challenges for proper implementation of residue upgrading ... · challenges for proper...

Challenges for proper implementation of

residue upgrading processes within oil

refineries

February 15, 2016 | A. Blumenstock (Speaker), W. Hamschmidt, T. Streich

2 | February 15, 2016 | Egypt Downstream 2016 – Challenges for proper implementation of residue upgrading processes within oil refineries | A. Blumenstock

thyssenkrupp Industrial Solutions

Summary 6

Increasing flexibility of the distillation plants 5

Implementation of a residue conversion plant 4

Measures and market - Bottom upgrading project 3

Oil refining and petrochemicals 2

thyssenkrupp Industrial Solutions - Process Technologies 1

Agenda



Summary 6






Agenda



Business Unit

Business Area

Regional Organi- zations

Industrial Solutions The new dimension in Plant Engineering

Car Body Technology

Lightweight Solutions

Forming Dies

Testing Solutions

Industrial Solutions

Resource Technologies (former Polysius and Fördertechnik)

Process Technologies (former Uhde)

Cement

Services

Fertilizer/

Coke Plant Technologies Surface Vessels

Services Chemicals/Oil & Gas

Services

Marine Systems

Assembly Systems Mining Submarines

System Engineering

Services

Americas CIS

Sub-Saharan Africa

Asia Pacific MENA

India

Europe



Delivering true efficiency!

by means of the combined power of 200

years of engineering excellence with

German roots.

to enable global industrial development

while protecting scarce resources,

develops reliable, long-term solutions

together with its clients,

Industrial Solutions



Summary 6






Agenda



Field of activities Overall value chain

Feed and product storage

Broad range of Refinery processing

- Pipeline

- Tankers

- Trucks

- Railcars

Sale to costumer

(petrol stations,

petrochemical

companies)

Survey

Exploratory

Drilling

Field

Level

Conventional Oil Processing

(Drilling)

Unconventional Oil Processing

(Hydraulic Fracturing, Oil Shale, Oil sands, etc.)

Crude oil / LPG

transportation

- Pipeline

- Railcars

- Trucks

- Barges

O

Exploration Production Crude Transportation

Upstream Midstream

2 3 1

Crude

Storage Refining

Prod.

Storage

Product

Transportation Distribution

Downstream

4 5 6 8 7

Main field of TKUES activities

https://www.google.de/url?q=http://www.fotosearch.de/clip-art/bagger.html&sa=U&ei=f10sU-6bO4eR7Aa6hIHIAg&ved=0CD0Q9QEwCA&sig2=B0ofRe1pX323dHQ4LT2P8Q&usg=AFQjCNE_cdeUYahKA05tZEualbUYXFZylQ

https://www.google.de/url?q=http://www.gograph.com/stock-illustration/oil-storage-tank.html&sa=U&ei=pvovU8H_NoemhAeWv4HwBg&ved=0CEEQ9QEwCg&sig2=gFckW5Fph04QOXx7JJzvmg&usg=AFQjCNG3bfGOdqCmMqZaQEVsKyGVOa-p4Q

https://www.google.de/url?q=http://www.gograph.com/stock-illustration/oil-storage-tank.html&sa=U&ei=pvovU8H_NoemhAeWv4HwBg&ved=0CEEQ9QEwCg&sig2=gFckW5Fph04QOXx7JJzvmg&usg=AFQjCNG3bfGOdqCmMqZaQEVsKyGVOa-p4Q



