Ian Clarke UOP Hydrocracking Technology

Hydroprocessing and Heavy Oil Upgrading Fuel Oil to Euro V Fuels

Technology Manager

5th December 2017  Bottom of the Barrel Workshop NIORDC, Tehran

© 2017 UOP Limited UOP 7200-0
Agenda

UOP Hydroprocessing Latest Technology Case Studies for Solutions for the
Experience Maximum ROI Iranian Market
Innovations

Hydrocracking is a key enabler to maximise transportation fuels

and to reduce fuel oil to less than 10% of crude
 2

Hydrocracking Unit
Natural Gas
Refinery Fuel Gas Hydrogen Plant H2

LPG
Saturated
Gas Plant
LPG Sales
Isomerate
Isom
Unit

Naphtha
Gasoline
NHT H2 LPG
Hydrotreating Sales
Splitter
Unit
Reformate
Crude Oil CCR
Unit
H2 UNI Naphtha Kerosene
C SR Kerosene Sales
D DHT Jet
U SR Light Gasoil Unit
Diesel
HCU
Naphtha Diesel Sales
Wet Gas + LPG
to Sat Gas Plant

HCU Kerosene
H2

DAO HCU
HCU Diesel

V VGO
D
SHC VGO
At Res U SDA
Unit SHC Diesel Bitumen
Sales
UCO

Slurry HC Pitch

Vac Res SDA Pitch Unit

 3

UOP Hydrocracking Process –

Increasing Conversion and Profitability

• Hydrocracking converts low value feeds to high value

transportation fuels and petrochemical feedstock
• Adds hydrogen which increases the volume of the products
• Converts heavy gas oils to clean jet and diesel,

Mild Partial Full

VGO Hydrotreating
Hydrocracking Conversion Conversion
(<20%)
(20-50%) (50-90%) (90+%)

Flexibility to Meet Refiner Processing Objectives

 4

UOP’s History of Hydrocracking Progress

UOP
UnicrackingTM
Process
UOP HDC Unibon™ UOP HC Unibon™
Process Process Present
(hydrotreating and (hydrocracking)
hydrocracking)

UOP ISOMAX 2000

UOP Lomax Process
Hydrocracking 1990
Process

1980

1970

1960
1950 UOP Hydrocracking Technology -
long history, sustained innovation
 5

Hydrocracking Technology Portfolio

Feedstock Reactor Section Fractionation Section Products

Naphtha
Once Through

Distillate
Dual Stripper/Dual Frac
Kero/
LCO
Jet Fuel
Single Stage
VGO Recycle

CGO Diesel Fuel

DAO

HPNA Management
Two
Stage Recycle Lubes Base
Stocks

Customized Solutions to Meet Customer Objectives

 6

65 years of Hydroprocessing Innovation

200,000
10 UOP Hydroprocessing Experience
Licensed 2012
Unionfining Units
2016
UniflowTM
Units in UnityTM
Licensed Capacity, BPSD

160,000 Unicracking Units

Reactor
Iran Internals Hydroprocessing
Catalysts
5th Generation
120,000

80,000

40,000

0
1950 1955 1960 1965 1970 1975 1980 1985 1990 1995 2000 2005 2010 2015 2020
Award Year

1952 1960 1990s/2006 2008

1st Hydrotreating 1st Hydrocracking HPNA E2S
Unit Unit Management Process

340+ Hydrotreating Units & 220+ Hydrocracking Units Licensed

 7

Comprehensive Hydroprocessing Solution

Catalyst Solutions Equipment Solutions Process Expert Knowledge Integrated

•Unified portfolio for • UniflowTM Reactor Technology • Training simulators Solutions
hydrotreating & Internals • Innovative flow • Bottom of the Barrel
hydrocracking • Experion Solution
• UOP Hydrogen schemes Suites (Uniflex™, RCD
•Crystaphase® Purification (Polybed™ Unionfining, & SDA
• Unicracking Process
PSA) Processes)
• Unionfining Process
• Callidus Combustion • Hydrogen recovery
Equipment • HPNA Management & purification
• Honeywell Advanced • New unit & revamp
Process Control experience
• Mitsui smiLLeTM
Metallurgy
• Filtrex® ACR Filtration
 8

