Refinery configurations for maximising

middle distillates
A comparison of configurations for upgrading residual oil products for the
maximum production of diesel
Arun Arora and Ujjal Mukherjee
Chevron Lummus Global

Shift in product demand

The IMOs looming specification

changes (see Figure 1) are likely to
accelerate the decline in demand for
HSFO by the year 2020, if not earlier.
Worldwide, including emerging
markets such as China, India and
the Middle East, there is a shift in
product demand from gasoline to
diesel. Ethanol substitution in gasoline and improvements in engine

[Link]

5.0
4.5
4.0

World
ECA

3.5

S, wt%

efiners globally continue to

face numerous challenges as
environmental laws become
increasingly stringent. Principal
among them in the near future will
be the International Maritime
Organisations (IMO) proposed
changes to bunker fuel oil sulphur
limits, from the current limit of over
3.5% down to 0.5% globally and
from 1% to 0.1% in Emission
Control Areas (ECA, see Figure 1).
Global demand for high-sulphur
residual fuel oil (HSFO) is steadily
declining too, by 35% since 1995.
Both of these changes will significantly impact a refiners ability to
market any significant quantity of
HSFO at a price that will maintain
refinery profitability. Refineries
currently making a significant
amount of fuel oil and lacking the
complexity to upgrade the residual
oil to premium products (middle
distillates) will face two difficult
options: either invest in commercially proven and reliable solutions
to convert HSFO to more valuable
liquid products such as Euro V
diesel to greatly improve the refinerys profitability, or face a threat to
shut down the refinery as the operation becomes uneconomical to
continue.

3.0
2.5
2.0
1.5
1.0
0.5
0.0
2005 2007 2009 2011 2013 2015 2017 2019 2021 2023 2025

Figure 1 Requirements of IMO regulations

Source: International Maritime Organisation

technology are just two of the

reasons why the demand for diesel
continues to outpace that of gasoline. IMO regulations will indirectly
increase diesel demand further as
refiners are forced to blend in additional low-sulphur diesel to meet
fuel oil sulphur specifications.
Worldwide, production of middistillates is projected to account for
55% of the rise in oil demand
expected over the next 20 years. The
shift to diesel puts emphasis on
bottom-of-the barrel processing.

diesel-driven vehicles in Europe

and developing countries.
Current refining investment is
predominantly made in Asia, the
Middle East, Russia and Latin
America regions with growing
demand for refined products.
Tightening of product quality specifications
will
accelerate
the
implementation of deep conversion
units in existing refineries, but often
these refineries are constrained by
plot space, hydrogen and other
infrastructural issues. Grassroots,
export-oriented refineries are all
geared towards high conversion to
mid-distillates.
For the strategically oriented
refiner, stringent requirements for
high-quality
products
actually
present an opportunity to invest in
the right technologies to significantly improve refinery margins.
Based on increasing product
demand and the closure of multiple
non-performing refineries, refining
margins are expected to recover
by 2015.

Growing demand

Worldwide demand for refined

products is projected to increase
significantly in the next 20 years,
driven by population growth and
the transition of emerging markets
into the global economy, with the
majority of growth coming from
China in particular and Asia in
general. According to OPEC, global
demand for diesel fuels is expected
to grow by 10 million b/d by 2030,
driven by an increased share of

PTQ Q3 2011 75

Max
Blue
bro
Alw
Eng
Lea
only

Coke
drum

Coke
drum
Fractionator

Reflux drum

Wet gas
Unstablised
naphtha

Gas oil
stripper
Light gas oil

Residual oil

Heavy gas oil

Heater

Figure 2 Schematic of a delayed coking unit

A wider and more intense

requirement for the deployment of
emissions reduction technologies
may also act as a catalyst for new
investments. Modern hydroprocessing technology will eliminate the
need for expensive downstream
remediation technologies.
It is our view that refining should
be viewed as an ongoing business,
where long-term average margins
and product price differentials will
support the investments that are
needed.

