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8/12/2019 05 Bottom of Barrel
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BottomofBarrelProcessingChapters5,6,&8
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Light Naphtha
CrudeOil
Desalter
AtmosphericDistillation
VacuumDistillation
GasSeparation &
Stabilizer
SolventDeasphal-
ting
Coking
Visbreaking
FluidizedCatalyticCracking
Hydro-cracking
NaphthaReforming
Isom-erization
Sat GasPlant
Polymer-ization
Alkylation
NaphthaHydro-treating
Treating &Blending
Coke
Fuel Gas
LPG
AviationGasoline
AutomotiveGasoline
Solvents
Jet Fuels
Kerosene
Solvents
Heating Oils
Diesel
ResidualFuel Oils
Lubricant
Greases
Waxes
Asphalts
HeavyNaphtha
Kerosene
Distillate
AGO
LVGO
HVGO
VacuumResiduum
CatDistillates
Gas OilHydro-treating
DAO
Isomerate
Gas
AlkylFeed
Alkylate
PolymerizationNaphtha
Gases
Butanes
LPG
Reformate
Naphtha
Fuel Oil
Bottoms
Distillates
DistillateHydro-treating
CatNaphtha
Cycle Oils
SDABottoms
CokerNaphtha
Heavy
CokerGasOil
Light CokerGas Oil
SulfurPlant
Sulfur
Naphtha
Fuel Oil
SolventDewaxing
Lube Oil
Waxes
2
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NeedForHeavyEndsProcessing Worldcrudeslatehasbecomeheavier thiswillcontinue
Concentrationofsulfur&othercontaminantshasbeenincreasing thiswillcontinue
Sulfurspecificationsbecomingmorestringent
Forenvironmentalprotection
DemandforNo.6FuelOildeclining
Forenvironmental
protection
Costoflightcruderelativetoheavycrudeisincreasing
Producersareincreasingthesaleofheavycrudestoprolongthelifeoflightcrude
fields
3
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ProcessingOptionsPhysicalseparations
Vacuumdistillation
Volatility
SolventDeasphalting
Solubility
Chemicalreactions(inorderofincreasingseverity)
Visbreaking
Catalyticcracking
Coking
Delayedcoking
Fluidizedbedcoking
Hydrocracking
LubeOilProcessing
Requiresspecializedfeedstocks
4
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U.S.RefineryImplementation
5
CORPORATION State Site
AtmosphericCrudeDistillationCapacity(barrelsperstreamday)
VacuumDistillation
DownstreamChargeCapacity,
CurrentYear(barrelsperstreamday)
ThermCracking,Visbreaking
DownstreamChargeCapacity,
CurrentYear(barrelsperstreamday)
ThermCracking,Other(IncldngGasOil)DownstreamChargeCapacity,
CurrentYear(barrelsperstreamday)
FuelsSolventDeasphaltingDownstream
ChargeCapacity,CurrentYear(barrelsperstreamday)
CONOCOPHILLIPS Louisiana WESTLAKE 252,000 132,000 0 10,600 0
CHEVRONCORP California RICHMOND 257,200 123,456 0 0 66,000EXXONMOBILCORP Texas BAYTOWN 584,000 297,000 0 0 47,000MARATHONPETROLEUMCORP Louisiana GARYVILLE 518,000 268,000 0 0 34,500VALEROENERGYCORP Texas TEXASCITY 233,000 142,500 0 0 33,500TESOROCORP Washington ANACORTES 125,000 47,000 0 0 24,300VALEROENERGYCORP Louisiana MERAUX 140,000 60,000 0 0 22,000CONOCOPHILLIPS NewJersey LINDEN 251,000 75,000 0 0 20,000VALEROENERGYCORP Texas HOUSTON 90,000 38,000 0 0 18,000BPPLC Texas TEXASCITY 475,000 237,000 0 0 17,000TOTALSA Texas PORTARTHUR 245,000 114,000 0 0 15,500VALEROENERGYCORP Texas SUNRAY 160,000 50,000 0 0 14,500MARATHONPETROLEUMCORP Kentucky CATLETTSBURG 253,000 119,000 0 0 13,000PLACIDOILCO Louisiana PORTALLEN 59,000 27,000 0 0 11,000VALEROENERGYCORP Texas THREERIVERS 95,000 35,000 0 0 10,000ALONISRAELOILCOMPANYLTD Texas BIGSPRING 70,000 24,000 0 0 10,000DELEKGROUPLTD Arkansas ELDORADO 85,000 45,000 0 0 7,400HOLLYFRONTIERCORP Utah WOODSCROSS 26,400 0 0 0 6,000CVRENERGY Oklahoma WYNNEWOOD 75,000 30,000 0 0 4,850HOVENSALLC VirginIslands KINGSHILL 525,000 225,000 40,000 0 0TESOROCORP Hawaii EWABEACH 95,000 40,000 11,000 0 0SANJOAQUINREFININGCOINC California BAKERSFIELD 25,000 14,300 5,000 0 0
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SolventDeasphalting Purpose
Removeasphaltsfromlubeplantfeeds
Increasegasoilyieldfromcrude
Makecommercial
asphalts
from
asphalticcrudeunitbottoms
Characteristics
Physicalrecoveryusinglighthydrocarbonsolvent(C3,C4,C5)
Dissolvesaturated
components
Leavebehind/precipitateasphaltenes
Resinssplitbetweenphases
Products
Deasphalted Oil(DAO)
Resins
Bottoms/pitch asphaltenes
6
HandbookofPetroleumRefiningProcessesRobertMeyers
McGrawHill,Inc,1986
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CharacteristicsofProducts DAOresemblesgasoilbutisofdrasticallydifferentboilingpointrange
