Worldwide Refinery Processing Review - 3Q2012 by Hydrocarbon Publishing Company

WORLDWIDE REFINERY PROCESSING REVIEW Monitoring Technology Development and Competition in a Single Source

Third Quarter 2012 Hydrocracking and Lube Oil Production Plus

Latest Refining Technology Developments & Licensing

HYDROCARBON PUBLISHING COMPANY Translating Knowledge into Profitability

P.O. Box 661 Southeastern, PA 19399 (U.S.A.)

Phone: (610) 408-0117/ Fax: (610) 408-0118

Review@Hydrocarbonpublishing.com

TABLE OF CONTENTS 3Q 2012 Review Hydrocracking and Lube Oil Production 1. Introduction.....................................................................................................................................1 2. Hydrocracking ................................................................................................................................5 2.1

2.2

MARKET/TECHNOLOGY TRENDS & OPPORTUNITIES ............................................................................................. 5 2.1.1 Introduction .............................................................................................................................................. 5 2.1.2 Market Conditions and Outlook................................................................................................................ 6 2.1.2.1 Refined Products Legislation...................................................................................................... 6 2.1.2.1.1 Gasoline and Diesel................................................................................................... 6 2.1.2.1.2 Bunker Fuels.............................................................................................................. 8 2.1.2.2 Refined Products Demand .......................................................................................................... 9 2.1.2.3 Increasing Middle Distillate Production ................................................................................... 13 2.1.2.3.1 Diesel Supply and Demand ..................................................................................... 13 2.1.2.3.2 Renewable and Bio-based Diesel and Jet Fuel ........................................................ 17 2.1.2.3.2.1 Renewable Diesel and Bio-based Diesel .......................................... 17 2.1.2.3.2.2 Renewable Jet Fuel and Bio-based Jet Fuel...................................... 19 2.1.2.4 Shifting Crude Slate.................................................................................................................. 21 2.1.2.4.1 Opportunity Crudes ................................................................................................. 21 2.1.2.4.2 Shale Oil .................................................................................................................. 24 2.1.2.5 Hydrogen Demand.................................................................................................................... 26 2.1.2.6 Capacity Expansion .................................................................................................................. 26 2.1.2.7 Construction Projects and Unit Revamps ................................................................................. 28 2.1.2.8 Hydrocracking Catalyst Market................................................................................................ 28 2.1.3 Technology Competition, Direction, and Future Prospects ................................................................... 31 2.1.3.1 Market Layout and Strategic Alliances .................................................................................... 31 2.1.3.2 Conventional and Mild Hydrocracking .................................................................................... 35 2.1.3.2.1 Catalyst Developments ............................................................................................ 36 2.1.3.2.2 Process and Hardware Developments ..................................................................... 38 2.1.3.3 Resid Hydrocracking ................................................................................................................ 39 2.1.3.4 Alternative Feed Hydrocracking............................................................................................... 41 2.1.3.5 Revamp and Integration Options .............................................................................................. 43 2.1.4 Conclusion .............................................................................................................................................. 45 STATE-OF-THE-ART TECHNOLOGY ..................................................................................................................... 47 2.2.1 Introduction ............................................................................................................................................ 47 2.2.2 Commercial Process Technology............................................................................................................ 48 2.2.2.1 Axens........................................................................................................................................ 49 2.2.2.1.1 Mild Hydrocracking ................................................................................................ 49 2.2.2.1.1.1 Mild-HCK......................................................................................... 49 2.2.2.1.1.2 HyC-10/HyC-10+ ............................................................................. 50 2.2.2.1.2 H-OilDC .................................................................................................................... 53 2.2.2.1.3 HyTail...................................................................................................................... 55 2.2.2.1.4 Medium-pressure Hydrocracking ............................................................................ 56 2.2.2.1.5 Conventional (High-pressure) Hydrocracking ........................................................ 56 2.2.2.1.6 Reactor Internals...................................................................................................... 60 2.2.2.2 Chevron Lummus Global ......................................................................................................... 60 2.2.2.2.1 ISOCRACKING...................................................................................................... 60 2.2.2.2.1.1 Single-stage Once Through and Single-stage Recycle ..................... 61 2.2.2.2.1.2 Two-stage Recycle............................................................................ 63 2.2.2.2.1.3 Optimized Partial Conversion........................................................... 67

