Residue Conversion Pathways: Hyvahl & H-Oil

Duc Nguyen Hong

Agenda

A technological solution for every problem

Production of Very Low Sulphur Fuel Oil with Hyvahl fixed bed technology

Resid Hydroconversion through Axens H-OilRC ebullated bed technology Pushing conversion one step forward by combining H-Oil with other units

Process Mapping
Ni + V in the Feed, wppm
1000 800 300

H-OilRC

H-OilRC
Ebullated Bed

Ebullated Bed + Other units

200 100
0

Hyvahl
Fixed Bed
30 40 50 60 70 80 90 100
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Net VR Conversion,%

Agenda

A technological solution for every problem

Production of Very Low Sulphur Fuel Oil with Hyvahl fixed bed technology

Resid Hydroconversion through Axens H-OilRC ebullated bed technology Pushing conversion one step forward by combining H-Oil with other units

RDS: Hyvahl Characteristics

PRS Guard Reactors
Gas Treatment

Fixed bed process from

AR to 100% VR hydrodesulfurization

R1A

R1B

Can process feeds with

high metals content using PRS technology
Fractionation Section

Feed AR / VR
Hydrogen

Low to medium diesel

production: 20-25%

Hydrotreated Residue applications:

ULSFO and stable fuel oil Excellent feed for resid FCC unit (R2R)
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Agenda

A technological solution for every problem

Production of Very Low Sulphur Fuel Oil with Hyvahl fixed bed technology

Resid Hydroconversion through Axens H-OilRC ebullated bed technology Pushing conversion one step forward by combining H-Oil with other units

Axens H-Oil Process

First unit started in 1968 Nine units in operation today Five units in design/construction Two recent awards Total capacity: > 800, 000 BPSD

Ebullated-Bed Reactor

Internal recycle of liquid Nearly isothermal Low and constant pressure drop Daily addition/withdrawal of catalyst No cycle length
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H-Oil Improvements
Make-Up H2
1st Stage 2nd Stage
3rd Stage
HP Air Cooler

HP Mem
HP Abs

PSA

Fuel Gas

Inter Stage Separator

Heater Used Catalyst

HP LT Separator

HP HT Separator

MP Abs MP LT Separator Atmospheric & Vacuum Fractionation

H-Oil Reactors

MP HT Separator

Resid Feed

Heater

Fresh H-Oil design features Catalyst IS: Inter-Stage Separator Optimized Hydrogen management CU: Cascade Catalyst Utilization

Sour Gas Naphtha Gasoil VGO VR

HCO/VR Co-processing: Pilot Plant Study

VR
Origin Density, Gravity, API kg/m3 URAL 1.005 9.1 2.65 5 500

HCO
URAL 1.089 -1.7 2.32 2 500

85% VR + 15% HCO

90% VR + 10% HCO 95% VR + 5% HCO 100% VR + 0% HCO

Sulphur, %W Nitrogen, wtppm

Ni + V, wtppm
CCR, %W IP375, %W

203
15.3 < 0.01

<2
5.9 -

Objective: Analysis of HCO (aromatic stream) effect on unit stability Test carried out on a 2 stages true ebullated bed pilot Target: 70% conversion in stable operation
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Conversion Trend with HCO in VR

15% HCO 10% HCO 5% HCO 0% HCO

Objective reached: 70 to 75% conversion

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Atm. Residue Stability Trend

Atm. Residue Sediments

Stable Fuel Oil

Conversion
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Targeting High Reliability

HCO co-processing reduces asphaltenes precipitation
CHEMISTRY Low sediment catalyst convert preferentially asphaltenes rather than resins CATALYST

Control of sedimentation & handle fouling DESIGN

RELIABILITY AT HIGH CONVERSION

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Unit Availability (%)

Industrial Results

Average on 4 units

Additional contributing factors Operator training Preventive maintenance Communication & Feedback
(Users seminar + unit follow-up)

Operating instructions R&D support Ebullating pump reliability

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Agenda

A technological solution for every problem

Production of Very Low Sulphur Fuel Oil with Hyvahl fixed bed technology

Resid Hydroconversion through Axens H-OilRC ebullated bed technology Pushing conversion one step forward by combining H-Oil with other units

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H-Oil vs. Coker

H-OIL COKER

Technology: Mature and

commercially proven

Technology: Mature and

commercially proven

Advantage: High Diesel

yield and ability to control product quality

Advantage: Low OPEX Drawback: Coke + poor

products properties and low distillates selectivity

Drawback: High pressure

with catalyst requirement and H2 consumption

Rather than in competition, H-Oil and Coker can show synergy towards higher conversion
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H-OilRC + Coking Association

H-Oil operated at 70% conversion Unconv. VR routed to coker No Fuel Oil produced but Coke
H2 100.0 Feed

H-OilRC@ 70% Net Conv.