Residue upgrading technologies

In view of the increasingly stricter

regulations expected in the near
future, along with the emerging
trends in product demand, CLG
evaluated multiple combinations of

76 PTQ Q3 2011

residue conversion technologies,

keeping the intentions of a global
refiner in mind. The conversion
technology:
Should be commercially proven
and reliable with a good on-stream
factor
Should maximise the most valuable product (diesel) while retaining
the capability to address niche
product demands for the foreseeable horizon
Should be flexible to handle more
difficult feedstocks
Should
be
environmentally
compliant to meet future stringent
specifications
Should have enough complexity
so that the refinery remains profitable when margins remain depressed
for prolonged periods (based on

[Link]
for further information

current trends only such refineries

will survive in the future)
Ideally, should be part of a
conversion platform encompassing
complementary technologies.
Technologies on the cusp of
commercialisation were excluded,
because we did not want to prescribe
any solution without a reasonably
long operating history. For example,
there are several slurry-phase residue conversion processes on the
verge of commercialisation, but
without a commercial operating
history there is no data on reliability
and on-stream factor a major
consideration in any residue upgrading process because of the difficult
nature of the feedstock.
Major refinery processes included
in this evaluation were:
Delayed coking
LC-Fining
(a high-conversion
residue hydrocracking process)
Residue desulphurisation (RDS)
Solvent deasphalting (SDA)
Combinations of the above, along
with secondary processes such as
hydrocracking, residue catalytic
cracking (RFCC) and gasification
(VR and coke), FCC feed/product
desulphurisation
and
various
gasoline-producing processes.
In the studies we conducted for
various clients, the residue conversion technologies that rose to the
forefront were delayed coking, LCFining and RDS. The screening

[Link]

Advantages and disadvantages of delayed coking

Advantages
Lower on plot capital investment compared to hydrogen addition processes
Can handle very poor-quality (high in contaminants) feeds
Widely used, with many references

Favoured in low crude oil price environment
No residual liquid product to deal with

Disadvantages
Coke handling, plot area limitations, and transportation and logistics
Additional environmental health and safety (EHS) requirements
Hydrogen addition still required to upgrade products and the process
does not share the same process platform as other hydroprocessing units
Loss of liquid yield compared to hydrogen addition processes
Coke disposition is a major issue

Table 1

phase quickly ruled out several

technologies as being too expensive,
such as gasification, or not geared
towards maximising diesel, the
product of choice. A brief description of the primary upgrading
processes follows.

Delayed coking

Delayed coking is the most widely

used residue conversion technology
and is particularly valuable when a
long-term off-take arrangement for
coke exists. Almost every major
grassroots refinery in the world has
considered it as a primary residue
conversion process, with the exception of locations such as Scandinavia,
Western Europe and Eastern
Canada, where coking units are not
preferred. Fuel-grade coke is used in
infrastructure
projects
(cement,
power) and demand remains robust
in developing countries. However,
with even more large coking units
coming online, coke demand could
come under pressure.
Vacuum
residue,
normally
destined for fuel oil, is thermally
cracked to obtain nearly 70% of
distillate products. All distillate
products require further hydroprocessing
to
make
finished
products. Coker naphtha requires
special and more severe hydroprocessing compared to straight-run
naphtha. Light coker gas oil (LCGO)
that boils in the diesel boiling range
has a much higher nitrogen content
compared to straight-run diesel and
operating pressures required for
hydroprocessing
are
relatively
higher. Heavy coker gas oil (HCGO)
boils in the vacuum gas oil (VGO)
boiling range. HCGO has much
higher total aromatics, nitrogen,
polycyclic aromatics and asphaltenes,
and requires more severe operating
conditions compared to straight-run

[Link]

Installed LC-Fining units

Start-up
2011
2010
2007
2003
2000
1998
1988
1984
Total

Client
Shell Canada
GS Caltex
Neste Oil
Shell Canada
Slovnaft
AGIP Petroli
Syncrude Canada
BP-Amoco
8 units

BPSD Unconverted oil

47 300
Stable HSSC
60 000
Stable FO
40 000
Stable FO
79 000
Stable HSSC
23 000
Stable LSFO
25 000
Stable LSFO
40 000
Coker feed
75 000
Coker feed
389 300

Table 2

VGO. HCGO is either sent to a FCC

feed pretreater (in a gasolineoriented refinery) or a hydrocracking
unit (in a diesel-oriented refinery).
The coke produced by a standalone
delayed coker (see Figure 2) is lower
value fuel-grade coke. If a hydroprocessing unit such as an LC-Fining
unit precedes the delayed coking
unit, the coke produced from the
delayed coking unit can be of superior anode-grade quality, suitable for
use in the aluminium industry.
Table 1 shows the main advantages
and disadvantages of the delayed
coking process.