3Q 2012 i Hydrocarbon Publishing Co./Copyright Protected

TABLE OF CONTENTS 2.2.2.2.1.4 Selective Staging............................................................................... 69 2.2.2.2.1.5 Split-feed Injection............................................................................ 72 2.2.2.2.1.6 Single-stage Reaction Sequencing .................................................... 73 2.2.2.2.2 ISOFLEX ................................................................................................................. 73 2.2.2.2.3 Reactor Internals ...................................................................................................... 75 2.2.2.3 DuPont Clean Technologies...................................................................................................... 76 2.2.2.4 ExxonMobil .............................................................................................................................. 79 2.2.2.4.1 Single-stage MPHC ................................................................................................. 80 2.2.2.4.2 MPHC-PTU ............................................................................................................. 84 2.2.2.4.3 MPHC-LCO............................................................................................................. 85 2.2.2.4.4 Two-stage MPHC .................................................................................................... 87 2.2.2.4.5 Spider-Vortex Reactor Internals .............................................................................. 89 2.2.2.5 Haldor Topsøe........................................................................................................................... 90 2.2.2.5.1 Mild Hydrocracking................................................................................................. 90 2.2.2.5.1.1 Staged Partial Conversion Hydrocracking ........................................ 92 2.2.2.5.1.2 Back-End Shift (BES) Process.......................................................... 94 2.2.2.5.2 Conventional (High-pressure) Hydrocracking......................................................... 94 2.2.2.5.3 Reactor Internals ...................................................................................................... 94 2.2.2.6 Shell Global Solutions .............................................................................................................. 96 2.2.2.6.1 Mild Hydrocracking................................................................................................. 97 2.2.2.6.2 Conventional Hydrocracking ................................................................................... 99 2.2.2.6.3 Reactor Internals .................................................................................................... 101 2.2.2.7 Sinopec.................................................................................................................................... 104 2.2.2.7.1 Flexible Hydrotreating/Mild Hydrocracking ......................................................... 104 2.2.2.7.2 Medium-pressure Hydro-Upgrading...................................................................... 105 2.2.2.7.3 Moderate-pressure Hydrocracking......................................................................... 108 2.2.2.7.4 High-pressure Hydrocracking................................................................................ 108 2.2.2.7.4.1 Single-stage Hydrocracking ............................................................ 109 2.2.2.7.4.2 Single-stage in Series Hydrocracking ............................................. 109 2.2.2.7.4.3 Single-stage, Double-catalyst Hydrocracking................................. 111 2.2.2.7.4.4 Two-stage Hydrocracking............................................................... 111 2.2.2.7.4.5 Flexible Hydrocracking................................................................... 112 2.2.2.8 UOP......................................................................................................................................... 113 2.2.2.8.1 MHC Unicracking.................................................................................................. 113 2.2.2.8.2 Unicracking............................................................................................................ 115 2.2.2.8.2.1 Single-stage Once Through or with Recycle................................... 115 2.2.2.8.2.2 Two-stage........................................................................................ 117 2.2.2.8.3 Partial-conversion Unicracking ............................................................................. 121 2.2.2.8.4 Dieselmax .............................................................................................................. 126 2.2.2.8.5 HyCycle Unicracking............................................................................................. 127 2.2.2.8.6 Advanced Partial Conversion Unicracking............................................................ 129 2.2.2.8.7 HPNA Removal Systems ....................................................................................... 130 2.2.2.8.8 Reactor Internals .................................................................................................... 131 2.2.2.9 Velocys ................................................................................................................................... 132 2.2.2.10 Summary of Hydrocracking Process Technologies ................................................................ 133 2.2.3 Commercial Catalysts ........................................................................................................................... 137 2.2.3.1 Albemarle................................................................................................................................ 138 2.2.3.2 Axens ...................................................................................................................................... 139 2.2.3.3 Chevron Lummus Global........................................................................................................ 140 2.2.3.4 Criterion Catalysts & Technologies ........................................................................................ 145 2.2.3.5 Haldor Topsøe......................................................................................................................... 149 2.2.3.6 JGC Catalysts & Chemicals .................................................................................................... 150 2.2.3.7 Sinopec.................................................................................................................................... 150