540 C- Prod.

30.0 Unconv. VR

Coker

540 C- Prod.

Overall Net conversion: 87.2% with high liquid yields

12.8 Coke
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H-OilRC + Coking Association Advantages

High Liquid Yields No more Fuel Oil produced Increase of Naphtha and Diesel Yields
(both by 20 to 25%) compared to a stand alone H-Oil

Less than 35% coke yield out of Unconverted Anode Grade Coke
VR Anode grade coke with less S and low metals content

Two steps Process

H-Oil to increase conversion and Diesel

production Coker (low capacity) for anode grade coke and no more Fuel Oil
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H-OilRC + Coking Association - Husky Unit

The unit is operated for 20 years and the coke is sold as anode grade on the market (3 times the price of fuel grade)
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H-OilRC + SDA Association

Conversion is limited for stability purpose A solution to push forward the conversion is to get rid of the asphaltenes
through the Solvent DeAsphalting process (Solvahl) Overall conversion is pushed to about 90% No more Fuel Oil is produced Middle Distillates production is increased
H2 Gas Feed 100 Naphtha Diesel VGO 9.7 Pitch
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H-OILRC
70% conversion Unconverted VR 30.0

SDA

DAO

H-OilRC + SDA + H-OilDC Association for High Conversion

Asphaltenes rejection in SDA allows increasing the conversion in the second ebullated bed reactor.

Feed and Hydrogen

H-OILRC
Reactor

VGO & DAO

H-OILDC
Ultimate conversion toward Diesel Pitch

Gas Naphtha Diesel

SDA
High conversion level

Minimize OPEX for VT cleaning Minimize CAPEX

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Maintain continuous VGO production

Arabian Heavy Vacuum Residue Feedstock

Items
Gravity Hydrogen Nitrogen

Unit
API wt % wt %

Arabian Heavy
4.6 10.07 0.46

Sulfur
Oxygen Nickel

wt %
wt % wt %

4.72
0.23 56

Vanadium
CCR Pentane Insolubles Heptane Insolubles

wt %
wt % wt % wt %

179
24.7 17.5 8.0
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Comparison of High Conversion Routes Arabian Heavy VR

100
Conversion, wt% Liquid yield, wt% Liquid selectivity, wt/wt

90

80

70

60

50 1

H-OilRC2

H-OilRC + Coker 3 4

H-OilRC + SDA 5 6

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H-OilRC + HCAT additive

H2 Pore Active Catalyst Site H+ Products & Sediment Thermal Reaction Zone Catalyst Addition Supported Catalyst Pellet

Large oil molecules cannot enter catalyst pores

Hydrogen

Catalytic Reaction Zone

Large Asphaltenic Hydrocarbons

Diffusion Limited to Supported Catalyst
Hot Feed Catalyst Withdrawal

Thermal Reactions Occur Outside

the Ebullated Catalyst Bed
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H-OilRC + HCAT additive

H2 Pore Active Catalyst Site Products with Less Fouling

H
+

Catalyst Addition Supported Catalyst Pellet

HCAT catalyst hydrogenates outside EB catalyst particles

Hydrogen

Catalytic Reactions in Entire Zone

Higher conversion (5-10%) Higher throughput also possible Reduced asphaltenes, even at higher
conversion

Catalyst Withdrawal Hot Feed

Higher on-stream time; better operability

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Summary

Hyvahl Fixed Bed technology gives the opportunity to produce ULSFO H-Oil is a proven technology allowing high conversion of residue when using low sediment catalysts and co-processing HCO with the VR feed H-OilRC and Coker association gives high liquid yields, allows anode grade coke production without any Fuel Oil H-OilRC and SDA association gives high conversion with high middle distillates yields H-OilRC, SDA and H-OilDC association gives high conversion with better operability H-OilRC with HCAT additive gives high flexibility to operators especially with opportunity crudes

Axens has an extensive experience in Resid upgrading and continues to improve technologies to maximize profitability

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