LC-Fining

The LC-Fining process is a residuum conversion process that

hydrocracks the most difficult,
heavy, lower-value hydrocarbon
streams such as petroleum residua,
heavy oils from tar sands and shale
oils to lighter, more valuable products such as VGO, diesel and
naphtha. The process involves an
ebullated-bed reactor (see Figure 3)
that completely mixes oil and
hydrogen. Due to continuous addition and the withdrawal of small
quantities of catalyst, the run
lengths between shutdowns are
long. Unconverted oil from the LCFining unit can be used as fuel oil

Effluent
Thermowell
nozzle

Catalyst
addition
line
Density
detector
radiation
source
well
Density
detectors
Normal
bed level

Skin
TCs
Catalyst
withdrawal
line

Feed
Recycle
pump

Reactor temperature
410440C
Reactor pressure
110180 bar
Resid conversion
5580%
Hydrogen P. P.
75125 bar
Chem H2
consumption
35300 Nm3/m3
Desulphurisation
6085%
CCR reduction
4070%
Demetallisation
6588%
Figure 3 Schematic of a LC-Fining reactor
with typical operating conditions

PTQ Q3 2011 77

Make-up
hydrogen

External gas oils

for MHC/HDT

HDT/MHC
reactor

Wash
tower

H2
purification
LP amine
scrubber

HP amine
scrubber

Vacuum
residue
and
diluent

Hydroprocessed
distillates
and gas oils
LVGO

LC-Fining reactors with

inter-stage stripper

To
fractionation

HVGO to FCC
To
fractionation
Hydroprocessed
residue

Figure 4 LC-Fining process with integrated hydroprocessing

Advantages and disadvantages of LC-Fining

Advantages
Disadvantages
Higher liquid gain compared to delayed coking
On plot investment is higher than delayed coking units
Can handle feeds higher in metals and other contaminants Residue stability may become a concern at high conversions (feed dependent)
compared to fixed-bed processes
Middle Eastern feeds, for example, have no stability concerns even at high

conversions (proven commercially)
Long run lengths
More complex process compared to delayed coking and requires better operator training
Can be integrated easily with other hydroprocessing units
Not as much commercial experience as delayed coking units but adequate
Ebullated-bed technology is a mature technology and over Spent catalyst disposal (trucks, rail car) has to be considered. Spent catalyst normally
30 years operating experience has led to many technological sent to metals reclaimer
advances and made the process very reliable
Requires less plot space compared to delayed coking units
Unconverted oil disposition can become an issue depending on sulphur/stability

specifications

Table 3

or as feed to power plants or a

delayed coking unit. Maximum
conversion is dependent on feedstock. Operating unit conversion
ranges from 60% to over 80%.
The LC-Fining unit operates at
pressure levels similar to highpressure
hydroprocessing
and
therefore offers excellent opportunities for capital reduction by
permitting integration of either
hydrotreatment (Shell, Canada) or
complete hydrocracking (Neste,
Finland, see Figure 4).
The conversion of Conradson
carbon is economically important if
LC-Fining vacuum bottoms are fed
to a downstream coking unit. A
lower carbon-content resid product

78 PTQ Q3 2011

to the coking unit means less coke

make and thus a higher yield
of liquid fractions that can
subsequently be converted to transportation fuels.
The LC-Fining unit has inherent
flexibility to meet variations in
feed quality/throughput, product
quality and reaction operating
severities
(temperature,
space
velocity, conversion and so on).
This flexibility is a direct result of
the ebullated catalyst bed reactor
system. In an ebullated-bed unit, if
the metals or sulphur content of
the feed increases, the product
quality is maintained by increasing
catalyst consumption. Conversely,
the
catalyst
consumption
is

reduced if the feed quality

improves.
There are only two ebullated-bed
processes in the world that have
been proven by long commercial
history: LC-Fining and H-Oil. Table
2 is a list of operating LC-Fining
units, and Table 3 shows the main
advantages and disadvantages of
the process.
The unconverted oil from the LCFining unit is normally used as fuel
oil. When combined with a delayed
coking unit downstream, the unconverted oil is converted to distillates
and anode-grade coke, which
fetches a far higher price compared
to fuels-grade coke. While LCFining can handle a relatively high