3Q 2012 ii Hydrocarbon Publishing Co./Copyright Protected

TABLE OF CONTENTS

2.3

2.2.3.8 UOP ........................................................................................................................................ 151 2.2.3.9 Summary of Commercially Available Hydrocracking Catalysts............................................ 155 2.2.4 Auxiliary Catalyst Technology.............................................................................................................. 157 2.2.4.1 Axens...................................................................................................................................... 158 2.2.4.2 Crystaphase Products.............................................................................................................. 158 2.2.4.3 Eurecat .................................................................................................................................... 158 2.2.4.4 TRICAT.................................................................................................................................. 159 2.2.5 Control and Optimization Systems........................................................................................................ 159 2.2.6 Resid Hydrocracking ............................................................................................................................ 163 2.2.7 Renewable Hydrocracking.................................................................................................................... 169 PLANT OPERATIONS AND PRACTICES ................................................................................................................ 173 2.3.1 General Hydrocracking Operations ..................................................................................................... 173 2.3.1.1 Feed Considerations, Operational Variables, Process Configurations, and Hardware........... 174 2.3.1.1.1 Feedstock Characterization.................................................................................... 174 2.3.1.1.2 Upgrading LCO and/or HCO in Hydrocrackers.................................................... 175 2.3.1.1.3 Undercutting LVGO to Increase Hydrocracker Utilization................................... 176 2.3.1.1.4 Optimizing Operational Variables......................................................................... 177 2.3.1.1.4.1 Recycle Rate in Two-stage Units.................................................... 177 2.3.1.1.4.2 Setting Operational Pressure........................................................... 177 2.3.1.1.5 Reactor Configuration ........................................................................................... 179 2.3.1.1.6 Optimized Hydrocracker Reactor Internals ........................................................... 179 2.3.1.1.7 Changing Unit Configuration to Boost Yields and Process Alternative Feeds ..... 180 2.3.1.1.8 Large Single Process Train vs. Smaller Parallel Trains in Hydrocrackers ............ 181 2.3.1.1.9 Reactor Fabrication and Metallurgy ...................................................................... 182 2.3.1.1.10 Comparison of Quench Systems............................................................................ 183 2.3.1.1.11 Hydrocracker Stripper Revamp: From Packing to Trays ...................................... 184 2.3.1.1.12 Hydrocracker Pump Selection ............................................................................... 184 2.3.1.2 Fouling, Particulate Deposition, and Corrosion...................................................................... 185 2.3.1.2.1 Causes of Hydroprocesser Fouling and Possible Treatments................................ 185 2.3.1.2.2 Ammonium Chloride Fouling in Effluent Exchangers.......................................... 186 2.3.1.2.3 Elimination of Polynuclear Aromatics (PNA) Buildup......................................... 187 2.3.1.2.4 Iron Sulfide Buildup in VGO Hydrocrackers........................................................ 188 2.3.1.2.5 Feed Filter Operation............................................................................................. 190 2.3.1.2.6 Mitigating High Temperature Hydrogen Attack ................................................... 191 2.3.1.2.7 Fouling in Furnace Tubes...................................................................................... 191 2.3.1.2.8 Corrosion in Overhead System.............................................................................. 192 2.3.1.2.9 Corrosion in Auxiliary Equipment ........................................................................ 193 2.3.1.3 Operational Problems ............................................................................................................. 193 2.3.1.3.1 Increased Yield Using Multivariable Predictive Control (MPC) .......................... 193 2.3.1.3.2 Improving Hydrocracker Temperature Control..................................................... 196 2.3.1.3.3 Detecting Radial Temperature Spread and Preventing Reactor Runaway ............ 199 2.3.1.3.4 Hydrocracker Furnace Operations......................................................................... 201 2.3.1.3.5 Causes of Overcracking......................................................................................... 201 2.3.1.3.6 Preventing Off-color Naphtha Product.................................................................. 202 2.3.1.3.7 Reducing the Level of Sulfur in Naphtha at EOR Conditions............................... 203 2.3.1.3.8 Limiting Ammonia Concentration in the Cold High-pressure Separator Overhead203 2.3.1.3.9 Inline Hydrocracker Cleaning System................................................................... 204 2.3.1.3.10 Improving Recycle Gas Compressor Operation .................................................... 204 2.3.1.4 Catalyst Management ............................................................................................................. 205 2.3.1.4.1 Selection Process for Hydrocracking Catalysts..................................................... 205 2.3.1.4.2 Measuring Hydrocracking Catalyst Activity ......................................................... 206 2.3.1.4.3 Catalysts for Processing Various Feeds................................................................. 207

