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ABSTRACT
The objective of this review is the production of middle distillate, 300-650°F cut point, while
maximizing diesel (550-650°F) yield. The new UOP’s new HyCycle (TM) Unicracking hydrocracking
technology is the basis of the evaluation. US Patents 5,980,729, 5,885,440 and a 2001 NPRA
publication [R98-07-001] have been served as a basis for evaluating the technology. The key
attributes to this technology are:
• Reverse arrangement of reactors system. The hydrocracking, with low conversion per
pass, about 33%, comes first followed by hydrotreating. The preheated feed enters the
hydrotreating reactor along with hydrocracker outlet product, for very deep sulfur and
nitrogen removal.
• The cracked products are separated from the reactor loop at about 1,800 psig in
hydrogen rich vapor phase. Product is condensed outside reactor loop prior to
conventional products recovery. An overall conversion of above 98% and below 650°F
cut point is achieved.
• Reactor loop nominal pressure of about 1,800 psig as opposed to 2,400 psig in more
conventional double reactor system.
• For 21.5 API, 2.5 wt% sulfur, 980°F TBP cut POINT VGO, the yield is 38 vol% diesel, 42
vol% kerosene and 29 vol% naphtha. The equivalent yield in conventional double
reactor system with 97% conversion to 650°F cut point is 19 vol% diesel, 54 vol%
kerosene and 36 vol% naphtha.
• The system comprises a finishing reactor, and naphtha product, meeting the 1 ppm
sulfur specification for typical downstream processing such as catalytic reforming.
• The hydrogen consumption for the above yield basis is reduced from 1,950 Scf/bbl in
conventional double reactor to 1,700 Scf/bbl in HyCycle.
• It is thought that the capital cost investment will be reduced by about 10-14% subject to
more detailed cost comparison.
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INTRODUCTION
Middle distillates, diesel and kerosene are the more important refinery products for Asian
countries like China and India, and other countries with emerging economy and infrastructure.
Even in Western European countries, the ratio of demand of middle distillate to gasoline products
is considerably higher compared to the ratio in North America. The newly emerging HyCycle(TM)
hydrocracking technology as developed by UOP is geared toward maximizing diesel yield, and
this is the focus of this report.
The hydrocracking process and chemistry are discussed along with the economics of
hydrocracking VGO to middle distillates in PEP Report 211, Hydrocracking (1994).
Hydrocracking of residual oils is discussed in PEP Report 228, Refinery Residue Upgrading
(2000).
The model used for this evaluation is a feed rate of 35,000 BPSD of (5,160 TPD, 5665
M3/day) of combined AGO and VGO (Atmospheric gas oil and 980°F TBP cut point vacuum gas
oil). These originate from atmospheric and vacuum fractionation of Arabian Light, crude oil, 34.5
API (SG=0.852). This capacity is based on an assumed 168,000 BPSD (350 days per year, 8.0
MMTPY) grass roots refinery, which is judged to represent an average future size refinery to be
built in emerging markets. The Arabian Light represents a common world benchmark of crude
oil. The results of this evaluation can be adjusted to many other potential hydrocracking feeds
and capacities while maintaining a reasonable accuracy. The size range of future hydrocracking
units is expected to be in the range of 20,000-50,000 BPSD per single train of production.
Diesel Specifications
Diesel fuel regulations over the next decade are reducing the sulfur content in all the major
markets to approach “sulfur free” fuel in order to reduce vehicle NOx and particulate emissions.
Parts of Europe have led the sulfur reduction. For instance, since 1991 Swedish Class 1 diesel
fuel has had <10 ppm sulfur, typically 1-3 ppm with cetane rating >51 [R98-07-005]. Diesel sulfur
content in Europe will be reduced to 50 ppm in 2005 (European Union, Stage 4 regulation). The
European commission’s (EC) latest Auto-Oil II discussion paper proposes a 10 ppm sulfur Ultra
Low Sulfur Diesel fuel be phased in starting on January 1, 2007 with a 10% supply requirement
[R98-07-004].
