Selecting the Right Technology for your Base Stock Manufacturing Needs Dr. Madhav Acharya Dr. Anna Gorshteyn
CIS Fuels and Lubricants May 21-23, 2013 Moscow, Russia
Overview • Basestock Trends • Basestock Manufacturing Routes • Upgrading of Solvent Facilities – Incremental approach – Petrolatum / Bright Stock processing
• Grassroots Group II/III Production – Hydrocracker bottoms
• Benefits of MSDW™ Technology
2
Global Basestock Demand Outlook by Region, kBD
• • •
Overall industry demand expected to grow ~ 1% / year till 2020 Europe, North America expected to be flat to slightly declining Majority of growth in Asia Pacific and developing countries 3
NOACK Volatility, Mass%
Fuel Efficiency Drives Demand for Lower Viscosity, Higher VI Grades
Group I / Group II 95 VI
19 17 15
Group II+
API SM Max
13
Mid Tier Group III
11 9 7 5 3 3.5
Top Tier Group III
GM Proposed Global Spec.
4.0
Group IV / PAO’s 4.5
5.0
Typ. API SM 5W30
5.5
6.0
6.5
7.0
7.5
8.0
8.5
Viscosity @ 100°C, cSt
4
Basestock Capacity Essentially Flat for 20 Years kBD
Evolving product mix – Growth in Group II and Group III – Group I declining
Global Basestock Capacity* (Paraffinic Basestocks By API Group)
1000
Group III
750
Group II 500
change
Group I
250
Viscosity grade mix changing
kBD 80 60 40
Net Capacity Change* (Paraffinic Basestocks by API Group) Group III Group II Group I
20 0
08 20
06 20
04 20
02 20
00 20
98 19
96 19
94 19
92 19
19
90
0
Basestock Viscosity Grades*, % 100% 80% 60%
Brightstock
40%
HN
20%
LN/MN
0%
-20 2007 2008 2009 2010 2011 2012 2013 2014 2015
2005 2009 Industry Industry Avg. Avg.
Typical Typical Lubes Fuels H/C H/C
*Source: ExxonMobil assessment of publicly available information
5
Multiple Pathways Exist for Lube Basestock Production RHC
Solvent Extraction
Distillate/DAO
Unicracking
Raffinate Hydroconversion
Hydrocracking
Gasoline & Diesel
Slack/ FT Wax
HC Bottoms
Hydrotreater
MSDWTM
MLDWTM Solvent Dewaxing
Hydrofinishing
Group I
Catalytic Dewaxing
Hydrofinishing
Group I
Solvent Dewaxing
Hydrofinishing
Group II
Catalytic Dewaxing
Hydrofinishing
Group II /III
Vacuum Distillation
Solvent Dewax
Catalytic Dewaxing
Hydrofinishing
Group II / III
Catalytic Dewaxing
Hydrofinishing
Group III / III+
MWITM
Group II
MAXSATTM 6
Manufacturing Considerations • Choice of manufacturing route depends on • Desired products • Available feedstocks – Certain crudes are highly suitable for lube yields • Existing infrastructure – Solvent plant upgrade versus grassroots
“One‐Size” Does Not Fit All. I. Capitalizing on existing solvent plant Incremental investment approach to achieving higher quality Processing of solvent streams (Bright stock, Petrolatum) II. Grassroots Catalytic Lube Plant Utilize Hydrocracker bottoms (UCO) with MSDW/MAXSAT to deliver Group II and III 7
Existing solvent facility LN & MN Raffinate Feed
Constant Solvent Extraction Unit (SEU) Feed Rate and Severity
Vacuum Fract.
Fuels TailGas
Lubes to Solvent Dewaxing
Base Case: Group I LN: 102 VI LN/MN
10.0 kB/D MN: 95 VI
HN Fuels Total Products H2 Consumption
4.7 kB/D
HN: 95 VI ----------
14.7 kB/D Base
8
Step 1: Add RHC to existing solvent facility • LN/MN Raffinates upgraded to Group II/II+ • Advantage: Retain wax LN & MN Raffinate Feed
Constant Solvent Extraction Unit (SEU) Feed Rate and Severity
Treat Gas
Base Case: Group I
Lubes to Solvent Dewaxing Step #1: RHC on LN/MN
LN: 102 VI LN/MN
10.0 kB/D
LN: 110 VI 8.9 kB/D
MN: 95 VI HN Fuels Total Products H2 Consumption
4.7 kB/D
Vacuum Fract.