Field of TKUES activities Oil Refining, Lube Oils and Waxes

References / Licensed by Others

Diesel / Gas Oil

Gasoline Pool

Cru

de

Coke

Heavy Fuel Oil

Food Grade Wax

Lube Oils

BTX

Technical / Medical

White Oils

Thermal

Cracker/Coker

Atm

osp

he

ric D

istilla

tio

n

Va

cu

um

Dis

tilla

tio

n

Residue

HDT / HC

Steam

Reformer

Amine

Treating

Lt. Naphtha

HDT

Hvy. Naphtha

HDT

Kero-/MD-

HDS

Sulphur

Recovery

VGO

HDS

Visbreaker

Solvent

Deasphalting

C5 / C6

Isomerization

Catalytic

Reformer

Kero-/MD-

HDA

VGO

Hydrocracker

FCC

Lube

Hydrocracker

Solvent

Extraction

Steam

Cracker

LPG

Separation

Butane Dehydrogen

C4 Selective

Hydrogenation

FCN Selective

HDS

Catalytic

Dewax/Isom

Solvent

Dewaxing

Wax Hydro-

isomerization

Wax

Hydrogenation

Hydrogen

Finishing

White Oil

Hydrogenation

Merox

Treater

MTBE / ETBE

Butane

Isomerization

Lube Oil

Blending

Alkylation

Catalytic

Polymerization H2

Ethylene / Propylene

LPG

H2

Partial Oxidation

Uhde or open art Technology



Field of TKUES activities Petrochemistry: Olefins and solvents

Propane

Butadiene

References / Licensed by Others

Propylene

Ethylene

C4 Cut (Butenes)

C5 Cut (i-Amylenes)

Dehydrogenation

(STAR)

Propylene

Purification

Isopropanol-

Alcohol (IPA)

DIPE

Iso-Octane

Metathesis

MTBE Selective

Hydrogenation

Butadiene

Extraction

Acetone

(DMK) MIBK

Alkylation

MEK SBA

Catalytic

Polymerisation

MeOH

EtOH

i-Butane

Uhde or open art Technology

TAME

ETBE

MTBE

MEK

SBA

i-Octane

Polymer Naphtha

Alkylate

DIPE

DMK

MIBK

IPA Propylene

ETBE

TAME

TAEE

1-Butene Butene Concentration

TAEE

DME DME



Summary 6






Agenda



Strategic search for new trends Refinery investment drivers

Change in Product Slate

Re-construction & Revamps

Change in Product Specs

Change in Crude Quality

New Regulations

Main drivers for investment

• Total investments of refining industry (avg. Annual CAPEX): 4 – 5 bn €

• Expected long-term trend:

– Decreasing overall fuel consumption

– Constant investments



Strategic search for new trends Opportunities

Source: 1. Oil & Gas Journal (2010) 2. Gazprom (2011) 3. MARPOL 73/78

Global Heavy Crude Proc.1

10

12

14

16

18

20

2010 2015 2020

LNG Demand Marine Sector2 Global Sulphur Limit.3

mio. b/d bil. m³/a [% w/w]

Focus on bottom upgrading processes

Worldwide shift to heavier crudes

Replacement of heavy fuels by LNG

More stringent regulations to heavy fuel

oils



Strategic search for new trends Opportunities

Source: Hydrocarbone Publishing 3Q, 2010

51%

36%

5%3%

3%

2%

Coking RFCC

Fixed-bed hydroproc. Visbreaking

Ebullated-bed Hydrocracking Solvent Deasphalting

78%

8%

8%

6%

Delayed Coking Fluid Coking Other unspecified

Distribution by Bottom Upgrading Processes Distribution by Coking Technologies



Focus on Residue Upgrading Processes

VISBREAKER PARTIAL

OXIDATION

FLUID CATALYTIC

CRACKER (FCC)

Atm.

Residue

BITUMEN

OXDATION

Syngas

Hydrogen

Steam

Power

Heavy

Fuel Oil

Petroleum

Coke

Licensed by Others;

TK References

Intermediate Product

to further Processing

in Refinery

Bitumen

Vacuum

Residue

Vacuum

Gas Oil

HYDROTREATER /

HYDROCRACKER

SOLVENT

DEASPHALTING

DELAYED

COKER

THERMAL GASOIL

UNIT

Licensed by TK



Summary 6






Agenda



Delayed Coker Unit (DCU) Project Up- and Downstream Plants

Power and

Heat Generation;

LPG Recovery

Naphtha

Hydrotreater Vacuum

Distillation

Hydrogen

Desulphurization

Power Station

Crude Oil

Distillation

Vacuum

Residue

Crude Oil

Marine

Diesel

Naphtha

Coke

Atmospheric

Residue

Coker gas

Middle Distillate

Desulphurization Diesel

Heavy Coker

Gas Oil

DC Naphta

Light Coker

Gas Oil Delayed Coker Unit

(DCU)