In the U.S., the Environmental Protection Agency has set a specification of 15 ppm sulfur for
June 1, 2006 [R98-07-006]. This regulation, concurrent with implementation of new gasoline
regulations, is being challenged in federal court by the National Petrochemical and Refiners
Association [R98-07-007; R98-07-008; R98-07-009]. The U.S. specification is currently 500 ppm
sulfur with aromatics <35 wt% (10 wt% in California with polyaromatics 1.4 wt%) and cetane
index >40 (>48 in California) [R98-07-002]. In order to provide 15 ppm sulfur fuel at the pump,
U.S. refiners may have to produce 1- ppm sulfur fuel at the refinery due to contamination in the
transportation system.
Japan is fine-tuning its program similar to the European and U.S. programs and tightening
NOx and particulates standards for diesel powered cars and small trucks [R98-07-003]. South
Korea is making major cuts in diesel sulfur levels later in the decade.
The Association for Latin American Refiners has proposed diesel sulfur and cetane
specifications of 2000 ppm sulfur and 47 respectively for 2005 [R98-07-003].
So far, the EC proposal and U.S. regulations have only defined the sulfur concentration;
other properties such as cetane number and aromatics content, have not yet been proposed.
However, the Category 3 diesel fuel specifications proposed under the automaker’s “World Wide
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Fuel Charter” suggest sulfur <30 ppm with cetane number >55 (or Cetane Index >52), total
aromatics <15 vol% with polyaromatics <2 vol%, and a density of 820-840 kg/m3 [R98-07-005].
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The design of the HyCycle combined with HPNA, heavy polynuclear aromatic, management
concept. The HPNA is known to be one of the undesirable hydrocracking products. The HPNA
separates from the cracked liquid at lower temperature and creates severe maintenance in the
colder sections, resulting in excessive down time of the hydrocracking unit. Using of hot
enhanced oil separation, at near reactor exit conditions, combined with downstream purge of
HPNA results in increasing catalyst cycle time and overall profitability. The enhanced separator
is using internal high pressure stripping with hydrogen, of diesel from liquid unconverted oil
(UCO) product. The enhanced separator /stripper recovers the distillate products as vapor at
reactor loop pressure. Liquid, consisting of unconverted oil from the separator, depleted of
distillate, recycles to the hydrocracker reactor within the hot high pressure loop. A small portion of
the unconverted oil in the “hot loop” high pressure cycle is let down from reactor loop pressure to
product fractionation, operating at close to atmospheric pressure this let down avoids build up of
HPNA in the reactor loop. The enhanced separator is combined with a finishing reactor. Traces
of olefins that exist in hydrocracking products could recombine with H2S and form mercaptans.
The finishing bed hydrotreats these mercaptans and bring down the sulfur content of the naphtha
range material, to under 1 ppm.
A range of catalysts are available from UOP for the HyCycle process [R98-07-001]. These
are zeolite based catalysts impregnated with metals on a proprietary support material. The
optimum balance between cracking and hydrogenation is judged on a case by case basis. The
DHC-32 LT catalyst can be operated for maximum diesel and no jet fuel or in a flexible mode
where naphtha and jet fuel are both produced along with increased diesel. The DHC-43 LT
catalyst is offered for maximizing the yield of jet fuel. Maximum naphtha yield is produced with
the HC-170 LT catalyst.
The reactor yields of the HyCycle process, when using a flexible, mixed mode catalyst
assumed in this Review, are compared with a conventional process in the table below. The
conventional hydrocracker is the unit described in PEP Report 211 for middle distillates. The
same Arabian Light VGO is processed in both cases. The single pass conversion of the
conventional process of Report 211 is 66%. The single pass conversion of the HyCycle process
in 30%. This comparison shows the yield for identical boiling range of diesel fuel is over 17%
points higher for the HyCycle process than for the conventional process. Incremental diesel is
produced at the expense of lighter products and fuel oil.
Yield, wt% FF
Product Conventional HyCycle Difference, %
Fuel Gas 0.84 0.75 -0.09
LPG 4.64 3.2 -1.44
Light Naphtha 8.22 5.70 -2.52
Heavy Naphtha 20.14 16.60 -3.54
Kerosene (Jet Fuel) 46.90 37.78 -9.12
Diesel 16.72 34.60 +17.88
Fuel Oil 2.69 2.67 -0.02
The HyCycle Unicracking process offers flexibility in staging the capital investment. As an
initial operation, the HyCycle can operate in a once through, partial conversion mode, avoiding
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the enhanced oil separation and post reactor. This mode of operation produces unconverted low
sulfur heavy fuel oil as a co-product in addition to diesel and lighter products and requires a lower
capital investment. As relative demand for diesel increases with time at the expense of demand
for low sulfur heavy fuel oil, the system can be modified to maximize diesel product as described
above.