Fuels TailGas
HN: 95 VI
MN: 110 VI 4.7 kB/D
HN: 95 VI
3.2 kB/D
Diesel (60 Cetane)
1.1 kB/D
Naphtha
---------14.7 kB/D
17.9 kB/D
Base
~ 70 Nm3/m3 over Base
9
Step 2: Replace solvent with catalytic dewaxing • Save on solvent dewaxing operating cost
Constant Solvent Extraction Unit (SEU) Feed Rate and Severity
LN & MN Raffinate Feed
Treat Gas
Step #1: RHC on LN/MN
Dewaxed lube
Step #2: RHC / MSDW
LN:110 VI
LN: 110 VI
LN/MN
8.9 kB/D
HN
4.7 kB/D
HN:95 VI
3.2 kB/D
Diesel
4.6 kB/D
Diesel (Low Pour)
1.1 kB/D
Naphtha
1.7 kB/D
Naphtha
Fuels Total Products H2 Consumption
MN:110 VI
Vacuum Fract.
Fuels TailGas
15.0 kB/D
MN: 110 VI HN: 110 VI
17.9 kB/D
21.3 kB/D
~70 Nm3/m3 over Base
~100 Nm3/m3 over Base
10
Step 3: Shutdown solvent extraction unit • Full catalytic production for LN, MN and HN • Increase valuable fuels byproducts LN, MN, HN VGO’s
Vacuum Fract.
Fuels TailGas
Treat Gas
Dewaxed Lubes
Step #2: RHC / MSDW LN/MN
LN:110 VI 15.0 kB/D
HN Fuels Total Products H2 Consumption
Step #3: Lube HDC / MSDW
MN:110 VI
LN: 115 VI 14.0 kB/D
MN: 110 VI HN: 110 VI Diesel (Low Pour) Naphtha
HN:110 VI 4.6 kB/D
Diesel (Low Pour)
12.9 kB/D
1.7 kB/D
Naphtha
2.4 kB/D
21.3 kB/D
29.3 kB/D
~ 100 Nm3/m3 over Base
~240 Nm3/m3 over Base
11
Hybrid Solvent + Catalytic option: Petrolatum upgrade to Gp III+
HDF
Boiling range 0.5% 353 C 50% 561 C 99.5% 728 C
MSDW
Density 0.859 Sulfur 0.29 wt% Nitrogen 160 ppm
HDT
Petrolatum (from solvent dewaxing)
KV100 24 cSt Wax content ~78%
• MSDW can process high wax content/heavy feed with good selectivity
Grade (cSt)
VI
Pour point (C)
NOACK (wt %)
2
124
‐42
70
4
136
‐33
13.8
6
139
‐30
3
8
139
‐29
1.3
12
131
‐32
0.2 12
Hybrid Solvent + Catalytic option: Bright stock raffinate processing • •
High tolerance for S (up to 2000 ppm) demonstrated over catalyst with no impact on overall life Demonstrated commercially at licensee site
HDF
MSDW
Density 0.9 Sulfur 1.6 wt% Nitrogen 250 ppm
HDT
BS properties
KV100 31 cSt
13
Grassroots Catalytic Lubes Plant • High upfront investment cost – but with lower long term operating expense Adjust Viscosity Atmospheric Resid
Vacuum Distillation
Vacuum Gas Oil
Hydroprocessing (HDT / RHC / HDC)
Catalytic Dewaxing (MSDW)
Hydrofinishing (MAXSATTM)
Improve cold flow properties Convert wax to high VI lube
Improve color and stability, Saturate polynuclear aromatics
Group II Group III
Vacuum Resid DAO
Deasphalting
Remove Asphaltic Material and Adjust Viscosity
Improve VI, reduce sulfur & nitrogen, saturate aromatics, reduce CCR, remove metals
Thermodynamics and catalytic functionality essentially requires a 3-step process to convert vacuum gas oil and DAO to high quality lube basestocks 14
Impact of Blocked vs Broadcut Operation • • •
Blocked operation has higher overall yield relative to broadcut Product slate is also different Tankage investment required for blocked operation LHDC Unit yield, wt%
45.0 Conversion
LHDC Btms, KTA
55.0
156.0
yield, wt%
yield, wt%
yield, wt%
4cSt Lube
76.6
17
Conversion
KTA
88.3 Conversion
LHDC Btms, KTA
49.0
17.0
6cSt Lube
87.0
77
Conversion
KTA
31.0
Total feed = 218 kTA
LHDC Btms, KTA
300.0
49.4
17
148.1 6cSt Lube LHDC Btms, KTA
Mixed VGO feed KTA
52.3
70.0
9
Conversion
