INFRASTRUCTURE

MINING & METALS

NUCLEAR, SECURITY & ENVIRONMENTAL

Upgrade High Sulfur Residues while adding
OIL, GAS & CHEMICALS flexibility to your refinery

Presented by:
Rashid Iqbal
Technical Specialist - Refining
Bechtel Hydrocarbon Technology Solutions, Inc.
© 2016 Bechtel | 2

Presentation Agenda

▪ Configuration of APAC region refineries making high sulfur residue fuels

▪ Goals for refinery upgrading

▪ Primary conversion technologies considered

▪ Maximize benefits from existing installed units

▪ Case studies and results

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Frequently used Configuration that
Produces HSB/HSF

Light Crudes Deasphalted Oil Typical Product Mix (vol. %)

CDU (DAO) Using RDS + RFCC
SDA Conversion Block Feed: Middle
East Light Crudes
RDS RFCC
Propane + LPG 4-6

Gasoline (Regular + Premium) 45-55

Distillates (Jet + Diesel) 30-40

Asphaltene Rich HSB & HSF 7–15

(Pitch)
VDU
Products
• High sulfur bunker (HSB) &
VB High sulfur fuel oil (HSF)
• Road Asphalt Potentially stranded product post IMO
VB Tar
• Pitch pellets to cement; 2020 that requires LSB S<0.5 wt. %
power plants
• Gasification

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Key Units with Capacities in the
Selected Base Refinery

Upgrading
Crude Distillation Conversion Finishing Support HSB/HSF

ATB KHT 26
RDS 53 SRU 390 HSB/HSF
Arab Light CDU 250
DHT 52 (MTPD) 24.5
VTB
VDU 53 VB 19
LNHT 17 HMU 100
(MMSCFD)
RFCC 85
HNHT 56

ATB split equally CCR 54

Alky 8
between VDU &
ARDS Requires additional
Isom 17
conversion capacity for
(C5/C6)
upgrading residue products
FCCGT 54

Capacities: X1000 BPD

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Goals for Refinery Upgrading

▪ Eliminate production of HSB & HSF

▪ Produce low sulfur bunker (LSB) when viable

▪ Maintain or increase production of higher value gasoline and middle distillates

▪ Maximize use of existing asset

▪ Increase flexibility for processing alternate opportunity crudes

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Primary Conversion Technologies Considered
for Residue Upgrading
• Coking (DCU) is the most widely used residue
Liquid
• Naphtha Upgradable to upgrading technology
DCU • Distillates End Products • Large market for coke (>140 MMTPA)
• Gas Oil • ~10% Pet-coke is used in CFB’s for power and
Pet-Coke
Sell; large market
steam production
• Liquid products from DCU require hydrotreating for
• Steam making products
CFB
• Power
• Flexibility for making transport fuels and/or LSB
• Can process residues from crudes with high
metals, sulfur, TAN, etc.
Liquid
Residue Resid • Naphtha Upgradable to • Includes ebullated bed and slurry phase RHC
RHC • Distillates End Products • Conversion (510+ to 510- C) range considered 65 – 85%
• Gas Oil • Gas oils from RHC are good feeds for RFCC and can be
UCO Blended into used for making ULS products
LSB/LSF • Unconverted Oil (UCO) is used for making LSB/LSF

Liquid • Limits crude selection to low metal (V & Ni) crudes for
• Naphtha Without reasonable catalyst activity & make-up rate
RFCC • Distillates • Requires other primary conversion units (coker, RHC) for
Hydrotreating Slurry
• Slurry Oil Oil HSB/HSF is proper disposition of slurry oil
Produced • Evaluated only in combination with solvent deasphalting
(SDA)
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Options Considered for Maximizing
Benefits from Existing Conversion
Units

Existing Potential future

Current Feed Potential Benefits
Unit Feeds

▪ Resid AR and/or Blend of some or all of New feeds will have lower levels of:
Hydrotreating VR the following: • Metals
(RDS) - Distillates from • CCR
Conversion units • Higher fraction boiling at <540 C
- DAO from SDA RDS Requires lower severity operation which opens up
- AR or VR residues opportunity for debottlenecking and adding some conversion
capability