Design Basis
The HyCycle process currently produces 10 ppm sulfur, diesel product from Arabian gas
oils. The diesel fuel also has a high cetane rating, low aromatics content and a density within the
Category 3 range of the automaker’s “World Wide Fuel Charter” [R97-07-005].
Design assumptions
• Make up hydrogen at 99.9 vol% is available at 340 psig from battery limits.
• Hydrocracking conversion per pass 33% and 650°F TBP cut point
• Nominal hydrocracking and hydrotreating: temperatures 700°F pressure 1,850 psig.
• Hydrogen at recycle compressor outlet: 90 mol%, for establishing purge rate.
• Operating temperature of finishing reactor 625°F.
• Sulfur content of naphtha material 1 ppm.
• Heat of reaction 45-50 Btu/Scf of hydrogen as consumed.
• Yield structure as shown
• Let down of to recycle of UCO (unconverted oil) from high pressure loop to low pressure
is 0.1.
The HyCycle hydrocracking plant comprises two (2) sections: Section 100, hydrogen make
up compression system reaction loop, and Section 200, product recovery. Other associated
process areas such as light end processing, naphtha splitter, sour water stripping, rich amine
regeneration, sulfur recovery, tail gas unit and waste water treating are considered outside the
battery limits (OBL) of the hydrocracking. The rationale is that light gases, naphtha, sour water,
H2S, ammonia, and waste water are generated in other areas of the refinery such as crude unit
and distillate hydrotreating. Therefore, all these streams are combined into a single central
operation of naphtha splitting, purge hydrogen recovery, sulfur recovery and waste water treating.
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Power recovery turbine, by reversed pumps, will be used only on one pump of the service.
No power recovery is applied for spare pump and normal let down valve is used when spare
pump is in service. About 300 kwh of power recovery is the assumed minimum size to
economically justify power recovery reversed pump system.
In general, hydrocrackers are designed for high level of heat integration in order to reduce
energy cost and steam generation in hydrocracking reactor loops is un-common. In this
particular case the level of heat integration is reduced while introducing steam generation to
move heat load from one section of the plant to the other. This is thought to result in higher
operating flexibility, at a slightly reduced thermal efficiency and probably reduced capital cost. All
steam generated in the high pressure loop, will go through analytical hydrocarbons detection,
through a “suspect” condensate system. Depending on specific application the “suspect
condensate” can be used for water wash service for ammonium sulfide in the cold section of the
hydrogen recycle. Low pressure “suspect” steam can be used for stripping services in the
fractionation, and ultimately will end in waste water. Therefore this practice of steam generation
avoids any potential contamination of the boiler feed water system.
Table 1
Vol% (TBP
WT% cut points)
H2S 2.44
NH3 0.10
CH4 0.35
C2 H6 0.40
C3 H8 1.30
C4 H10 1.90
C5 2.20 3.01
C6 3.50 5.01
C7 –310°F (154°C) Heavy Naphtha 16.6 20.74
310-550°F (154-288°C) Kerosene 37.78 42.47
550-650°F (288-343°C) Diesel 34.6 38.46
650°F + (343°C +) Heavy fuel oil 1.50 1.46
Total 102.67 111.15
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PROCESS DISCUSSION AND RATIONALE
The design of the HyCycle hydrocracker, the make up hydrogen compression, reaction loop,
vapor recovery and liquids recovery, depend on desired product slate. This is an attempt to
optimize the design for maximum diesel yield at the expense of kerosene and naphtha. The
following issues have been considered while establishing the design basis.
Feedstock
The feedstock is a blend of atmospheric and vacuum gas oils produced from Arabian Light
Crude oil, 680-980°F/BP.