KTA
1.9
Lube Product = 103 kTA
77 KTA
8cSt Lube
12cSt Lube
12.7 Conversion
4cSt Lube
11.4
KTA
6.2
74.6 VGO for 12cSt, KTA
MSDW Unit
13.7
56.6 VGO for 6cSt, KTA
LHDC Unit
22.1 49.1
VGO for 4cSt, KTA
MSDW Unit
5.9 Conversion
Conversion
49.0
9.3
Total feed = 300 kTA
9 KTA
Lube Product = 103 kTA
15
Lower Yield When Manufacturing Gp III • Extent of yield loss depends on feed wax content, boiling range and desired VI of Gp III LHDC Unit
MSDW Unit
yield, wt%
yield, wt%
LHDC Unit
MSDW Unit
yield, wt%
yield, wt%
3cSt Lube
3cSt Lube
20.7
12
VI = 103
18.2
KTA
58.0 VGO KTA
4cSt Lube
58.0
100.0
70.0 LHDC Btms, KTA
41
7
VI = 118
KTA
VI = 109
KTA
100.0 39.8 VGO KTA
4cSt Lube
39.8 LHDC Btms, KTA
69.9
28
VI = 124
KTA
Overall Lube Yield
Overall Lube Yield
52.6
35.0
16
Select the Technology with a Proven Track Record • Over 70% of Group II and III base oils are produced using the MSDW catalyst system – Two reactor system Others • Reactor 1: Zeolite catalyst for dewaxing EMRE • Reactor 2: Noble metal Hydrofinishing catalyst MSDW • Highest lube product yield and low fuels/gas production Technologies • Features include • Demonstrated ease and stability of operation • Long life with yield maintenance (~12 years) • High tolerance to contaminants • No catalyst load ever replaced for: – Reaching end‐of‐cycle condition – Feed contamination upset – Yield degradation 17
Extensive Global Experience across wide range of feeds/configurations
Operating unit Awaiting startup/under design/licensed unit 18
EMRE/UOP Licensing Alliance • • •
• •
Licensing Alliance joins UOP Hydroprocessing technology with EMRE Catalytic Lubes technology and Fuels dewaxing for low cloud diesel UOP brings extensive knowledge and experience in all refinery hydroprocessing technologies, and extensive catalyst portfolio, to the Alliance EMRE brings worldwide lube process, operation, production experience and extensive specialized dewaxing catalyst knowledge for both Fuels and Lubricants Alliance allows UOP‐EMRE cooperation in two refining areas to give Licensees a cost efficient Fuels & Lubes processes UOP and EMRE working together provides synergy to improve outcome to Licensees
A One‐Stop‐Shop for Premium Lubes and Fuels Production The alliance brings together the UOP hydroprocessing technology, catalysts and equipment with EMRE’s catalytic dewaxing technology and other EMRE hydroprocessing solutions to produce high yields of low sulfur, ultra‐clean diesel with excellent cetane and cold flow properties and lube base oils 19
Summary •
Overall capacity growth in basestocks will mainly be seen in Group II/III Light and Medium Neutral stocks
•
Investment options include incremental upgrade of solvent facilities or grassroots catalytic plant – consider target market for products, capital constraints and hydrogen availability
•
EMRE’s suite of technologies are commercially proven in numerous applications – MSDW technology provides feed/product flexibility, long cycle length and high degree of robustness
•
UOP‐EMRE Licensing alliance allows the refiner the simplicity of “one stop shopping” for technologies to maximize lube yield and value
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