3Q 2012 iii Hydrocarbon Publishing Co./Copyright Protected

TABLE OF CONTENTS

2.4

2.3.1.4.4 Replacing a Noble Metal Catalyst with a Base Metal Catalyst.............................. 207 2.3.1.4.5 Catalyst Structure: Homogeneous vs. Stacked....................................................... 208 2.3.1.4.6 Ex-Situ Sulfiding (Presulfiding) of Hydrocracking Catalysts ............................... 208 2.3.1.4.7 Ammoniation Passivation during Startup .............................................................. 210 2.3.1.4.8 Disproportionate Catalyst Deactivation in the First Bed of a Hydrocracker ......... 211 2.3.1.4.9 Asphaltene Contribution to Catalyst Deactivation................................................. 212 2.3.1.4.10 Impact of HPNAs on Catalyst Activity and Stability ............................................ 212 2.3.1.4.11 Regenerated Hydrocracking Catalyst Use ............................................................. 213 2.3.1.4.12 Recovering Spent Hydroprocessing Catalysts ....................................................... 215 2.3.1.5 Reducing Hydrocracker Energy Use....................................................................................... 215 2.3.1.5.1 Modeling................................................................................................................ 216 2.3.1.5.2 Cleaning ................................................................................................................. 216 2.3.1.5.3 Heat Integration ..................................................................................................... 216 2.3.1.5.4 Power Recovery ..................................................................................................... 217 2.3.1.5.5 Process Heaters ...................................................................................................... 217 2.3.1.5.6 Impact of Catalysts................................................................................................. 217 2.3.1.6 Hydrocracker Safety ............................................................................................................... 218 2.3.1.6.1 Hydrocracker Safety Incidents............................................................................... 218 2.3.1.6.2 Emergency Depressurization: Triggering Criteria, Rates, and Modes................... 219 2.3.1.6.3 Operational Status of Emergency Depressurizing Valves and Interlocks.............. 221 2.3.1.6.4 Safely Performing Inter-reactor Sampling in Hydrocrackers ................................ 221 2.3.2 Mild Hydrocracking (MHC).................................................................................................................. 222 2.3.2.1 Mild Hydrocracking: Feedstock, Conversion, and Product Quality ....................................... 222 2.3.2.2 Converting a Cat Feed Hydrotreater to a Mild Hydrocracker................................................. 223 2.3.2.3 Options for Improving the Cycle Length of Mild Hydrocrackers........................................... 224 2.3.3 Distillate Hydrocracking ....................................................................................................................... 225 2.3.3.1 Shifting from Maximum Naphtha to Maximum Middle Distillate Yields .............................. 225 2.3.3.2 Maximizing Diesel Production in VGO Hydrocrackers ......................................................... 227 2.3.3.3 Benefits of Moderate Pressure Hydrocracking (MPHC) in Clean Diesel Production ............ 229 2.3.3.4 Adjusting CAT to Maximize Diesel Production ..................................................................... 230 2.3.3.5 Reactor Revamp to Improve ULSD Production ..................................................................... 231 2.3.3.6 Loading Hydrocracking Catalyst in the Last Bed of a ULSD Unit......................................... 233 2.3.3.7 Process Revamp for Added H2S Removal to Meet ULSD Standards..................................... 233 2.3.3.8 Hydrocracking Catalysts for Cold Flow Property Improvements........................................... 234 2.3.4 Integrated Processing Schemes............................................................................................................. 234 2.3.4.1 Delayed Coker with Hydrocracker.......................................................................................... 234 2.3.4.2 Solvent Deasphalting with Hydrocracker ............................................................................... 235 2.3.4.3 Mild Hydrocracker with FCC ................................................................................................. 237 REFINING R&D ALERT!..................................................................................................................................... 238 2.4.1 Introduction........................................................................................................................................... 238 2.4.2 General Hydrocracking......................................................................................................................... 243 2.4.2.1 Process .................................................................................................................................... 243 2.4.2.1.1 Patents.................................................................................................................... 243 2.4.2.1.2 Research................................................................................................................. 244 2.4.2.2 Catalyst.................................................................................................................................... 245 2.4.2.2.1 Patents.................................................................................................................... 245 2.4.2.2.2 Research................................................................................................................. 250 2.4.2.3 Hardware................................................................................................................................. 252 2.4.2.4 Integrated Operations (Conventional Feeds) .......................................................................... 253 2.4.3 Product Selective Hydrocracking.......................................................................................................... 254 2.4.3.1 Middle Distillates .................................................................................................................... 254 2.4.3.1.1 Patents.................................................................................................................... 254