The blend has the following distillation curve:
The 21.5 API gravity oil (0.9246 specific gravity) contained 21 wt% monoaromatics and 32
wt% total aromatics. Sulfur, nitrogen and conardson carbon contents were:
Hydrocracking catalyst
In general Amorphous or zeolitic catalyst is used for middle distillate hydrocracking and both
produce high quality product. The amorphous is somewhat more distillate selective, however
requires a higher reaction temperature. On the basis of UOP data specific to low-conversion
HyCycle, it was decided to use zeolite based catalyst. This rational can be reviewed on a case
specific basis.
Potential heat recovery at the reactors
The estimated heat of reaction is 45-50 Btu/Scf of reacted hydrogen, which amounts to
about 105-115 MM Btu/hr heat release in the reactors and end up as low level heat. Since
reactors pressure is 1,800-1,900 psig as opposed to 2,400 psig in the more traditional design, the
use of an isothermal reactor with 2,000 psig steam generation at 635°F may be worth further
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consideration. The steam pressure is above reaction pressure, thus avoiding a concern of
hydrocarbon leaks into the steam system, the steam can be let down in pressure if need to, and
can be superheated at the fired heaters. About 150,000 lb/hr of steam can be recovered
assuming boiler feed water preheat to about 450°F by recycle gas cooling. After the steam is
superheated to 930°F its motive power can amount to 20,000 kW. At the same time, much of the
lower level heat load on the air coolers will be eliminated. Almost needless to say that under
such a scenario, the load on the fired heaters will increase substantially due to the assumed
superheating.
Conversion
Data from UOP’s NPRA public release suggests 20-40% conversion per pass, US
5,980,729 suggests a case with 30% conversion per pass [R98-07-001]. It is understood that the
above conversion is in the high pressure hot loop. It is further understood that this low
conversion low severity is applied to avoid cracking of diesel product that recycles in the loop. It
was judged that 33% conversion per pass is a reasonable optimum in the high pressure loop. It
was assumed that the combined conversion per pass including the fractionation, is 83% per long
pass. The ultimate conversion(3) at 650°F TBP cut point is assumed at 98.5 wt%. In 2001 issue
of NPRA publications [R98-07-001] UOP indicates an ultimate conversion of 99.5%, however the
cut point is not indicated in NPRA issue. Additional information received by UOP refers 99.5%
conversion at 730°F cut point and the 650°F cut point in this case is the basis of the adjustment
in the overall conversion. The conversion is at 650°F cut point, however if kerosene is blended to
the diesel pool, higher cut point, gas oil material could be blended into the diesel pool. This may
result in higher middle distillate yield.
Hydrogen Requirement
Hydrogen is consumed by hydro-desulfurization, hydro-denitrification, aromatics saturation
and hydrocracking. If VGO from delayed coking or visbreaking, is combined in the feed, an
additional amount of hydrogen would be needed for saturating olefins. About 4% of the hydrogen
is dissolved in the liquid product and purged from the high pressure loop. The net hydrogen
consumption was estimated at 1,630 SCF/BBL feed, about 56% in hydrocracking reactor and
42% in hydrotreating reactor where most of hydrotreating is dedicated to aromatic saturation.
The consumption in finishing reactor is estimated at 2% of the hydrogen. The pressure in the
flash drum, 300 psig is suitable for hydrogen recovery by PSA (pressure swing adsorption) [see
PEP Report 212 “Options for Refinery Hydrogen,” (1994)]. A diesel oriented refinery would
normally have a relatively smaller catalytic reforming unit which co-produces hydrogen at about
90% purity. Under the most reasonable scenario a dedicated hydrogen plant, in this case 60 MM
Scfd (67,000 M3/hr) at high purity, and less than 100 ppm CO, would be required. Steam
reforming of light naphtha, about 6,000 bpsd, or LPG is thought to be worth a serious
consideration as a hydrogen source, unless low cost natural gas is available. Under this
scenario, the light naphtha and LPG produced in the hydrocracking can satisfy about 80% of the
feed to the hydrogen plant. Other light naphtha sources such as straight run naphtha from a
crude unit could be a good source for hydrogen production. Any impure hydrogen resulting from
catalytic reforming, say about 1,500 Scf/bbl, would be used as a separate hydrogen stream for
less severe hydroprocessing services such as straight run diesel hydrotreating at about 1,000
psig.
