Enhance Refinery Margins by Producing Premium Refinery Products from FCC Slurry Oil CSIR - INDIAN INSTITUTE OF PETROLEUM (Council of Scientific and Industrial Research) DEHRADUN M. O. Garg, Manoj Kumar and Manoj Srivastava 1 New Delhi, India • October 2013
21
Embed
Enhance Refinery Margins by Producing Premium Refinery ...refiningcommunity.com/wp-content/uploads/2017/07/Enhance-Refinery... · Enhance Refinery Margins by Producing Premium Refinery
This document is posted to help you gain knowledge. Please leave a comment to let me know what you think about it! Share it to your friends and learn new things together.
Transcript
Enhance Refinery Margins by Producing Premium Refinery Products from FCC Slurry Oil
CSIR - INDIAN INSTITUTE OF PETROLEUM(Council of Scientific and Industrial Research)
DEHRADUN
M. O. Garg, Manoj Kumar and Manoj Srivastava
1New Delhi, India • October 2013
Challenges
• FCC unit in refinery produces Slurry Oil, an aromaticsladen residue stream, which is refractory in nature.
• Upgradation of slurry oil into transportation fuelsthrough catalytic route is very difficult
• slurry oil recycling in FCC unit is limited
• Therefore, refiners blend major portion of slurry oil intofuel oil - demand of which is continuously declining or as‘Delayed Coker’ feed - if such a unit exists in the refinery
2
General Refining Scheme
GAS
PARTLY SLURRY OIL RECYCLING
FCC
LPG
GASOLINE
HCO
Slurry Oil(To Fuel Oil Pool
/Delayed Coker Feed)
LCOFEED
3
Technology for Production of Premium Products from FCC Slurry Oil
• A novel application for upgrading slurry oil into valueadded premium refinery products
• Innovative concept of integration of two differentprocesses :
– Solvent Extraction
– Catalytic Cracking
4
Innovative Processing OptionGAS
(IMPROVED FCC RECYCLE STREAM)
FCC
EXTRACTION
LPG
GASOLINE
HCO
Slurry Oil
LCO
Slurry Oil
NMP
FEED
RAFFINATE
EXTRACT
CBFS / PITCH 5CBFS / PITCH
Process Flow Diagram
6
Technology Objectives
This technology is aimed to achieve the following :
- Generation of additional quantity of clean FCC feed andthereby enhanced distillate yields
- Reduction in fuel oil components
- Production of premium quality carbon black feed stock(CBFS)
- Conversion of aromatics present in slurry oil into highvalue mesophase pitch - precursor for advanced carbonmaterials
7
Key Features/Advantagesof Technology
• Provides improved quality FCC feed stock, which is as clean asfresh feed (VGO)
• Higher yields of FCC products (gas/distillate) of better quality(reduced sulfur)
• Co-production of high BMCI aromatic extract (premium qualityCBFS)
• Reduction in coke lay down on cracking catalyst leading toenhanced catalyst efficacy and cycle life, reduced catalystconsumption and regenerator load
• Reduced CO2 emissions (meeting future carbon emissionlegislations of the refinery)
• No major investment, high profitability 8
Technology Development
• Phase I : Basic data generation (single stage andmultistage extraction, Cracking Studies in ACE unit) atlab scale
• Phase II : Fine tuning with process parameters of currentoperation of HPCL refinery
• Phase III : Successful commercial run at HPCL to provetechnology concept
The technology is currently operating successfully9
Typical Feed Properties
PropertiesDensity gm/ml d4
15 0.8927Kin Viscosity cSt at 100⁰C 4.18Pour Point, ⁰C +45Flash Point, ⁰C 122BMCI 36IBP, ⁰C 282.9FBP, ⁰C 516.9
• Technology was developed/fine tuned based on HPCLfeed stock (slurry oil) with properties as given below :
10
Slurry Oil Extraction Data
Parameter Bench Scale Data Test Run DataSingle Stage
Potential for Further Value Addition of Aromatic Extract Stream
• The extract stream produced is very rich in aromaticsand can be converted into high value mesophase pitch –a precursor for a variety of advanced and engineeringcarbon materials.
• This is a very major value addition to aromatic extractwith potential to make huge money.
• Advanced carbon materialsproduced from mesophase pitchare needed for various strategicallyimportant materials
Mesophase Pitch 14
Commercial Run at HPCL Mumbai Refinery
• M/s HPCL carried out‘commercial run’ forprocessing of slurry oil inone of their existingsolvent extraction units oflube block at Mumbairefinery.
• The commercial run was agreat success.
• Technology is tailor madeto HPCL but not limiting toit.
15
Investment/Economic Impact of Technology
• HPCL invested ~ Rs 50 Lakhs only for implementing thistechnology
• Gross refinery margin (GRM) of HPCL has increased by~ US $ 0.14/bbl
• Increase in profit of refinery to the tune of ~US$ 15million/annum)
• Reduction in generation of fuel oil components by~65 TMT (0.9 wt%) annually/5.45 TMT per month
• Monthly production of 3.85 TMT of premium cat feed(raffinate) and 1.60 TMT of premium CBFS (Extract)
16
Other Potential Applications of Technology
Other potential applications of Technology include :
• Production of paraffinic feed for isodewaxing/isocracking to make new generation high qualitygroup-II and Group-III lube base oils
• Production of low aromatic raffinate from LCO which canbe blended for quality upgradation with diesel
• Production of needle coke from premium CBFS (themajor demand of needle coke is met through import)
17
Recognition This innovative technology begged prestigious
‘CSIR Technology Award’
18
Conclusions• A novel technology for production of valuable refinery
products from low – value slurry oil such as good qualityFCC feed, premium quality CBFS, precursor for advancedcarbon materials
• Concept of integration of solvent extraction and FCC isnew
• This is a proven technology as it is successfully running atHPCL Mumbai refinery
• Investments are low, enhancement in annual refineryprofit is high
• Best suited for refineries having FCC and Solvent extractionunits but can be implemented to other refineries also withonly small investment
19
Acknowledgements
• The lab study was financially supported by Centre for HighTechnology (CHT), New Delhi and Hindustan Petroleumcorporation Limited (HPCL), Mumbai
• The contributions of M/s CPCL, EIL and HPCL in thecollaborative project leading to development of basicknow-how of this technology are gratefully acknowledged
• We compliment M/s HPCL for implementing thetechnology in its Mahul Refinery for which they aredeservedly reaping rich dividends.
20
CSIR-Indian Institute of PetroleumP.O. IIP, MohkampurDehradun – 248005