Copyright 2013 DuPont. The DuPont Oval Logo, DuPont, and The miracles of science are trademarks or
registered trademarks of E.I. du Pont de Nemours and Company or its affiliates. All rights reserved.
Andrew R Tyas
Regional Engineering Manager
DuPont Clean Technologies
African Refiners Association AGM
March 2013, Cape Town
IsoTherming
Hydroprocessing Technology
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Contents
DuPont Clean Technologies
IsoTherming Principles
Revamp Approach
Capital and Operating Cost Savings
Commercial Offerings
Conclusions
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DuPont Clean Technologies Strategic Businesses & Offerings
Alkylation STRATCO H2SO4 Alkylation Technology
Hydroprocessing IsoTherming Hydrocracking &
Hydrotreating Technology
Air Pollution Control BELCO Clean Air Technologies
Sulphuric Acid MECS Sulphuric Acid & Environmental
Technologies
Oil Recovery MATRx Enhanced Oil Recovery
Technologies
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IsoTherming Overview
This is a step-change versus standard (trickle bed)
technology for hydrotreating :
Commercially Available Catalysts
Lower Capital Investment
Lower Cost Revamps
Lower Operating Expense
Operating Flexibility
Ultra Low Sulphur
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IsoTherming Applications
Euro V Diesel or USA Ultra Low Sulphur Diesel (Both < 10 ppm Sulphur)
Vacuum Gas Oil (FCC Feed) Hydrotreating
Mild Hydrocracking
Grass Roots or Low Cost Revamps of Existing Units
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IsoTherming History IsoTherming developed by Process Dynamics a
technology development company based in Fayetteville,
Arkansas, U.S.A.
First commercial unit: Diesel Hydrotreater Unit revamp in April 2003 for U.S.A. ULSD (
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Conventional Trickle Bed Process Flowscheme
Two Phase Reactor
Once Through Liquid
Gas Recycle
Distribution critical
Hydrogen diffuses into liquid as it is
consumed in the catalyst bed
AMINE
SCRUBBER
SEPARATOR
TO LP FLASH / STABILISER
MAKE UP
HYDROGEN
HP FLASH
RECYCLE GAS COMPRESSOR
FEED
MAKE UP COMPRESSOR
CONDENSER FEED/EFFLUENT
EXCHANGERS
HEATER
REACTOR
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IsoTherming Process Flowscheme
Single Phase Reactor
Once Through Hydrogen
Liquid Recycle
All Hydrogen in liquid
phase within the catalyst
bed
Distribution less critical
MAKE UP
HYDROGEN
FEED
MAKE UP COMPRESSOR
REACTOR
TO LP FLASH / STABILISER
RECYCLE PUMP
HEATER
MIXER
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IsoTherming Advantages (1)
Recycle of Hydrogen Accomplished by Liquid Recycle
Elimination of Recycle Gas Equipment in Grassroots Units
Liquid Phase Ensures Catalyst Bed Completely Wetted
1) All Catalyst Sites Utilised
More effective use of catalyst
2) Minimizes Hot Spot Formation
Decreased catalyst deactivation / coking / thermal cracking
Decreased light end formation
Increased diesel yields
Heat of Reaction Absorbed by High Liquid Recycle Rate
Adiabatic temperature rise much less than conventional technology
Reactor operation is tending towards isothermal conditions
Lower heater firing rates during normal operation
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Flexibility in Reactor Shape
L/D and bed depth not dependent on two phase flow regime
Reactor Fabrication
Often, reactor diameter and wall thickness can be minimized to allow use of cold-rolled plate instead of forged plate
Reactor design can be optimized for local fabricator capabilities and transportation logistics
Projects not dependent on just a few fabricators worldwide
Shorter reactor delivery time possible
Can be optimized based on fabricators capabilities
Plot Plan can be Smaller than Conventional
Customers have reported up to 4 times smaller when comparing proposals
Heat Integration can Lead to Smaller Carbon/GHG Footprint
IsoTherming Advantages (2)
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Challenges for Revamping Existing Units
Increasing desulphurisation and/or capacity requires more reactor capacity, more make-up gas and more recycle gas.
Increased gas circulation and/or feed increases pressure drop through heat exchangers, condensers, furnaces, reactors, amine
column.
Recycle compressors typically have very limited capability for more throughput combined with increased head especially if unit already
revamped.
In many designs, hydrogen make-up is routed to recycle compressor inlet. The required recycle compressor capacity is then
increased by two effects :
More make-up hydrogen required
Increased recycle rate required due to higher consumption if outlet hydrogen partial pressure is to be maintained
Extensive modifications may be required to overcome these bottlenecks
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Conventional Trickle Bed Revamp, Impact of
additional Hydrogen Requirement
AMINE
SCRUBBER
SEPARATOR
TO LP FLASH / STABILISER
MAKE UP
HYDROGEN
HP FLASH
RECYCLE GAS COMPRESSOR
FEED
MAKE UP COMPRESSOR
CONDENSER FEED/EFFLUENT
EXCHANGERS
HEATER
REACTOR
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PRESSURE DROP INCREASES, COMPRESSOR HEAD DECREASES
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registered trademarks of E.I. du Pont de Nemours and Company or its affiliates. All rights reserved.
MAKE UP
HYDROGEN
HP FLASH
AMINE
SCRUBBER
RECYCLE GAS COMPRESSOR
Conventional Trickle Bed Revamp For Euro V
FEED
MAKE UP COMPRESSOR
SEPARATOR
ADDITIONAL REACTOR
TO LP FLASH / STABILISER
CONDENSER FEED/EFFLUENT
EXCHANGERS
HEATER
OLD
REACTOR
NEW OR ADDITIONAL EQUIPMENT MODIFIED EQUIPMENT 11
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MAKE UP
HYDROGEN
HP FLASH
AMINE
SCRUBBER
RECYCLE GAS COMPRESSOR
FEED
MAKE UP COMPRESSOR
SEPARATOR
TO LP FLASH / STABILISER
CONDENSER FEED/EFFLUENT
EXCHANGERS
R
E
A
C
T
O
R
REACTOR
RECYCLE PUMP
HEATER
NEW OR ADDITIONAL EQUIPMENT MODIFIED EQUIPMENT
RECYCLE GAS HEATER
IsoTherming Revamp
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Advantages of IsoTherming Revamp
New IsoTherming Reactor achieves 80-90% of hydrogen consumption without gas recycle.
Existing reac