Challenges for DCU integration Many pieces must fit together to form a coherent whole

Revamp, modification or installation

of complete new processing units

like HDS/HDA/HT

Implementation of ThruPlus®

Delayed Coker Unit (ISBL

process plant)

Revamp, modification or

installation of associated

utilities, offsite and auxiliary

facilities



Considerations for Coker Implementation

Crude

Oil

Fuel Gas

Naphtha

Kerosene

Gas Oil

Heavy

Gas Oil

Crude and Reformer

Naphtha

Fractionation

Hydrogenation

Isomerization

Catalytic

Reformer

H2 H2

Steam Reformer

(H2 Plant)

H2

C4

Diesel

Vacu

um

Desti

llati

on

Vacuum Gas oil Catalytic Cracker

(FCC)

Fuel Gas

Vacuum Residue Cracker Residue

Deb

uta

niz

er

Sp

litt

er

Heavy F

ue

l O

il

Ble

nd

ing

Heavy

Fuel Oil

Gaso

lin

e B

len

din

g

Gasoline

Hea

tin

g O

il

Ble

nd

ing

Heating Oil

Atm

os

ph

eri

c D

isti

llati

on

C5

Light Gasoline

Isomerisate

C4

stabilized Reformate

Heavy FCC Gas Oil

Light FCC Gas Oil

LP

G

Reco

very

Fuel

Gas

Desalt

er

HDS

HDS

HDS

HDA

HDS

FCC Naphtha

HDS

unstabilized

Reformate

C3

Aviation Fuel

(Kerosene)

Refinery

Gas

C3

ISB

L.

OS

BL

.

C4

Boiler

Feed

Water

Steam

Cooling

Water

Electrical

Power

MEA

Sour

Water

Treatment

Flare

Claus

H2



Considerations for Coker Implementation

Crude

Oil

Fuel Gas

Naphtha

Kerosene

Gas Oil

Heavy

Gas Oil

Crude and Reformer

Naphtha

Fractionation

Hydrogenation

Isomerization

Catalytic

Reformer

H2 H2

Steam Reformer

(H2 Plant)

H2

C4

Diesel

Vacu

um

Desti

llati

on

Vacuum Gas oil Catalytic Cracker

(FCC)

Fuel Gas

Vacuum Residue Cracker Residue

Deb

uta

niz

er

Sp

litt

er

Gaso

lin

e B

len

din

g

Gasoline

Hea

tin

g O

il

Ble

nd

ing

Heating Oil

Atm

os

ph

eri

c D

isti

llati

on

C5

Light Gasoline

Isomerisate

C4

stabilized Reformate

Heavy FCC Gas Oil

Light FCC Gas Oil

LP

G

Reco

very

Fuel

Gas

Desalt

er

HDS

HDA

HDS

HDS

HDS

FCC Naphtha

HDS

unstabilized

Reformate

C3

Aviation Fuel

(Kerosene)

Refinery

Gas

C3

ISB

L.

OS

BL

.

C4

Boiler

Feed

Water

Steam

Cooling

Water

Electrical

Power

MEA

Sour

Water

Treatment

Flare

Claus

H2

Dela

yed

Co

ker

Un

it

Heavy Coker

Gas Oil Atmospheric Residue Coke

Lig

ht

Co

ke

r G

as

Oil

Marine

Diesel

Cra

cked

Nap

hth

a

Hyd

rotr

eate

r

HDS

Co

ker

Gas

H2

H2

WSA

(H2SO4)



Considerations for Coker Implementation Additional units and expansion of existing units

ISBL:

• Delayed Coker (CDU) – new

• Marine Diesel Desulphurization (MDD) – new

• Cracked Naphtha Hydrotreater (CNHT) – new

• LPG Recovery including Caustic Wash/Water Wash or Merox – new

• Crude and Reformer Naphtha Fractionation (CPL) – revamp, modifications

• Naphtha Hydro Desulphurization (NHD) – revamp, modifications

• Diesel Hydro Desulphurization / Dearomatization (HDS / HDA) – revamp, modifications



