Worldwide Refinery Processing Review by Hydrocarbon Publishing Company

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

Fourth Quarter 2013 Visbreaking and Thermal Cracking 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 4Q2013 Review Visbreaking & Thermal Cracking 26. Visbreaking & Thermal Cracking ................................................................................................ 1 26.1 MARKET/TECHNOLOGY TRENDS & OPPORTUNITIES ............................................................................................. 1 26.1.1 Introduction .............................................................................................................................................. 1 26.1.2 Coker vs. Visbreaker ................................................................................................................................. 1 26.1.3 Market Conditions and Outlook................................................................................................................ 2 26.1.3.1 Declining Residual Oil Demand ................................................................................................. 3 26.1.3.2 Impact of Legislation on Residual Fuel Oil Outlets ................................................................... 4 26.1.3.3 Bottom of the Barrel Upgrading Capacity and Distribution ....................................................... 8 26.1.3.4 Construction Projects ................................................................................................................ 11 26.1.4 Latest Developments in Visbreaking Technology and Marketing........................................................... 11 26.1.4.1 Hardware Improvements .......................................................................................................... 12 26.1.4.2 Additive and Fouling Management .......................................................................................... 12 26.1.4.3 Optimization/Monitoring .......................................................................................................... 13 26.1.4.4 R&D Focus-Integration and Specialty Products ....................................................................... 14 26.1.5 Conclusion .............................................................................................................................................. 16 26.2 STATE-OF-THE-ART TECHNOLOGY ..................................................................................................................... 16 26.2.1 Introduction ............................................................................................................................................ 16 26.2.2 Commercial Processes ............................................................................................................................ 19 26.2.2.1 Axens ........................................................................................................................................ 19 26.2.2.2 Eadie Oil ................................................................................................................................... 22 26.2.2.3 Foster Wheeler/UOP................................................................................................................. 22 26.2.2.3.1 Coil-type Visbreaking ............................................................................................. 23 26.2.2.3.2 Visbreaker with Vacuum Flash ............................................................................... 25 26.2.2.3.3 Two-stage Visbreaker/Thermal Cracker.................................................................. 26 26.2.2.3.4 Wood's Technology ................................................................................................. 26 26.2.2.4 KBR .......................................................................................................................................... 27 26.2.2.5 Lummus Technology/Shell Global Solutions ........................................................................... 28 26.2.2.5.1 Shell Soaker Visbreaking ........................................................................................ 29 26.2.2.5.2 Shell Deep Thermal Conversion.............................................................................. 31 26.2.2.5.3 Shell Thermal Gasoil Process and Shell Deep Thermal Gasoil Process ................. 33 26.2.2.6 PDVSA-Intevep ........................................................................................................................ 35 26.2.2.7 PetroBeam ................................................................................................................................ 39 26.2.2.8 Summary of Commercial Visbreaking Processes ..................................................................... 40 26.2.3 Additives and Fouling Control................................................................................................................ 42 26.2.3.1 Baker Hughes ........................................................................................................................... 42 26.2.3.2 Instituto Colombiano del Petróleo ............................................................................................ 44 26.2.3.3 GE Water & Process Technology ............................................................................................. 44 26.2.3.4 Nalco Energy Services.............................................................................................................. 46 26.2.4 Optimization Programs ........................................................................................................................... 48 26.2.4.1 Axens ........................................................................................................................................ 48 26.2.4.2 Invensys .................................................................................................................................... 49 26.2.4.3 KBC .......................................................................................................................................... 49 26.2.5 Hardware ................................................................................................................................................ 49 26.2.5.1 Alfa Laval ................................................................................................................................. 49 26.2.5.2 Metso ........................................................................................................................................ 50 26.2.5.3 MOGAS .................................................................................................................................... 51

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TABLE OF CONTENTS 26.3 PLANT OPERATIONS AND PRACTICES................................................................................................................... 52 26.3.1 Visbreaking Various Feeds ..................................................................................................................... 52 26.3.2 Soaker Visbreaking vs. Coil-type Visbreaking ........................................................................................ 52 26.3.3 Vacuum Flashing to Increase Distillate Yields ....................................................................................... 53 26.3.4 Simulation of Visbreaker: Case Study ..................................................................................................... 54 26.3.5 Controlling Fouling and Coking to Optimize Visbreaker Operation ...................................................... 54 26.3.5.1 Operational and Design Heuristics to Reduce Coking .............................................................. 55 26.3.5.2 Monitoring Coke Formation and Applying Chemical Additives .............................................. 56 26.3.5.3 Cleaning and Maintenance Strategies ....................................................................................... 57 26.3.5.4 Various Visbreaker Cleaning Methods ..................................................................................... 59 26.3.5.5 Alternative Pigging Method ...................................................................................................... 60 26.3.5.6 Identifying Carburization of Visbreaker Furnace Tubes........................................................... 60 26.3.5.7 VisTec Repsol Tarragona Refinery: Case Study....................................................................... 62 26.3.6 Identification, Monitoring, and Prevention of Naphthenic Acid Corrosion ............................................ 62 26.3.7 Effects of FCCU Severity and Other Factors on Visbreaker Fuel Oil Stability ...................................... 64 26.3.8 Revamping Distillation Units to Visbreakers .......................................................................................... 66 26.3.9 Energy Efficiency and Environmental Emissions .................................................................................... 67 26.3.10 Cogeneration Using Visbroken Residues ................................................................. 67 26.4 REFINING R&D ALERT! ....................................................................................................................................... 69 26.4.1 Introduction ............................................................................................................................................. 69 26.4.2 Process .................................................................................................................................................... 71 26.4.2.1 Patents ....................................................................................................................................... 71 26.4.2.1.1 Configuration ........................................................................................................... 71 26.4.2.1.2 Alternative Energy & Efficiency ............................................................................. 72 26.4.2.1.3 Yield Improvement .................................................................................................. 74 26.4.2.2 Research .................................................................................................................................... 77 26.4.2.2.1 Coke Suppression .................................................................................................... 77 26.4.3 Integration ............................................................................................................................................... 78 26.4.4 Additives and Fouling ............................................................................................................................. 80 26.4.5 Optimization/Monitoring ......................................................................................................................... 81 26.4.6 Modeling/Characterization ..................................................................................................................... 82 26.4.7 Hardware ................................................................................................................................................ 84 26.4.7.1 Patents ....................................................................................................................................... 84 26.4.7.2 Research .................................................................................................................................... 85 26.4.8 Adsorbents ............................................................................................................................................... 85 26.5 WORLDWIDE INSTALLED CAPACITY .................................................................................................................... 86 26.6 CONSTRUCTION ................................................................................................................................................... 90 26.6.1 Recent Construction Activity ................................................................................................................... 90 26.6.2 Completed Construction Projects............................................................................................................ 91 26.7 REFERENCES ........................................................................................................................................................ 94