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IsoTherming Hydroprocessing Technology - afrra.org · PDF file•IsoTherming® Hydroprocessing Technology may be applied for ULSD (Euro V) and mild hydrocracking service in either

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Text of IsoTherming Hydroprocessing Technology - afrra.org · PDF file•IsoTherming®...

  • 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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    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.

    Contents

    DuPont Clean Technologies

    IsoTherming Principles

    Revamp Approach

    Capital and Operating Cost Savings

    Commercial Offerings

    Conclusions

    2

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    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.

    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

    3

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    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.

    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

    4

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    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.

    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

    5

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    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.

    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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    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.

    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

    6

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    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.

    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

    7

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    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.

    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

    8

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    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.

    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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    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.

    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

    10

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    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.

    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

    6

    PRESSURE DROP INCREASES, COMPRESSOR HEAD DECREASES

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    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.

    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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    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.

    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

    16

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    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.

    Advantages of IsoTherming Revamp

    New IsoTherming Reactor achieves 80-90% of hydrogen consumption without gas recycle.

    Existing reac

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