7
0.0000
0.0005
0.0010
0.0015
0.0020
0.0025
500 600 700 800 900 1000 1100 1200 1300 1400 1500
Boiling Point (F)
MassYieldD
istribution(1/F)
Feed
DAO
Bottoms
Recombined (51.1wt% Lift)
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Provider Features
FosterWheelerKBR
LighthydrocarbonsolventwithDAO/solventseparationatsupercriticalconditions
SDATechnologyProviders
8
HydrocarbonProcessings2008RefiningProcessesHandbook
Foster Wheeler KBR ROSE
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IntegrationofSDAintoRefinery
9
HandbookofPetroleumRefiningProcessesRobertMeyers
McGrawHill,Inc,1986
Atm ResidVacuum
DistilationGas Oil HDS FCC
SDAVac Bottoms
SDA Bottoms
DAO
Cycle Oil
Slurry
Fuel Gas
C3/C
4
Naphtha
Distillate
H2
Base With SDA Base With SDA
Atm Resid Feed bpsd 50,000 50,000 Feed to FCC bpsd 27,340 40,651
API 15.1 15.1 API 24.0
wt% S 4.02 4.02 HDS Fuel Gas Mscfd 4,200 6,310
ppmw metals 69 69 FCC Fuel Gas Mscfd 4,430 6,582
Vac Resid bpsd 20,000 20,000 Total Fuel Gas Mscfd 8,630 12,892
API 5.6 5.6 HDS C3/C4 bpsd 190 289
wt% S 5.55 5.55 FCC C3/C4 bpsd 5,220 7,765
ppmw metals 160 160 Total C3/C4 bpsd 5,410 8,054SDA Bottoms bpsd 5,400 HDS Naphtha bpsd 260 388
API -12.6 FCC Naphtha bpsd 15,420 22,927
wt% S 7.15 Total Naphtha bpsd 15,680 23,315
ppmw metals 475 API 54.5 54.5
SDA DAO bpsd 14,600 FCC Cycle Oil bpsd 7,108 10,569
API 11.4 API 25.5 25.5
wt% S 4.84 FCC Slurry bpsd 1,367 2,033
ppmw metals 20 API 0.9 0.9
Gas Oil bpsd 30,000 30,000 HDS Distillate bpsd 2,750 4,090
API 22.3 22.3 API 32.5 32.5
wt% S 3.04 3.04
Feed to HDS bpsd 30,000 44,600
API 22.3 18.5
wt% S 3 3.66
ppmw metals 7
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Visbreaking
Purpose
Cutviscosityinoffeed(specsfor
heavyfueloil)
Reduces"cutter
stock
Reducesheavyfueloilamount
Characteristics
Relativelymildthermalcracking
operation
Flexibleonfeedstockquality
Typicallyhighresincrudeoils
Lowcapitalcostforprocess
Products
About20%feedcrackedtolightends,naphtha,gasoil&sometimesdistillate.
Low
yield
of
valuable
naphtha Productscontainalotofolefins
Olefinic C3s&C4softenrecovered
Naphtha&distillateoftenhydrotreatedbecauseofolefins&sulfur
Gasoil
high
in
aromatics
more
appropriateforhydrocrackingthancatcracking
Largevolumesofheavyfueloilwithhighsulfurcontent
Bottoms(visbreaker tar)
sent
directly
to
heavyfueloil
10
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TypicalCoilVisbreaker
11
http://www.fwc.com/industries/pdf/Residue_upgrading_English_10th_Sept.pdf?DIRNAME=%23dirName%23
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VisbreakingTechnologyProviders
12
HydrocarbonProcessings2008RefiningProcessesHandbookFosterWheeler ShellGlobalSolutions
Provider Features
FosterWheelerShellGlobalSolutions Visbreakerheater&downstreamcoil
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CatalyticCracking Purpose
Makegasoline&distillates
(diesel/heatingoil)
Tryto
minimize
heavy
fuel
oil
Characteristics
Mediumseveritycrackingprocess
Gasoilsaretypicalfeedstocks
Notnormallyusedonwhole
atmosphericorvacuumresids
PNAstendtocondense,leadingto
coking
Catalystssensitive
to
poisoning
by
sulfur&metalspresentinPNAs
Products
Lightgases
Olefins
Light&HeavyNaphtha
Light&HeavyCycleOils
Slurry
13
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Hydrocracking
Purpose
Minimizeheavyfueloil
Characteristics
Severecrackingprocess
Combinescracking&hydrogenation
Cokingbetterforresids
Highpressures&largeamountsof
hydrogenrequired
Products
Produceshighyieldsofliquids
Hydrogensuppressescokeformation
Liquidslowinsulfur&olefins
14
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Coking
Purpose
Createlightgases&distillates
Carbonrejection
Characteristics
Severethermalcrackingprocess
Canprocessawidevarietyof
feedstocks
Highmetals(nickelandvanadium),
sulfur,resins&asphaltenes withPNAs
SeparatesthermallystablePNAcores
fromtheirsidechains
PNAscontain
majority
of
the
heteroatoms(sulfur,nitrogen,metals)
ConcentrateinthecokeasPNAs
condense
Products
Produceslightgases,distillates
(naphthas &gasoils)forcatalytic
upgrading Lowyieldsofliquidsrelativeto
hydrocracking
Liquidscontainlargeamountsofsulfur
&olefinsbutlittlearomatics
Coke
Containslargeamountsofmetals&
sulfur.
Cokeusedependsuponquality
- May
pose
a
disposal
problem
15