▪ RFCC HDT residue Blend of some or all of New feeds will have higher hydrogen content and reduced
and SR VGO the following: metals, CCR and sulfur. Potential benefits to RFCC include:
• HDT residue from 1. Higher conversion and higher yields of naphtha and
RDS distillates
• HDT straight run and 2. Lower slurry oil make
cracked gas oils 3. Lower coke production
• SR or HDT DAO 4. Reduced sulfur in products reducing severity of FCC
gasoline hydrotreater

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DCU-based Schemes
Operating Ranges for Existing Key Units
Scheme with Highest NPV
Acceptable Operating
Unit SRGO
Range (1) Range
LVGO
VDU HVGO RDS to
VDU
CGO
MHC 30%
Capacity MBPD 53 - 126 53 - 65
HGO
Cut point °F 1050 - 1150 1050 - 1100
DCU
RDS
Pet-Coke
Capacity 53 - 85 65 – 70 RFCC

Residue in feed % 100 - 0 65 – 70

Power
CFB
Conversion % 20 - 70 30

RFCC
▪ Optional CFB improves NPV by > 20% over base DCU case
▪ Provides reliable power source for internal use or sale
Capacity 85 - 95 85 - 90

HDT residue in feed % 100 - 0 65 - 70

Conversion % 75 - 90 85

(1) Existing units with minor modifications and processing mostly

distillate feeds in future.
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RHC-based Schemes

Operating Ranges for Existing Key Units Best RHC-based scheme

Acceptable Operating
Unit
Range (1) Range
VDU
VDU SRGO RDS to
MHC <30%
Capacity MBPD 53 - 126 126 Best case needs
additional VDU HGO
Cut point °F 1050 - 1150 1050 - 1100 RHC

RDS
UCO to
Capacity 53 - 85 <60 LSB
RFCC
VDU2 Slurry to
Residue in feed % 100 - 0 40 - 0 LSB
Capability of
existing units could
Conversion % 20 - 70 30
not be fully utilized
RFCC • Unable to take full advantage of RDS as to
match capacities it is operated at low
Capacity 85 - 95 60 - 90 conversion
• Unable to fill the RFCC in most cases
HDT residue in feed % 100 - 0 65 - 70 • LSB/LSF produced and used as outlets for
UCO
Conversion % 75 - 90 90 • Economics improve with RHC conversion
assuming TIC for higher conversion is <10%
(1) Existing units with minor modifications and processing mostly distillate feeds in future. higher than lower conversion unit
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RFCC Case with SDA for Feed Pre-treatment

VGO Best SDA + RFCC Case includes:

VDU
HDT Residue from RDS • DAO yield of 50%, which allows use of pitch
for making road bitumen.
• Lower yield limits RFCC capacity growth by
10% allowing revamping of existing RFCC and
Deasphalted Oil (DAO) removing need for a new RFCC.

SDA RFCC

Pitch Slurry Oil

Road Bitumen HSB/HSF

SDA + RFCC
1. Gives lowest NPV Residue products ~ 85 - 90% of VR has negative
2. Has lowest TIC impact on overall economics for this case.
3. Remains HSB/HSF producer

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Results
2) DCU with
1) DCU 3) RHC
RDS to MHC

NPV over base case as a multiple of TIC*

1. Without CFB 6.5 – 7.5 4.5 – 5 0.5 – 1.5

2. With CFB 4.5 - 5.5 2 – 2.4 N/A
TIC of Revamp X 2.2X 4X
Impact on NPV of installed cost of RHK
Conversion 65% 85%
1. NPV when TIC of RHC = 2 x installed cost of a 2500 psi fixed bed HCK 0.6 1.0
2. NPV when TIC of RHC = 1.5 x installed cost of a 2500 psi fixed bed HCK 1.2 1.7
3. NPV when TIC of RHC = 1 x installed cost of a 2500 psi fixed bed HCK 2.2 3.0
HSB/HSF Eliminated Eliminated Eliminated
In cases
LSB Possible Possible
considered
Crude Flexibility Yes Yes Some
Notes:
1. TIC includes changes to all impacted process units and utility systems.
2. TICs for all new units developed using Nelson Farrar investment cost curves published in OGJ.
3. Revamp / upgrade for all cases is completed in 36 months
4. Average annual escalation 2.8%.
5. Cost for revamp estimated as a % of new unit cost depending on 1) capacity, 2) operating severity, and new equipment required for
revised service.
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Unit Sizes for the Best NPV Case