Considerations for Coker Implementation Additional units and expansion of existing units

PSA (H2) unit – expansion of existing PSA unit

MEA (amine) absorbers – new absorbers and modifications of existing absorbers

MEA regeneration – 1 new regeneration unit

Sour water/process water – revamp and 1 new sour water stripper

Wet Sulphuric Acid Plant (WSA) – new (alternatively revamp of Claus Plant)

Coke Handling Unit – new

Coke Loading (ship / rail) – new

LPG Loading (rail) – revamp depending on logistics

Offsites

BFW / Steam / Condensate – revamp and 1 new demin water unit

Cooling water – 1 new circulation system with air cooler or cooling tower

Instrument Air / Plant Air – revamp, 1 new compressor (existing drying unit is sufficient)

Flare – new flare for new plants (DCU, MDD,) etc. and study of existing flare/ flare system

Slop system – extension

Flushing oil system – extension (new vessel and new pump)

Biological waste water plant – revamp

Utilit

ies

OSBL



Consideration of Coker Implementation Total cost evaluation

OSBL – all existing units reflecting the Integration

Invest Cost: ~ 50% – 60%

ISBL - new Coker

Invest Cost: ~40% – 50%

Implementation of residue upgrading processes within oil refineries

Challenge for modifying of

crude oil processing

(CDU and VDU)



Summary 6






Agenda



Increasing flexibility of the distillation plants

Heavy Crude Oil The continuous rise of heavy crude oils production in the

upstream industry requires modification of CDU/VDU sections

Changes of feedstock quality

The need of higher sulpher-rich and higher corrosive feedstock

processing requires a specific material selection for long-term

operation

Demand of middle distillate

Increasing of flexibility of Naphtha Cut point reduction reflects the

higher demand of Diesel towards Gasoline /Naphtha

Bitumen production Increasing of flexibility of VDU matching Bitumen product quality

for high range of crude slates

Economic driven considerations for increasing crude oil processing flexibility



Increasing flexibility of the distillation plants Example: Top1 / Vak1 Project for a client in Europe

Units Objectives Modifications of existing plants or

new design

Crude oil

Distillation Unit

(CDU)

• Increasing of middle distillate yield by

means of Naphtha Cut Point reduction

• Processing crude oils currently not

applicable

• Decreasing of Maintenance Cost

• Replacement of the column top (new

design and material selection)

• Replacement of column trays (middle

section of column)

• Additional new UCR System

• Modifications regarding the LGO

withdrawal route (new LGO pump, new

LGO cooler, etc.)

• Optimization of material selection

Vacuum Distillation

Unit (VDU)

• Increasing the range of crude slates for

Bitumen production in order to allow:

• Processing crude oils currently not

applicable for Bitumen production

• Increasing of VGO yields

• New vacuum column,

• Replacement of relevant hot pumps

(Vacuum Residue, VGO, etc.)

• Replacement of heat exchangers and air

coolers

• new vacuum system (2 stages ejectors

and liquid ring pump)



Summary 6






Agenda



Summary

The new installation of a Residue Conversion Unit and the necessary revamp of existing plants constitutes a major challenge for refiners and engineering contractors

• The worldwide crude slate has shifted to heavy and extra heavy feeds with high sulphur

content.

• New maritime bunker fuel specifications with stringent emission norms for SOx and NOx

increase the switch over from heavy fuel oil to clean combustion natural gas (LNG)

• Decreasing of the use of residue fuel oils in power production requires a further processing

of Residues by producing more valuable distillate products.

There is a growing drive to cost effectively maximize production from every barrel of crude

oil processed.

• By integrating a Residue Upgrading Process there is a advantage of being able to process

heavier and sulphur-rich feedstock and therefore reasonable priced crude oil. This requires

a high flexibility of the distillation plants

Thank you!

challenges for proper implementation of residue upgrading ... · challenges for proper...

Documents