[Link]

!TMOSPHERIC
RESIDUE

,OW3.
DISTILLATES
AND6'/

VDU

Solvent
LC-Fining
deasphalting

0ITCHPELLETS

,3&/

Figure 5 SDA upstream of an LC-Fining

unit

metals content in the feed, the high

level of nickel and vanadium in the
unconverted LC-Fining bottoms
could limit the production of anodegrade coke in the downstream
delayed coking unit. LC-Fining by
itself produces significantly more
liquid yield compared to delayed
coking and improves the refiners
volume gain.
The LC-Fining process is also easily
integrated with a solvent deasphalting unit either upstream (see Figure
5), downstream (see Figure 6) or as
an inter-stage process.
An upstream SDA significantly
reduces
metals,
CCR
and
asphaltenes. Operating conditions
required in the LC-Fining unit

become less severe and conversions

can be pushed much higher. The
yield slate shifts towards lighter
products and catalyst consumption
drops significantly. Without heavy
asphaltenes in the process, unit
operating factors improve as well.
The obvious disadvantage is the
loss of global conversion, as a
significant volume of residue is
removed as pitch and, without a
dedicated disposition of the large
volume of pitch (such as a gasifier),
the economics may not be favourable. The option becomes very
attractive in those situations where
an SDA is already in operation and
there is a need to upgrade the DAO
to diesel rather than routing to an
FCC unit for conversion to
gasoline.
The SDA process can also be
integrated downstream, where
deasphalting removes the heaviest
asphaltenic residue from the
unconverted oil. The DAO can be
recycled back to the LC-Fining
process, while the pitch can be
blended in with incremental VR to
an existing delayed coking unit
(BP, Texas City). Conversion is
boosted and the volume of pitch
to
be
handled
is
reduced
significantly.

Residue desulphurisation

RDS is a fixed-bed process that has

multiple beds of catalyst to remove

,OW3.
DISTILLATES

!TMOSPHERIC
RESIDUE

VDU
0REMIUM
&##2&##
FEED

LC-Fining

Solvent
deasphalting

0ITCHPELLETS
DELAYEDCOKING

Figure 6 SDA downstream of an LC-Fining

unit

metals, nitrogen and sulphur from

petroleum residua in the presence of
hydrogen (see Figure 7). Conversion
results from the level of desulphurisation required and is not by itself a
target. The process is normally used
to produce low-sulphur fuel oil or to
produce a feed stream that is suitable for cracking in a residue FCC
(RFCC) unit.
The RDS process is by far the
most widely used residue upgrading process. Catalyst and process
innovations for RDS include the
upflow reactor (UFR) and onstream

Make-up
hydrogen
To gas recovery

Reactors
Recycle gas
scrubbing

H2S

Cold HP
separator
H2O

Product
stripper

Unstabilised
naphtha

Fresh feed

Filter

Sour
water

Hot HP
separator

Product

LP
separator

Figure 7 Schematic of RDS process

[Link]

PTQ Q3 2011 79

Upgrading configurations

CLG explored several configurations, including some that are based

on the residue upgrading platforms
described here, along with other
major processes such as hydrocracker, hydrotreater and FCC
to
maximise
conversion
to
mid-distillates.

Catalytic
reforming
Gasoline

Atmospheric
tower

HDT

FCC

Vacuum
tower

Jet/diesel

Hydrocracking

Refinery with delayed coking as

primary upgrader

Delayed
coking

Coke to
power plants
and
cement industry

Figure 8 Simplified refinery with delayed coking as a residue conversion process

catalyst replacement (OCR). UFR is

typically used in revamp situations
or when concerns about metals
levels and catalyst pore mouth
plugging might shorten downflow
reactor run lengths due to excessive
pressure drop. OCR is used when
the metals level in the feed is
excessive.