3Q 2012 iv Hydrocarbon Publishing Co./Copyright Protected

TABLE OF CONTENTS

2.5 2.6

2.7

2.4.3.1.2 Research ................................................................................................................ 257 2.4.3.2 Naphtha................................................................................................................................... 258 2.4.3.2.1 Patents ................................................................................................................... 258 2.4.3.2.2 Research ................................................................................................................ 259 2.4.4 Resid Hydrocracking ............................................................................................................................ 260 2.4.4.1 Process .................................................................................................................................... 260 2.4.4.1.1 Patents ................................................................................................................... 260 2.4.4.1.2 Research ................................................................................................................ 265 2.4.4.2 Catalyst ................................................................................................................................... 266 2.4.4.2.1 Patents ................................................................................................................... 266 2.4.4.2.2 Research ................................................................................................................ 268 2.4.5 Hydrocracking Alternative Feedstocks ................................................................................................. 270 2.4.5.1 Fischer-Tropsch Liquids......................................................................................................... 270 2.4.5.1.1 Process................................................................................................................... 270 2.4.5.1.2 Catalyst .................................................................................................................. 271 2.4.5.1.2.1 Patents............................................................................................. 271 2.4.5.1.2.2 Research.......................................................................................... 272 2.4.5.2 Renewable Feedstocks............................................................................................................ 274 2.4.5.2.1 Patents ................................................................................................................... 274 2.4.5.2.2 Research ................................................................................................................ 276 WORLDWIDE INSTALLED CAPACITY.................................................................................................................. 277 CONSTRUCTION ................................................................................................................................................. 280 2.6.1 Recent Construction Activity................................................................................................................. 280 2.6.2 Completed Construction Projects ......................................................................................................... 285 REFERENCES ..................................................................................................................................................... 298

3. Lube Oil Prodution .....................................................................................................................321 3.1

3.2

MARKET/TECHNOLOGY TRENDS & OPPORTUNITIES ......................................................................................... 321 3.1.1 Introduction .......................................................................................................................................... 321 3.1.2 Market Conditions and Outlook............................................................................................................ 322 3.1.2.1 Supply and Demand................................................................................................................ 323 3.1.2.1.1 World..................................................................................................................... 323 3.1.2.1.2 The Americas......................................................................................................... 325 3.1.2.1.2.1 North America ................................................................................ 325 3.1.2.1.2.2 South America and Mexico ............................................................ 327 3.1.2.1.3 Europe, Middle East, and Africa ........................................................................... 327 3.1.2.1.3.1 Europe............................................................................................. 327 3.1.2.1.3.2 Middle East..................................................................................... 328 3.1.2.1.3.3 Africa .............................................................................................. 329 3.1.2.1.4 Asia-Pacific ........................................................................................................... 329 3.1.2.2 Market Competition................................................................................................................ 330 3.1.3 Technology Competition, Direction, and Future Prospects ................................................................. 332 3.1.3.1 Hydroprocessing-based Technology ...................................................................................... 334 3.1.3.2 Hybrid Processes .................................................................................................................... 335 3.1.3.3 Alternative Feeds .................................................................................................................... 336 3.1.4 Conclusion ............................................................................................................................................ 337 STATE-OF-THE-ART TECHNOLOGY ................................................................................................................... 338 3.2.1 Introduction .......................................................................................................................................... 338 3.2.2 Commercial Processes.......................................................................................................................... 342 3.2.2.1 Axens...................................................................................................................................... 342 3.2.2.1.1 Solvent Refining.................................................................................................... 343

