WORLDWIDE REFINERY PROCESSING REVIEW Monitoring Technology Development and Competition in a Single Source
Fourth Quarter 2010 Visbreaking
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TABLE OF CONTENTS 4Q2010 Review Visbreaking 26. Visbreaking...................................................................................................................................... 1 26.1 MARKET/TECHNOLOGY TRENDS & OPPORTUNITIES ............................................................................................. 1 26.1.1 Introduction .............................................................................................................................................. 1 26.1.2 Market Conditions and Outlook................................................................................................................ 1 26.1.2.1 Refined Products Supply and Demand ....................................................................................... 2 26.1.2.2 Impact of Legislation on Residual Fuel Oil Outlets ................................................................... 5 26.1.2.3 Bottoms Upgrading Capacity and Expansion: Focus on Visbreaking ........................................ 8 26.1.2.4 Construction Projects ................................................................................................................ 10 26.1.3 Latest Developments in Visbreaking Technology and Marketing........................................................... 10 26.1.3.1 Maximize Conversion via Vacuum Flash and Thermal Cracking ............................................ 11 26.1.3.2 Improvements in Residue Stream Stability............................................................................... 12 26.1.3.3 Optimization Programs, Monitoring Tools, and Maintenance Strategies ................................. 13 26.1.3.4 Integration Options are Available ............................................................................................. 14 26.1.3.5 Revamp Opportunities Provide Low-capital Means to Increase Conversion ........................... 14 26.1.3.6 Visbreakers for Heavy Oil Upgrading ...................................................................................... 15 26.1.4 Conclusion .............................................................................................................................................. 15 26.2 STATE-OF-THE-ART TECHNOLOGY ..................................................................................................................... 16 26.2.1 Introduction ............................................................................................................................................ 16 26.2.2 Commercial Processes ............................................................................................................................ 17 26.2.2.1 Axens ........................................................................................................................................ 18 26.2.2.1.1 Tervahl..................................................................................................................... 18 26.2.2.1.2 Advanced Process Control ...................................................................................... 20 26.2.2.2 Foster Wheeler/UOP................................................................................................................. 20 26.2.2.2.1 Coil-type Visbreaking ............................................................................................. 20 26.2.2.2.2 Visbreaker with Vacuum Flash ............................................................................... 23 26.2.2.2.3 Two-stage Visbreaker/Thermal Cracker.................................................................. 23 26.2.2.2.4 Wood's Technology ................................................................................................. 24 26.2.2.3 KBR (formerly Kellogg Brown & Root) .................................................................................. 25 26.2.2.4 Lummus Technology/Shell Global Solutions ........................................................................... 26 26.2.2.4.1 Shell Soaker Visbreaking ........................................................................................ 27 26.2.2.4.2 Shell Deep Thermal Conversion.............................................................................. 28 26.2.2.4.3 Shell Thermal Gasoil Process and Shell Deep Thermal Gasoil Process ................. 30 26.2.2.5 PDVSA-Intevep ........................................................................................................................ 32 26.2.2.6 Summary of Commercial Visbreaking Processes ..................................................................... 35 26.2.3 Optimization Programs ........................................................................................................................... 37 26.2.3.1 Axens ........................................................................................................................................ 37 26.2.3.2 Baker Hughes ........................................................................................................................... 38 26.2.3.3 Instituto Colombiano del Petróleo ............................................................................................ 39 26.2.3.4 KBC .......................................................................................................................................... 39 26.2.3.5 GE Water & Process Technology ............................................................................................. 40 26.2.3.6 Nalco Energy Services.............................................................................................................. 41 26.3 PLANT OPERATIONS AND PRACTICES .................................................................................................................. 43 26.3.1 Visbreaking Various Feeds ..................................................................................................................... 43 26.3.2 Soaker Visbreaking vs. Coil-type Visbreaking ........................................................................................ 44 26.3.3 Vacuum Flashing to Increase Distillate Yields ....................................................................................... 45 26.3.4 Controlling Fouling and Coking to Optimize Visbreaker Operation ..................................................... 45 26.3.4.1 Operational and Design Heuristics to Reduce Coking ............................................................. 46 26.3.4.2 Monitoring Coke Formation and Applying Chemical Additives.............................................. 47
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TABLE OF CONTENTS
26.4
26.5 26.6
26.7
26.3.4.3 Cleaning and Maintenance Strategies ....................................................................................... 48 26.3.4.4 Identifying Carburization of Visbreaker Furnace Tubes........................................................... 50 26.3.5 Identification, Monitoring, and Prevention of Naphthenic Acid Corrosion ............................................ 51 26.3.6 Effects of FCCU Severity and Other Factors on Visbreaker Fuel Oil Stability ...................................... 53 26.3.7 Revamping Distillation Units to Visbreakers .......................................................................................... 54 26.3.8 Energy Efficiency and Environmental Emissions .................................................................................... 55 26.3.9 Cogeneration Using Visbroken Residues ................................................................................................ 56 REFINING R&D ALERT! ....................................................................................................................................... 58 26.4.1 Introduction ............................................................................................................................................. 58 26.4.2 Process .................................................................................................................................................... 59 26.4.2.1 Patents ....................................................................................................................................... 59 26.4.3 Integration ............................................................................................................................................... 60 26.4.3.1 Patents ....................................................................................................................................... 60 26.4.4 Additives and Optimization Programs .................................................................................................... 62 26.4.4.1 Patents ....................................................................................................................................... 62 26.4.4.2 Research .................................................................................................................................... 63 26.4.5 Heavy Oil Upgrading .............................................................................................................................. 63 26.4.5.1 Research .................................................................................................................................... 63 26.4.6 Other........................................................................................................................................................ 64 26.4.6.1 Patents ....................................................................................................................................... 64 WORLDWIDE INSTALLED CAPACITY .................................................................................................................... 65 CONSTRUCTION ................................................................................................................................................... 69 26.6.1 Recent Construction Activity ................................................................................................................... 69 26.6.2 Completed Construction Projects............................................................................................................ 70 REFERENCES ........................................................................................................................................................ 72
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