UOP Hydrocracking Differentiators

• Extensive experience in revamping existing Hydrocracking Units
- Maximize value from existing assests

• Novel Fractionation
- Reduced CAPEX and OPEX of fractionation section

• HPNA Managament
- Enabler for higher conversion

• Uniflow reactor internals

- Maximize catalyst utilization

• Catalyst
- pre treat and cracking
 9

Improving Profitability from Existing Asset

• A challenging market demands innovative solutions
• UOP can provide a variety of revamp options to meet your
objectives
- Innovative process solutions
- Experience with different flow schemes
- Uniflow reactor internals
- Complete catalyst portfolio
- Targeted studies to resolve issues, assess future expansion or
investigate different processing objectives

• UOP Worldwide Hydroprocessing Revamp

experience
- 74 Revamp Studies and 42 Revamp Schedule
A’s conducted in the last 10 years
 10

Energy Savings with Novel Fractionation

Traditional Single Stripper Design The Novel Fractionation Flow Scheme

Off Gas
Off Gas
Product Cold Heavy
Cold Fractionator Stripper
Separator/
Fractionator
Flash Drum Stripper Cold
Separator/
Flash
Hot Fractionator Drum
Separator/ Feed Heater Steam
Flash Drum
Light
Steam Fractionator

Unconverted
Oil Hot Hot
Separator/ Stripper
Flash
Drum

Steam Steam

Heavy Fractionator Unconverted

• The separation accomplished in the hot Feed Heater Oil

and cold separators is further improved in

separate hot and cold strippers
• Improved Diesel/UCO separation with
heavy fractionator
 11

Novel Fractionation Benefits

54%
2015

• Dual Zone Stripper + Dual Fractionator

– Improved fractionation efficiency
– Diesel yields improved by approximately 1%
– Produces dry diesel directly from fractionator
 12

UOP HPNA Management Technology

Enables Higher Conversion

• Heavy Polynuclear Aromatics

can build up in recycle oil
• HPNA Management Solutions
‒ Split shell fractionator
concentrates HPNA’s in a small
bleed stream
Distillate
 15 units designed with split Split Shell
Reactor Product
shell fractionator, 5 operating Fractionator

‒ External HPNA stripper is VGO

Feed
available as a revamp HPS

HPNA rich
Hot material to
Separator fuel oil
or FCC

Up to 99.5% conversion for Slip stream to

HPNA Stripping

entire catalyst cycle Section

 Improved Distribution with 13

UOP Uniflow Reactor Internals

• New design offering a step Example: Installed in 5-bed HC reactor in

change in performance & Nov, 2014. Unit operating at 32% higher
speed of installation feed rate compared to previous cycle.
• First sale in 2013 Hydrocracking Radial Spread (ºF) Radial Spread (ºF)
Bed New Cycle Previous Cycle
• Sold into 16 units (new and
Top: 1 Top: 3
revamp) with 6 operating Bed 1
Bottom: 1 Bottom: 18
successfully Bed 2
Top: 4 Top: 2
Bottom: 3 Bottom: 6
Top: 4 Top: 5
Bed 3
Bottom: 2 Bottom: 6
Top: 4 Top: 12
Bed 4
Bottom: 3 Bottom: 36
Top: 4 Top: 11
Bed 5
Bottom: 4 Bottom: 45

Customer Feedback:

“We would never have been able to operate this unit

where it is today without these new internals.
This is a step change for UOP”