3Q 2012 v Hydrocarbon Publishing Co./Copyright Protected

TABLE OF CONTENTS

3.2.2.2

3.2.2.3

3.2.2.4

3.2.2.5

3.2.2.6

3.2.2.1.2 Hydroprocessing .................................................................................................... 343 3.2.2.1.2.1 Hydrorefining.................................................................................. 343 3.2.2.1.2.2 High Conversion Hydrocracking .................................................... 344 3.2.2.1.2.3 Lube Oil Hydrofinishing................................................................. 345 3.2.2.1.2.4 White Oils Hydrotreatment ............................................................. 346 3.2.2.1.2.5 Wax Hydrotreatment (Wax HDT) .................................................. 346 Bechtel .................................................................................................................................... 346 3.2.2.2.1 Solvent Refining .................................................................................................... 346 3.2.2.2.1.1 MP Refining.................................................................................... 347 3.2.2.2.1.2 Furfural Refining............................................................................. 348 3.2.2.2.1.3 Solvent Dewaxing ........................................................................... 349 3.2.2.2.1.4 Wax Fractionation........................................................................... 350 3.2.2.2.2 Hydroprocessing .................................................................................................... 350 3.2.2.2.2.1 Hy-Raff ........................................................................................... 351 3.2.2.2.2.2 Hy-Finishing ................................................................................... 352 3.2.2.2.2.3 Hy-Starting...................................................................................... 353 3.2.2.2.2.4 Wax Hy-Finishing........................................................................... 353 3.2.2.2.2.5 White Oil Hy-Finishing .................................................................. 354 Chevron Lummus Global........................................................................................................ 354 3.2.2.3.1 Hydroprocessing .................................................................................................... 354 3.2.2.3.1.1 ISOCRACKING ............................................................................. 355 3.2.2.3.1.2 ISODEWAXING ............................................................................ 356 3.2.2.3.1.3 ISOFINISHING .............................................................................. 359 3.2.2.3.1.4 Integration Opportunities ................................................................ 360 ExxonMobil ............................................................................................................................ 362 3.2.2.4.1 Solvent Refining .................................................................................................... 363 3.2.2.4.1.1 EXOL N Extraction ........................................................................ 363 3.2.2.4.1.2 DILCHILL ...................................................................................... 364 3.2.2.4.1.3 Propane Dewaxing .......................................................................... 366 3.2.2.4.2 Hydroprocessing .................................................................................................... 367 3.2.2.4.2.1 Lube HYDROFINING.................................................................... 367 3.2.2.4.2.2 LHDC.............................................................................................. 368 3.2.2.4.2.3 Raffinate Hydroconversion ............................................................. 369 3.2.2.4.2.4 MSDW ............................................................................................ 370 3.2.2.4.2.5 MLDW ............................................................................................ 373 3.2.2.4.2.6 MWI................................................................................................ 373 3.2.2.4.2.7 Wax HYDROFINING .................................................................... 374 3.2.2.4.2.8 MAXSAT........................................................................................ 375 3.2.2.4.3 Membrane Separation ............................................................................................ 375 3.2.2.4.4 Integration Opportunities ....................................................................................... 375 Process Dynamics ................................................................................................................... 377 3.2.2.5.1 Integrated Extraction/Dewaxing ............................................................................ 377 3.2.2.5.2 IsoTherming........................................................................................................... 378 Shell Global Solutions ............................................................................................................ 379 3.2.2.6.1 Solvent Refining .................................................................................................... 379 3.2.2.6.2 Hydroprocessing .................................................................................................... 379 3.2.2.6.2.1 Pretreating/Hydrofinishing.............................................................. 379 3.2.2.6.2.2 Hydrocracking................................................................................. 380 3.2.2.6.2.3 Catalytic Dewaxing and Wax Isomerization................................... 380 3.2.2.6.2.4 Food Grade Oils and Wax............................................................... 381 3.2.2.6.3 Hybrid Process ....................................................................................................... 381