3x50% make up hydrogen compressors have been assumed, however 2x100% units could
be a reasonable selection depending on a very case specific basis. Air cooling combined with
trim water cooling was assumed for interstage cooling. However, depending on water quality, air
coolers could be avoided, thus resulting in cost reduction. The hydrogen recycle loop is cooled
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only by air coolers as a safety concern to avoid any of the high pressure rich gas from leaking to
cooling water system. It is reasonable to assume that usage of cooling water could result in
lower capital and compression cost, however, at some added cost to overcome safety concerns.
All these issues could be addressed on a case specific basis.
Reactors
Based on prior art and UOP patent US 5,980,729, it was estimated a cold liquid space
velocity of 1.4 /hr for hydrocracking and 2.8/hr for hydrotreating where catalyst amounts to 80% of
reactor T-T volume. Details of the reactor internals are discussed in [R98-07-001]. A design
pressure margin of 10% was allowed. Design margins of 5% could be possible under a different
ASME code and these issues could be addressed on a case specific basis. External insulation of
the reactors will bring down the outside temperature to 140°F. The option of internal insulation, a
“cold wall” design is thought to be of lower capital investment but was judged to present operating
and safety risks.
The Finishing Reactor/ Enhanced Separator uses [US 5980729] hydrogen heating as a
reflux duty. In this particular design, reflux duty can be provided by generating 600 psig steam
and hot hydrogen for diesel stripping will come from the reheated hydrogen sources. An
alternative concept for stripping could be generating 2,000 psig steam in reactor effluent coolers,
or by isothermal reactor, and using the steam for stripping the diesel instead of hydrogen. In this
case the reflux duty will be provided by generating 600 psig steam.
Recycle compressor
A centrifugal compressor, 3,300 kW operating was selected for the recycle loop. Although a
centrifugal compressor is of lower cost and higher reliability compared with a reciprocating
compressor, several issues need to be sorted out on a case specific basis. These issues are
related to variance in conditions between start of run (SOR) and end of run (EOR). Variation in
molecular weight, resulted from light gas production, and pressure drop, resulted from changes in
catalyst, could be key issues in actual design. A steam turbine drive, using 600 psig/750°F
steam, condensing at vacuum, with option of steam extraction at 150 psig will provide a good
speed control on the compressor. The steam turbine would handle variance of feed and changes
from start of run (SOR) and end of run (EOR). A multi-stage steam turbine will provide over 70%
adiabatic efficiency. An electric motor drive could also be a viable selection depending on a case
specific and overall steam balance of the refinery.
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Product fractionation
At this point, we assume a LPG stripper at 120 psig, followed by an atmospheric column, at
10 psig at the receiver. Steam is generated in pump-around loops and kerosene-diesel product
side strippers. As an alternate, a combination of atmospheric distillation along with mild vacuum,
of 100-150 mm Hg, could be a viable option, depending on a case specific basis. Combined full
range naphtha C5-310°F is sent to OBL for further product recovery and upgrading. The
assumed downstream naphtha fractionation could become heat integrated with pump-around
loops of the main distillate fractionator.
Heaters
The more common practice for recycle heater is to use a mixed phase heater in the reaction
loop for both hydrogen recycle and liquid feed recycle. The alternate common approach would
be to use separate heaters for the liquid feed and gas recycles. In the Hycycle case, the
hydrotreating and hydrocracking reactors are in reversed arrangement and the UCO recycles hot
within the high pressure loop. Because of this configuration, heating of hydrogen recycle as an
exclusive source of thermal duty, is the chosen option. This gas recycle heating results in
somewhat higher exit temperature and higher skin temperature, compared with mixed phase
heating, thus fuel gas firing will be the highly preferred mode of operation.
The heater for the fractionation unit is operating in lower severity in both temperature and
pressures, thus fuel firing or dual firing would be an acceptable approach. The UCO is purged at
650°F from the recycle seems to be a good low sulfur low nitrogen fuel source.
Materials of Construction
All the issues of hydrogen graphitization and sulfur corrosion resulting from high pressure,
high temperature are fully considered, using the latest version of “Nelson Curves”. For a
conservative design the following is suggested. For hydrocracking reactor, we selected 2.25% Cr
1.0 % Mo. For hydrotreating reactor we selected 2.25 Cr 1.0% Mo, with 347 stainless cladding.