UOP 7432D-13
 14

Hydrocracking Catalyst System Components

Grading System • Controls pressure drop

• Removes metals

Hydrotreating Catalyst • Sulfur removal

• Nitrogen removal
• Aromatic saturation

Hydrocracking Catalyst • Selective cracking to reduce

boiling range
• Aromatic saturation
• Selective isomerisation
 15

Iranian Hydrocracking Opportunities

 16

Revamp of existing Iranian units

• Key enablers for staged investment and fuel oil

reduction

• Maximum utilisation of existing refinery assets

• Revamp Opportunities for increased throughput

• Phased investment for Bottom of the Barrel upgrading

• Delayed investment of major unit revamp

 17

Existing Unit – Iranian Isomax Unit

19%
Fuel
Oil

LIGHT ENDS

FULL RANGE
NAPHTHA
Existing
FRESH FEED Isomax
(HVGO)
10,000 BPSD
Unit KEROSENE

12,000 BPSD
DIESEL

RECYCLE OIL UNCONVERTED

OIL
2,000 BPSD
 18

Existing Unit – Iranian Isomax Unit

13%
Phase 1 – New VDU Fuel
Oil

Original Capacity = 12,000 BPSD

Current Capacity = 12,600 BPSD
LIGHT ENDS

HVGO FULL RANGE

NAPHTHA
2,600 BPSD
Existing
FRESH FEED Isomax
(HVGO)
10,000 BPSD
Unit KEROSENE

12,600 BPSD
DIESEL

RECYCLE OIL UNCONVERTED

OIL
2,000 BPSD
 19

Existing Unit – Iranian Isomax Unit

4%
Phase 2 – New SDA Fuel
Oil

Original Capacity = 12,000 BPSD

Current Capacity = 15,600 BPSD
LIGHT ENDS

HVGO FULL RANGE

NAPHTHA
2,600 BPSD
Existing
FRESH FEED Isomax
(HVGO)
10,000 BPSD
Unit KEROSENE

1.0 CFR
DAO 14,880
30%BPSD
DIESEL
3,000 BPSD Higher
than
RECYCLE OIL
Design UNCONVERTED
OIL
2,000 BPSD
 20

Existing Unit – Iranian Isomax Unit

0%
Phase 3 – New Slurry Hydrocracker Fuel
Oil

Original Capacity = 12,000 BPSD

Current Capacity = 16,800 BPSD
LIGHT ENDS

HVGO FULL RANGE

NAPHTHA
2,600 BPSD
Existing
FRESH FEED Isomax
(HVGO)
10,000 BPSD
Unit KEROSENE

1.0 CFR
DAO 14,880
40%BPSD
DIESEL
3,000 BPSD Higher
than
SLURRY VGO RECYCLE OIL
Design UNCONVERTED
OIL
1,200 BPSD 1,876 BPSD
 21

Existing Unit – Iranian Isomax Unit

Increasing Complexity

Current Phase 3
Phase 1 Phase 2
Add Slurry
Operation New VDU Add SDA
HCK

12,000 BPSD 12,600 BPSD 15,600 BPSD 16,800 BPSD

No Recycle Unit Revamp Required

60-70% Maximise yield of Distillates

Conversion Maximum Conversion
 22

Unit Revamp Options

New 1st Uniflow Reactor

HVGO, DAO and
SLURRY VGO Stage Internals

16,800 BPSD

16,800 BPSD
LIGHT ENDS
NAPHTHA
Fractionation
At KEROSENE
original Section
design DIESEL
capacity
HPNA
Existing
Management
Isomax
Unit UNCONVERTED OIL

12,000 BPSD

RECYCLE OIL
12,000 BPSD
VCMStudy.ir
 23

Impact on Refinery Yields

100

90

80

70
PRODUCT YIELD, VOL%

60

50

40

30

20

10

0
Current Performance Phase 1 - New VDU Phase 2 - New SDA Phase 3 - New Slurry
Hydrocracker

Fuel Oil Bitumen Euro 5 Diesel Kerosene Naphtha LPG

 24

Summary of Case Study

Phase 1 Phase 2 Phase 3

+VDU +SDA +Slurry HCU

Hydrocracking Unit Creep of existing

Add additional stage to existing unit
Revamp Concept unit

Euro 5 Diesel
43 vol% 52 vol% 61 vol%
(vol% of product)

Fuel Oil
13 vol% 4 vol% 0 vol%
(vol% of product)

UOP has the knowledge and capability to provide

an integrated revamp solution to phase your project to
maximise transportation fuels and to
reduce fuel oil to less than 10% of crude
 25

MIDOR Refinery Expansion Project

Boosting Refinery Capacity – 100,000 to 160,000 BPSD

Project Objectives (all achieved)

• Refinery throughput increased 60%
• Increase middle distillate yield 75%
• Meet future legislation of high
quality EuroV specifications
• Zero fuel oil production
• Internal rate of return 30%

Additional Requirements
• Maximum utilisation of existing
refinery units
• Minimise refinery downtime
• Limited plot space

