Research and Engineering Commercial Technology to Convert Group I Facilities to Group II/III Lube Production PETROTECH: November 1-3, 2010.

Research and Engineering

Commercial Technology to Convert Group I Facilities to Group II/III Lube Production

PETROTECH: November 1-3, 2010

PETROTECH:November 1-3, 2010

History of Lubricants and Basestocks

• Lubricants have been used since ancient times

• Petroleum-based lubricants business began in the mid-1800’s

• Initial processing was limited to separation by boiling point


• Group II and Group III Base Oils are the high growth areas– Demand for improved fuel economy and lower emissions mean lower

viscosity/volatility engine oils

– Demand for increased equipment reliability

– Extended service intervals/fill for life for engines requires both performance and stability

– Group II/III plants have Opex advantages versus Group I plants

0

50

100

150

200

250

1993 1995 1996 1997 1998 1999 2000 2001 2002 2003 2004 2005 2006 2007

Hydroisomerization Capacity (kbpd)

Lu

be

Pro

du

ct,(

kb

pd

)

Lube Activity Focused on Group II & Group III Production

ExxonMobilTechnologies

Others


Performance Requirements Pushes Quality

Improved fuel economy

Lower Emissions

Longer Life

Better low temperature performance

High temperature performance

Viscometrics Thermal stability

Soot handling (diesels)

Lower Viscosity

Lower Volatility

Higher Saturates

Lower Pour, Lower CCS

Higher VI Higher Saturates

Higher Saturates


Volatility a Driver for Increased VI

3

5

7

9

11

13

15

17

19

3.5 4 4.5 5 5.5 6 6.5 7 7.5 8 8.5

Viscosity @ 100°C, cSt

No

ack

Vo

lati

lity

, M

ass%

API SM 5W30

API SM Max

GM Proposed Global Spec.

Group I / Group II 95 VI

Group II+

Mid Tier Group III

Top Tier Group III

Group IV / PAO’s


Gasoline& Diesel

HC Bottoms

VacuumDistillation

Common Routes for Base Oil Production

CatalyticDewax

Fuels Hydrocracker

LubeHydrocracker

SolventExtraction

SolventDewaxing

Dis

tilla

te/D

AO

Group I

Group II

Group II /III

Group II / III

CatalyticDewax

RHCTM

Group II

Group II /IIIHydrofinishing

Solvent Dewax

Vacuum Distillation

HydrofinishingCatalyticDewax

RHCTM

Hydrofinishing


Process Choice: Blocked or Broadcut?

• Blocked: Lube Grades Processed Individually– Pro:

• Smaller catalytic equipment• Production to optimum specification for each product• Clear target response to feed change

– Con: • Intermediate tankage required between units• More complex operation

• Broadcut: Unfractionated Fuels H/C Bottoms or VGO to Lube H/C– Pro:

• Single operation, no stock switch—simpler control• Minimal/no intermediate tankage

– Con: • Larger catalytic vessels• One grade dictates operating severity—possible overtreating of others


Integrated Group I Facilities

Group IIGroup III

HydroprocessingHydroprocessing(RHT or RHC™)(RHT or RHC™)

CatalyticCatalyticDewaxing (MSDW™ )Dewaxing (MSDW™ )

HydrofinishingHydrofinishing(MAXSAT™)(MAXSAT™)

Converting Vacuum Gas Oil and DAO to High Quality Lube Base Stocks is a multi-step Process

Converting Vacuum Gas Oil and DAO to High Quality Lube Base Stocks is a multi-step Process

Atm

os

ph

eri

c R

es

id

VacuumGas Oil

DA

O

Vac

uu

m

Res

id

VacuumVacuumDistillationDistillation

Group IGroup IFacilitiesFacilities

Extract

Solvent Solvent Dewaxing Dewaxing

Group IIGroup III

Remove Remove AsphalticAsphalticMaterial Material

andandAdjust Adjust

ViscosityViscosity

Adjust Adjust ViscositViscosit

yy

Improve Cold Flow

Properties

Convert wax to High VI Lube

Improve Color and Stability, Saturate

Polynuclear

Aromatics

Improve VI, Reduce Sulfur &

Nitrogen, Saturate or Extract Aromatics,

Reduce CCR, Remove Metals

DeasphaltingDeasphalting


Integrated Route to Base Oils

0

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60

70

80

Base

VI

Incr

ease

Conversion to 360-O C Fuels

Group III

Group II

Aromatic Extract

Group III

Group II

Group IIGroup III

CatalyticDewaxing (MSDW)

CatalyticDewaxing (MSDW)

Hydrofinishing(MAXSAT)

Hydrofinishing(MAXSAT)