3Q 2012 vi Hydrocarbon Publishing Co./Copyright Protected

TABLE OF CONTENTS

3.3

3.4

3.2.2.7 Suncor Energy ........................................................................................................................ 382 3.2.2.7.1 HT Severe Hydrocracking..................................................................................... 382 3.2.2.7.2 HydroIsomerization ............................................................................................... 383 3.2.2.8 Uhde ....................................................................................................................................... 383 3.2.2.8.1 Solvent Refining.................................................................................................... 384 3.2.2.8.1.1 Solvent Dewaxing and Wax Deoiling ............................................ 384 3.2.2.8.1.2 Slack Wax Deoiling........................................................................ 384 3.2.2.8.1.3 Liquid-liquid Extraction ................................................................. 385 3.2.2.8.2 Hydroprocessing.................................................................................................... 386 3.2.2.8.2.1 Hydrofinishing................................................................................ 386 3.2.2.8.2.2 White Oil and Wax Hydrotreating.................................................. 386 3.2.2.9 Washington Group International/SK Innovation.................................................................... 387 3.2.3 Summary of Commercial Lube Oil Manufacturing Processes.............................................................. 389 3.2.4 Summary of Commercial Lube Oil Manufacturing Catalysts............................................................... 394 PLANT OPERATIONS AND PRACTICES ................................................................................................................ 395 3.3.1 Process.................................................................................................................................................. 395 3.3.1.1 Selecting a Lube Production Process...................................................................................... 395 3.3.1.2 Break-even Cost Comparison ................................................................................................. 395 3.3.1.3 Improvements in Plant Efficiency, Performance, and Profitability ........................................ 395 3.3.1.3.1 Revamps to Existing Equipment ........................................................................... 396 3.3.1.3.1.1 Vacuum Distillation Unit................................................................ 396 3.3.1.3.1.2 Solvent Extraction Unit .................................................................. 397 3.3.1.3.1.3 Solvent Dewaxing Unit .................................................................. 398 3.3.1.3.2 Optimization of Operating Conditions .................................................................. 399 3.3.1.3.2.1 Vacuum Distillation Unit................................................................ 399 3.3.1.3.2.2 Solvent Extraction Unit .................................................................. 400 3.3.1.3.2.3 Solvent Dewaxing Unit .................................................................. 401 3.3.1.3.2.4 Lube and Wax Hydrofinishing Unit ............................................... 402 3.3.1.3.3 Retrofitting ............................................................................................................ 402 3.3.1.3.3.1 Solvent Extraction Unit .................................................................. 403 3.3.1.3.3.2 Solvent Dewaxing Unit .................................................................. 403 3.3.1.3.3.3 Hydrofinishing Unit........................................................................ 404 3.3.2 Alternative Base Oil Sources ................................................................................................................ 404 3.3.2.1 Recycled Used Lubricants ...................................................................................................... 404 3.3.2.2 Biolubricants and GTL Lubricants ......................................................................................... 405 3.3.2.3 Other Chemicals ..................................................................................................................... 405 3.3.3 Wax Production .................................................................................................................................... 406 3.3.3.1 Waxes from Fischer-Tropsch ................................................................................................. 407 3.3.3.2 Hybrid Installations ................................................................................................................ 407 REFINING R&D ALERT! .................................................................................................................................... 408 3.4.1 Introduction .......................................................................................................................................... 408 3.4.2 Solvent-based Lube Production ............................................................................................................ 412 3.4.2.1 Fractionation........................................................................................................................... 412 3.4.2.2 Solvent Extraction .................................................................................................................. 413 3.4.2.2.1 Patents ................................................................................................................... 413 3.4.2.2.2 Research ................................................................................................................ 414 3.4.2.3 Solvent Dewaxing................................................................................................................... 415 3.4.2.3.1 Patents ................................................................................................................... 415 3.4.2.3.2 Research ................................................................................................................ 419 3.4.2.4 Heavy Oil Feed....................................................................................................................... 419 3.4.2.5 Product Quality....................................................................................................................... 421 3.4.2.6 Miscellaneous ......................................................................................................................... 422

