 600 700 800 900 1000 1100 1200 1300

Operating WABT R-002

0.3 C/month after 1200 days on stream

Deactivation rate measured at Refinery 1

Outstanding stability (HYC 652)

C

Days on Stream

Base + 80

Base + 70

Base + 60

Base + 50

Base + 40

Base + 30

Base + 20

Base + 10

Base

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340

350

360

370

380

390

400410

420

430

440

100 200 300 400 500 600 700 800 900

Observed WABT

Outstanding stability (HYC 652)

C

Days on Stream

Deactivation rate measured at Refinery 2


Base +100

Base + 90

Base + 80

Base + 70

Base + 60

Base + 50

Base + 40

Base + 30

Base + 20

Base + 10

Base

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350

360

370

380

390

400

0 40 80 120 160 200 240 280 320 360 400 440 480

Outstanding stability (HYK 742)

Days on Stream

C Deactivation rate measured at a European Refinery

0.5 C/month at high LHSV, 4 h-1

Base + 50

Base + 40

Base + 30

Base + 20

Base + 10

Base

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375

380

385

390

395

0 200 400 600 800 1000

Outstanding stability (HYK 742)

Deactivation rate measured at an Asian Refinery


C

Days on Stream

Base + 20

Base + 15

Base + 10

Base + 5

Base

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In the world

Focus in India






Agenda

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Zeeland Refinery

Located in Vlissingen

(Netherlands)

Started-up in 1974

Shareholders

Crude distillation capacity : 150,000 BPSD

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Hydrocracker Unit

Started-up in 1986

Feed: SRVGO from VDU + Imported VGO

Feed rate: 455 m3/h (68,500 BPSD)

Density: 0.908 - 0.920 t/m3

S: 1.0 1.7 wt%

N: 1000 1300 wt ppm

Production

Light Naphtha, Heavy Naphtha

Jet Fuel, Light Diesel, Heavy Diesel

Base Lube Oils

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Hydrocracker Catalyst Replacement (I/II)

Objectives

90 to 95%wt conversion

Maximize Cycle Length

Maximize Middle Distillate production (Euro V)

Achieve Base Lube Oil group III quality with UCO

Dedicated full pilot test program launched inTotal facilities to select the optimized catalyst

systemamong catalyst manufacturer offers

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Hydrocracker Catalyst Replacement (II/II)

Constraint

Solution

Unit limited by the pretreatment

Use ofhigh nitrogen toleranthydrocracking catalyst to compensate

for the pretreatment section

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390

395

400

405

410

415

420

0 100 200 300 400 500Days on oil

WABT, C

0

50

100

150

200

250

300N slip, ppmwWABT HYK 742 Op

WABT HYK 742 Normalized

Nslip

TBase + 5

TBase

TBase + 10

TBase + 15

TBase + 20

TBase + 25

TBase + 30

Excellent stability(0.4 0.5

C/month) of HYK 742

even under 250 wppm organic Nitrogen

permitting an increase in the catalyst cycle length

Hydrocracker Catalyst Cycle 1 Nitrogen Slip

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HYK 732 / HYK 742 stability not

impacted by the Nslip increase

TBase + 5

TBase

TBase + 10

TBase + 15TBase + 20

TBase + 25

TBase + 30

TBase + 5

TBase

TBase + 10

TBase + 15TBase + 20

TBase + 25

TBase + 30

Hydrocracker Catalyst Cycle 2 Nitrogen Slip

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Case Study Conclusions

Cycle 1 & 2 demonstrated the excellent

performance of HYK 742 and HYK 732 zeolite

catalysts

High Nitrogen tolerant zeolite catalyst

is one of the solutions to improve economics of any

hydrocracker constrained by pretreatment activity

Axens selected for Cycle 3 (just started-up)

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In the world

Focus in India






Agenda

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Technical Services for Hydrocrackers

Technical assistance based in India, New Dehli AIPL supported by Axens HQ in France

Start-up of the unit

In charge of catalyst loading, unit inspection, review of operating conditions

Follow-up of the unit

Performance follow-up based on data received from the Refinery

Recommendations and advices in order to optimize the unit operation

In case of troubleshooting, access to Axens troubleshooting team: Tech

Service and Technology Group, Process Group, Mechanical & CorrosionGroup, Analytical Group

Axens can supply feed and products analysis

Access to IFPEN State-of-the-Art Analytical know-how.

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Strong R&D : Continuous catalyst development

Pretreatment catalyst Impulse Technology: A breakthrough technology

for maximum refinery profits

Hydrocracking catalyst Full set of catalyst HYK series

Outstanding stability

Nitrogen tolerant

Technical Services Team based in India, AIPL

Conclusion

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