ExistingSolvent Dewaxing

ExistingSolvent Dewaxing

Group IIGroup III

Group I Integrated into Group II & Group III Lube Plant

• 8 RHC or RHT units in operation or in design

• Group I solvent operation improves VI with a yield loss to aromatic extracts

• Removal of 3-4 ring aromatic compounds and complex sulfur and nitrogen compounds allows reduction in hydroprocessing severity, hydrogen consumption and associated yield loss

Hydroprocessing(RHT/RHC)

Hydroprocessing(RHT/RHC)

Group I Solvent Plant

Group I Solvent Plant


Raffinate Hydroconversion (RHC) or Hydrotreating (RHT) Add Flexibility

• Lower investment than grass roots• Maintains use of solvent-based lube facilities and Debottlenecks

solvent extraction• Produces high quality Group II & II+ base stocks; also Group III

capable

– Higher VI, higher saturates, lower volatility, lower sulfur

– Improved color and stability

• Easily processes full range of viscosity grades

• Preserves wax production with solvent dewaxing, or…

• May use Catalytic Dewaxing (MSDW) to eliminate solvent dewaxing


Maximize Use of Existing Group I EquipmentL

ub

e V

acu

um

L

ub

e V

acu

um

D

isti

llati

on

Dis

tilla

tio

n

Aromatic Extract

Fuels

Light Neutral

Medium Neutral

Heavy Neutral

So

lve

nt

Dew

axin

gS

olv

en

t D

ewax

ing

RHC™ RHC™ or or

RHTRHT

So

lve

nt

Ex

tra

cti

on

So

lve

nt

Ex

tra

cti

on

50-70% Yield with 15-35 VI Uplift

80-98% yield with 3-30 VI Uplift and H2 use of 300-600 scf/B

DW: 70-85% Base Oil Yield

High-quality wax with upstream Hydroprocessing


Case Studies – Overview• Solvent Extraction Unit (SEU) and Solvent Dewaxing Unit (SDW) Exist to

Process a Full Range of Lubes (Can Include Bright Stock)

• Flexibility Required to Produce Group II / II+ Lubes

• Options:

– CASE 1: SEU, RHC and SDW – keep Neutral grades of wax production with improved slack wax quality

– CASE 2: SEU, RHT and catalytic dewaxing (MSDW) – maximum production, but no wax product

• All Products Produced to 110VI with Addition of RHC or RHT

• Solvent Dewaxing and Catalytic Dewaxing (MSDW) Considered


Case Studies – Overview (2)

• Three Products – 100N/325N/600N

• Base Production of 100VI/95VI/95VI

• SEU Solvent Ratio Decreased to Increase Overall Production

SEU Raffinate produced at 85 VI (DWO basis)

• Two Crudes Considered:

– Arab Light – high quality crude source example

– Urals – low quality crude source example


Case Studies – Results

• Total Production Maintained with Both Solvent Dewaxing and Catalytic Dewaxing (MSDW) – 110VI Products – by Balancing Process Steps

• Large Increase in Extraction Capacity with Reduction in Severity; Substantial Product Rate Increase Possible

• VDU Side Streams Viscosity Increased to Meet Constant Product Viscosity– Hydroprocessing viscosity impact differs from solvent processing

• Wax Production Increase is Possible When SDW Can Support

• Effects are Crude Independent – Relative Changes Consistent for AL and Urals


Study Case 1 – Summary of Effects

Impact of RHC Addition with Optimization To Existing Basic SEU/SDW

100N/325N/600N products Production Change

Group I Base Case — 100/95/95 VI Products Base Ops today

Group II 110 VI Products — Constant SEU Feed Rate and Severity -- Raise VI

Group II 110VI Products — Reduce SEU Severity to 85 VI Base First step-recover

capacity

Group II 110VI Products—Max SEU Feed to Solvent Limit + Wax production based on SDW

+Increase raffinate

to raise base oil & wax production


Study Case 2 – Summary of Effects

Impact of RHT Addition with Optimization To Existing SEU

Replace SDW with Catalytic Dewaxing (MSDW)

100N/325N/600N products Production Change

Group I Base Case — 100/95/95 VI Products Base Ops today

Group II 110 VI Products — Constant SEU Feed Rate and Severity -- Raise VI

Group II 110VI Products — Reduce SEU Severity to 85 VI Base First step-recover

capacity

Group II 110VI Products — Max SEU Feed to Solvent Limit +

Increase raffinate to raise base oil

production


RHC is Commercially Proven . . .