RDS is a widely used technology,

especially in the Far East. It is the
only technology that can produce
<0.5 wt% sulphur fuel oil. The
technology is used in this context
in Japan, but the most prevalent
use of RDS is as a unit feeding a
RFCC unit for the production of
gasoline.

The configuration shown in Figure

8 is one of the most common refinery configurations and is a
benchmark against which other
configurations have been evaluated.
The configuration is robust and,
depending on the crude slate, the
capacities of the hydrocracking and
FCC unit vary to obtain the right
balance between gasoline and diesel
production. In extreme situations,
where gasoline production is to be
avoided, the configuration will have
no catalytic reforming and no
FCC unit.
Figure 9 shows a refinery configuration where there is virtually
no demand for gasoline and
the refiner is only interested in
making middle distillates and
petrochemicals naphtha. Such a

LPG

LPG

Light naphtha
Heavy naphtha

Petro-chemical
Naphtha

NHT

CDU

Jet A-1
H2 plant

Coker
Naphtha

Diesel
HCR

VDU
HCGO

DCU

DHT

UCO

Fuel oil

LCGO

Fuel coke

CFB
CFB: Circulating fluidised bed boiler

Figure 9 A delayed coking-based refinery with no gasoline production

80 PTQ Q3 2011

[Link]

Catalytic
reforming

Gasoline

FCC

Atmospheric
tower

HDT

*ETKEROSENE

Vacuum
tower

Delayed
coking unit

Hydrocracking

Jet fuel
Diesel

$IESEL

LC-Fining

Anode-grade
coke

Figure 10 Optimised residue conversion using LC-Fining and delayed coking

configuration is likely to become

increasingly important in the next
decade.

Further optimisation of the delayed

coking-based refinery

The overall profitability and return

on investment in the configuration
depicted in Figure 10 improves
significantly with the addition of

the LC-Fining process to the

upgrading of residue.
The LC-Fining unit is the primary
residue conversion process, where
conversion is pushed to the maximum because unconverted oil
stability is not an issue. The unconverted oil, low in sulphur and
metals, is converted to high-priced
anode-grade coke in the delayed

coking unit, which also converts

part of the UCO to distillates to be
processed in downstream hydroprocessing units. This configuration
has no undesired or low-valued
products and is therefore truly
bottomless.
Furthermore, the configuration is
very amenable to phasing; the LCFining unit can be built first and

Catalytic
reforming
Gasoline
RFCC

Atmospheric
tower

,#/

Vacuum
tower

Hydrocracking

*ETKEROSENE
$IESEL

Residual
desulphurisation
(RDS)

(#/

Diesel

Low sulphur
fuel oil

Figure 11 Refinery scheme with RDS as residue upgrader

82 PTQ Q3 2011

[Link]

Environment. The daily availability

willthese
be profitable
until
such
time as
of
values has
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edged
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refinerys current situation and to

coking, provides
maximum
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operating the
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and the
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other words,
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There
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a dedicated, multi-disciplinary team
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Further reading
together
the defined
objec1 Spieler towards
S, Mukherjee
U, Dahlberg
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UpgradingThird,
residuum the
to finished
products
tives.
transfer
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knowledge
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SIR was
solutions and challenges,
2006 NPRA, on-site
Utah.
provided
by training,
2 Mukherjeeand
U, LC-Fining:
high conversion
missions
continuous
support
during the project and following its

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completion. These factors not only

residue hydrocracking, Middle East Petrotech,
guaranteed
that the project was
2010.
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for
parties,
but
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N, Delayed
coking
andalso
LCensured
continuous
improvement
Fining technology a winning combination,
after
the Coking
project
completed.
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andwas
Gasification
conference,
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has led several high-pressure hydroprocessing
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projects and refinery configuration studies.
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Ujjal Mukherjee is Vice President, Technology,
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with Chevron Lummus Global. With particular
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expertise in technology development
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for distillate and residue hydrocracking,
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he has several patents in high-pressure
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hydroprocessing and is the author of numerous
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technical articles and papers relating to refining
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technologies.
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;^e`bnf'>fZbe3an`n^l'lm^_Zgldb9[^elbf'\hf

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PTQ Q3 2011 83