UPGRADING
Crude Distillation conversion Finishing Support
ATB KHT 26 29
CDU 250 250 ARDS 53 59(1) SRU 390 476 HSB/H
Arab Light (MTPD)
VTB DHT 52 54 24.5
SF 0
VDU 53 60 VB 19 S/D
HMU 100 120
LNHT 17 18 (MMSCFD)
RFCC 85 89(2)
HNHT 56 58
CCR 54 54
LSB/LSF Converted to
Alky 8 12 Higher Value Products
New DCU 23
Isom 17 18
(1) AR in feed < 70% (C5/C6)
(2) RFCC feed: 100% HDT
FCCGT 54 57

Capacities: X1000 BPD

xx Unit capacities in BPD for highest NPV case
Existing units with 20% or higher increase in capacity

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Existing Visbreakers Could Provide Additional
Conversion or Fractionation Capacity

1. Make LS Bunker by cracking blend of SR 2. Use for additional fractionation capacity

and HDT residues
RDS
UCO
RFCC
Vacuum
Fractionator
Flasher

VB HDT Feed Feed • Fractionator • Optional used in

Preheat Heater • With or W/O about 50% of
soaker drum existing VB
AR/VR
LS Bunker

• Cracking paraffin rich UCO is easier than asphaltene rich
SR residues
• Lower asphaltene reduces stability concerns of LSB/LSF,
thus allowing more conversion in VB
• SR residue can be blended in VB bottoms to make
0.5 wt.% sulfur LSB or use some LS crude
• Could be retrofitted as additional small crude unit for
processing additional or special opportunity crudes
• Could provide some additional VDU capacity
• Requires in-depth evaluation for each case

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Why Conversion of Visbreaker to DCU May Not
be a Viable Option
Major Sections

Visbreaker
Preheat Furnace Fractionation

- Coker has higher conversion, makes more

- Some equipment may be reused
with modifications
- Additional equipment is also
usually required
- VB furnace has 60 – 70% duty of coker
furnace for same feed capacity
- Usually require major modifications
- Plot layout is a major consideration
light products, and requires larger fractionator
with more cuts
- Possible re-use of existing fractionator with
new internals in some cases
- Detailed check required to confirm changes

Preheat Furnace Fractionation

GRU Coke Drums

Coker New
Coke Storage Water
Coke Handling
and Shipping System

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Existing SDA Could be Used for Reducing
Cost of Refinery Upgrade

Debottleneck RDS
➢ Reduced metals and asphaltene in feed
➢ Possible improvement in catalyst life

DAO ➢ RDS
Only when residue goes directly to RFCC
➢ RFCC ➢ Reduced metals and asphaltene in feed
➢ Possible improvement in catalyst life
VR/AR
SDA
Potential for hydraulic debottlenecking
➢ Coke make remains largely unchanged as pitch contains
Pitch ➢ Coker most coke precursors
➢ Potential DCU furnace design/operating challenges at
higher DAO yields
➢ Road Asphalt

➢ Possible additional revenue stream

➢ Usually limits DAO yield
➢ Will reduce size of DCU with TIC benefits

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Conclusions

▪ DCU
─ Eliminates low value residue products (HSB/HSF)
─ Provides flexibility of making LSB or additional distillates
─ Offers highest crude flexibility
─ Makes best use of existing units

▪ RHC
─ In most cases eliminates HSB/HSF
─ UCO and slurry oil can usually be blended into LSB/LSF
─ Cases considered had lower NPV and higher TIC than
DCU Cases

▪ RFCC or SDA +RFCC

─ Do not eliminate HSB/HSF products
─ Has lowest NPV and TIC

▪ Existing VB and SDA may be repurposed for

reducing TIC

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