• First Unit Streamed in 1999 – Ten Years of Consistent Performance

• Commercial Sequence of SEU/RHC/SDW (Ketone)

• Very Low Catalyst Ageing

• EHCTM Group II+ Products Show Excellent Performance in Formulations

• Multiple Units Designed and Operating/In-construction

• Excellent Flexibility for Complete Slate of Viscosity Grades including Bright Stock

• Group III Capable


First RHC Unit Streamed in 1999

EHC™ 45 EHC™ 60

SUS @ 40°C 150 200

Pour point, °C -18 -18

VI 116 114

NOACK Volatility, wt% 14 8

Saturates by Clay Gel, wt% 96 95

Group II+ Production


MSDW – Leading Selective Dewaxing Catalyst System

• Integrates with RHC/RHT, and Lubes or Fuels Hydrocracking

• Waxes Selectively Isomerized to High VI Lube• Highest Lube Product Yield and Low Fuels/Gas

Production• Two Reactor Cascade System

– Reactor 1: Zeolite Catalyst for dewaxing– Reactor 2: Noble Metal Hydrofinishing Catalyst

• Low Hydrogen Consumption• Processes Full Range of Base Stocks• MSDW-2 Life Demonstrated >7 Years in Jurong and

> 9 Years with Licensee• MSDW Licensed in 23 Units with 20 Units Starting

up from 2002 to 2011• New MSDW Catalyst – Commercialized in 6+ Units

Since 2005

ExxonMobilTechnologies

Others


MSDW: Leads by . . .• Feed Flexibility from Light Neutral to Bright Stock...Excellent Viscosity

Retention

• Product Flexibility for Group II and Group III

• High Lube Product Yields with Minimum Fuels Byproducts

• Excellent Low Temperature Properties of Products

• Latest MSDW Shows Higher Activity than Prior Generations, Yet Maintains Exceptional Yield Selectivity, Robust Operation when Faced with Feed Contamination, and Superb Feed Rate Maintenance

• No MSDW Load Ever Replaced for Reaching End-of-Cycle Condition, or Because of Feed Contamination Upset– Fully recovers activity after feed contamination upset – including hydro-

processed coker gas oil

– High tolerance for contaminants in feed: S, N, PNA’s


MSDW: Proven Catalyst StabilityExxonMobil Selective Dewaxing

HDW Catalyst Aging With More Advanced Catalysts

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-10

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Days on Stream, [Day]

Del

ta T

emp

erat

ure

, °C

Cat: MSDW-2

Year 2003

100N,150N,500N, BS

Group II

Feed S < 150 wt ppm

Feed N < 3 wt ppm

LHSV: 0.6 - 1.2

Jurong

Cat: MSDW-2

Year 2000

150N, 500N

Group II

Feed S < 50 wt ppm

Feed N < 20 wt ppm

LHSV: 0.38 - 0.8

Cat: MSDW-2

Year 2004

150N, 500N

Group II+

Feed S < 10 wt ppm

Feed N < 2 wt ppm

LHSV: 0.5 - 1.7

Cat: MSDW-2

Year 2002

100N,150N

Group III

Feed S < 7 wt ppm

Feed N < 1 wt ppm

LHSV: 0.65 - 2.0

Cat: MSDW

Year 2006

70N,150N

Group III

Feed S < 30 wt ppm

Feed N < 1 wt ppm

LHSV: 1.6 - 2.7

Cat: MSDW

Year 2006

100N,150N

Group III

Feed S < 30 wt ppm

Feed N < 1 wt ppm

LHSV: 1.1 - 2.0

Cat: MSDW-2

Year 2000

100N, 150N, 600N

Group II

Feed S < 10 wt ppm

Feed N < 1 wt ppm

LHSV: 0.95 - 1.95

Jurong

Cat: MSDW

Year 2007

150N, 500N

Group II

Feed S < 50 wt ppm

Feed N < 20 wt ppm

LHSV: 1.2 - 1.4


MSDW Will Continue to Improve by . . .

• Continuous Development Work to Further Improve Flexibility and Operation. New generations in Development Today to…

– Expand already wide range of LHSV operation

– Enhance already high tolerance to feed contaminants of S and N

– Expand present exceptional operating stability and flexibility for very low pour point products (<-40°C)


Catalytic Lube Application of EMRE’s Technologies ... Since 2000

Operating or in Operating or in Design/ConstructionDesign/Construction

Lube Hydrocrackers 5

RHT or RHC 8

MSDW 23

MAXSAT 18


In Conclusion . . .

• Adding RHC to Existing Solvent-Based Lube Facilities Raises Lube Quality from a Wide Range of Crude Sources

• SEU/RHC/SDW will Produce Group II/II+ Lubes and is Capable for Group III Lubes (All Viscosity Grades)

• Adding RHC to Existing Solvent-Based Plant Retains (And May Increase) Wax Production; Improves Wax Appearance Quality

• MSDW for the Dewaxing Step May Further Increase Production, will Eliminate Wax Products

• Join Our Satisfied Clients and Let EMRE's Lube Experience Work For You!


THANK YOU !

Research and Engineering Commercial Technology to Convert Group I Facilities to Group II/III Lube Production PETROTECH: November 1-3, 2010.

Documents

facilities group

integrated group

rhc tm group

mid tier group

stability group iiiii

lube grades

paos slide

lower ccs higher vi