UOP 7432D-10
 26

MIDOR Refinery Expansion Project

Boosting Refinery Capacity – 100,000 to 160,000 BPSD
CDU LPG LPG from other units LPG LPG LPG Fuel Gas
SGP C3/C4 LPG
Merox Frac.
SRN
Crude HC LPG
Isomerate
Oil C ISOM
D Kero Euro V
U Gasoline
NHT NS R95

Reformate
SRD
KHT CCR
NAP
At Res V
D KHT
U Kerosene
VGO
CDU LPG
DHT NAP
SRN
Crude
Oil C New
D Kero DHT
HT Diesel Local
U Diesel

HC NAP
SRD
HC LPG to LPG Frac
HC Kero
HC
V DC HC Diesel Euro V
At Res D VGO
NAP LCGO HCGO Diesel
U UCO
Delayed
Coker
Pitch
Coke
SDA DAO New Unit
Revamp

Existing Unit
UOP 7432D-26
 27

MIDOR Refinery Expansion Project

Current Kerosene and Diesel Processing Configuration

SR Kerosene Existing Kerosene

Merox Jet A1
11,000 BPSD

SR Diesel + LCGO Existing DHT Local Diesel

29,000 BPSD 50 wtppm S

Current Configuration
• Targets local diesel production
• Kerosene to Jet A1 pool only
• No ability to achieve EuroV diesel specifications

UOP 7432D-12
 28

MIDOR Refinery Expansion Project

Maximising Euro V Diesel Production

SR Kerosene Existing Kerosene

Merox Jet A1
11,000 BPSD

SR Kerosene KHT
(Revamped DHT) Local Diesel
18,000 BPSD 50 wtppm S

SR Diesel + LCGO Euro V Diesel

New DHT
48,000 BPSD
10 wtppm S

Ultimate flexibility between Jet A1 and EuroV Diesel

production. Minimum shutdown and plot space
UOP 7432D-13
with optimised investment
 29
Make-up Gas Unicracking Unit
Existing Configuration

Naphtha

Kerosene
33,000 BPSD
VGO+HCGO Separation Fractionation Diesel

UCO

17,000 BPSD

UOP 7432D-14
 30
Make-up Gas Unicracking Unit
New Configuration

New RG Scrubber
Naphtha

Kerosene
50,000 BPSD
VGO+HCGO+DAO Separation Fractionation Diesel

Uniflow Reactor
Internals

35,000 BPSD
MUG UCO

Common H2
Recovery

Naphtha

Kerosene

Separation Fractionation Diesel

HPNA UCO
Management

UOP 7432D-130
 31

MIDOR Refinery Expansion Project

Boosting Refinery Capacity – 100,000 to 160,000 BPSD

• Maximum utilisation of existing refinery units

• Minimise refinery downtime
• Refinery throughput increased 60%
• Increase middle distillate yield 75%
• Meet future legislation of high quality EuroV specifications
• Zero fuel oil production
• Internal rate of return 30%

UOP 7432D-16
 32

Enhanced Two-Stage Unicracking

Tüpras Residue Upgrading Project Success Story

Delayed Coker
UOP Hydroprocessing
Complex

Vacuum Distillation

Hydrogen Generation Unit Control Room

 33

Enhanced Two-Stage Unicracking

Tüpras Residue Upgrading Project Success Story
 34

Enhanced Two-Stage Unicracking

Tüpras Residue Upgrading Project Success Story

• Smooth and safe unit start-up

• On spec product with 36 hours of feed introduction
• All guarantees and met in August 2015
• One of the most profitable units in Tüpras
• Operating at 110% of design feed meeting all product qualities
• Forecast to exceed the catalyst cycle length
 35

Summary – UOP Hydrocracking Technology

Upgrading Fuel Oil to Euro V Fuels

• Licensor of choice for integrated hydrocracking solutions

• Technology to enable the phasing of Iranian bottom of the barrel projects

• Existing hydrocracking units are key enablers for staged investment

• Extensive experience of revamp design to align with existing unit

constraints and minimize downtime

• History of partnering with customers for successful bottom of the barrel

upgrading projects
 36

The information contained in this presentation is provided for general information purposes only
and must not be relied on as specific advice in connection with any decisions you may make.