3Q 2012 vii Hydrocarbon Publishing Co./Copyright Protected

TABLE OF CONTENTS

3.5 3.6

3.7

3.4.3 Hydroprocessing-based Lube Production............................................................................................. 423 3.4.3.1 Process .................................................................................................................................... 423 3.4.3.1.1 Heavy Oil Feed ...................................................................................................... 423 3.4.3.1.1.1 Patents ............................................................................................. 423 3.4.3.1.1.2 Research .......................................................................................... 426 3.4.3.1.2 Product Quality ...................................................................................................... 427 3.4.3.1.2.1 Patents ............................................................................................. 427 3.4.3.1.2.2 Research .......................................................................................... 430 3.4.3.1.3 Miscellaneous ........................................................................................................ 431 3.4.3.1.3.1 Patents ............................................................................................. 431 3.4.3.1.3.2 Research .......................................................................................... 432 3.4.3.2 Catalysts .................................................................................................................................. 432 3.4.3.2.1 Preparation ............................................................................................................. 432 3.4.3.2.2 Formulation............................................................................................................ 435 3.4.3.2.2.1 Zeolite ............................................................................................. 435 3.4.3.2.2.1.1 Patents ...................................................................... 435 3.4.3.2.2.1.2 Research ................................................................... 442 3.4.3.2.2.2 Active Metals .................................................................................. 443 3.4.3.2.2.2.1 Patents ...................................................................... 443 3.4.3.2.2.2.2 Research ................................................................... 446 3.4.3.2.2.3 Ionic Liquid..................................................................................... 447 3.4.4 Hybrid Lube Production Processes....................................................................................................... 449 3.4.4.1 Patents ..................................................................................................................................... 449 3.4.4.2 Research .................................................................................................................................. 452 3.4.5 Alternative Feeds................................................................................................................................... 453 3.4.5.1 F-T Wax .................................................................................................................................. 453 3.4.5.1.1 Process ................................................................................................................... 453 3.4.5.1.1.1 Patents ............................................................................................. 453 3.4.5.1.1.2 Research .......................................................................................... 457 3.4.5.1.2 Catalyst .................................................................................................................. 458 3.4.5.2 Bio and Unconventional Feeds ............................................................................................... 460 3.4.5.2.1 Patents.................................................................................................................... 460 3.4.5.2.2 Research................................................................................................................. 463 WORLDWIDE INSTALLED CAPACITY .................................................................................................................. 466 CONSTRUCTION ................................................................................................................................................. 469 3.6.1 Recent Construction Activity ................................................................................................................. 469 3.6.2 Completed Construction Projects.......................................................................................................... 473 REFERENCES ...................................................................................................................................................... 479

4. Latest Refining Technology Developments & Licensing ........................................................ 495 4.1 4.2 4.3 4.4 4.5 4.6 4.7 4.8 4.9 4.10 4.11 4.12

FLUID CATALYTIC CRACKING ........................................................................................................................... 495 COKING ............................................................................................................................................................. 495 HYDROGEN PRODUCTION AND PURIFICATION ................................................................................................... 496 SULFUR PLANT .................................................................................................................................................. 496 AROMATICS PRODUCTION ................................................................................................................................. 496 LIGHT OLEFINS PRODUCTION ............................................................................................................................ 497 GAS CONCENTRATION PLANT/VAPOR RECOVERY ............................................................................................. 499 PROCESS CONTROLS, SOFTWARE, AND SIMULATION ......................................................................................... 500 GAS-TO-LIQUID AND COAL-TO-LIQUID .............................................................................................................. 500 BIOFUELS PRODUCTION ..................................................................................................................................... 503 ENERGY MANAGEMENT..................................................................................................................................... 503 REFERENCES ...................................................................................................................................................... 503

3Q 2012 viii Hydrocarbon Publishing Co./Copyright Protected

TABLE OF CONTENTS

This pages is intentionally left blank