For the Finishing Reactor and enhanced separation use 1.25% Cr 0.5% Mo and SS 317
cladding. Outside insulation will bring the temperature to 140°F.
For reactor loop heater, 2.25 Cr 1.0 Mo is used. For the fractionator heater and all
exchangers above 450°F we used 1.25% Cr 0.5% Mo. All services below 450°F use C.S,
regardless of pressure. For sulfur corrosion above 625°F use 321 SS in heat exchangers.
Products quality
The diesel product will meet the Euro IV specification and will be mixed with hydrotreated
straight run diesel, about 35,000 BPSD as produced in the crude distillation unit. The kerosene
product, as described, meets the specifications for jet fuel. It would be a common practice to mix
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this kerosene product with straight run (310-550°F) kerosene material as produced in crude unit
after a MEROX (mercaptans oxidation) unit, if needed. The heavy naphtha product is of low
octane, thus could be very synergistic for catalytic reforming (CCR) along with straight run
naphtha. The light naphtha (C5/C6) could be a good stock for hydrogen production by steam
reforming. The LPG (C3/C4) could meet typical market specifications.
Waste treatment
The hydrocracking process design feature includes water wash of tube sheets and other
elements of the cold sections of the reactor loop. This water, about 80 gpm after dissolving
ammonium sulfide, is directed to waste water. For the particular case as depicted in this design
basis ammonia recovery, being only about 5.0 tpd, would not be economical. The wastewater is
directed to sour water stripper along with sour water from other units such as distillate
hydrotreating and CCR. The H2S and ammonia are stripped, and routed to conventional Claus
type sulfur plants and associated tail gas treating. Ultimately, 99.5% or higher sulfur recovery is
achieved. All the ammonia is oxidized, in the sulfur plant, to elemental nitrogen. Additional
wastewater, about 65 gpm will result from live steam stripping in fractionation. This water will be
routed to API separator with other wastewater streams.
PROCESS DESCRIPTION
The conceptual design for a 35,000 B/SD gas oil HyCycle hydrocracker is shown in Figure
1. The process design, yields and utility consumption rates are based upon engineering
principles, computations, published information and other nonconfidential information. The
design may or may not be similar to that licensed or otherwise used.
The product yields at the reactor discharge and product quality are listed in Table 1. Table 2
provides the flows and approximate composition of the major streams. Major equipment size and
material of construction are listed in Table 3. Estimated utility consumption is summarized in
Table 4.
The plant consists of two sections:
• Section 100—H2 Compression and Reactor Loop
• Section 200—Product Recovery
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Section 200 product recovery
Liquid 1,765 psig from V-105 rich in diesel kerosene and naphtha is separated from sour
water and let down to Cold Flash Drum V-201 at 300 psig. Dissolved hydrogen containing traces
of H2S methane and ethane combines with purge hydrogen and flash hydrogen from area 100.
This crude hydrogen stream about 3.0 Mmscfd at about 80 vol % is release to PSA hydrogen
recovery at OBL or fuel gas system. Liquids from V-201 depleted of most of the hydrogen and
portion of CH4 and C2H6 is let down to C-201, LPG stripper operating at 120 psig (9.4 kg/cm2-a)
where essentially all C4 and most C3 are recovered as mixed liquid, about 1,600 BPSD with 38
liquid vol% propane. About 20% of C3 along with residual methane and ethane are released to
refinery fuel gas header operating at 80 psig. The stripper feed is preheated by E-201 using 50
psig steam, and reboiled by 600 psig steam at E-203 and stripping is enhanced by small injection
of 150 psig live steam.
Heavy liquid from Hot Flash Drum V-107 is let down to the coil of fired heater F-201 and
partially vaporized at end point of 700 F. Vapor /liquid mixture is introduced to the flash zone of
the Fractionation Column C-202 with total of 50 trays. The UCO at 650°F and 30 psig, from the
bottom of fractionation column C-202 enters a booster pump provides suction pressure to the
recycle pump which recycles the UCO at 2200 psig to the hydrocracking reactor R-103 in area
100. A HPNA purge of about 525 BPSD is drawn from the discharge of the booster pump and
could be used as a major source of fuel for F-201.
The 10,066 BPSD full range naphtha C5-310 F is recovered as overhead product of C-202
and sent to OBL by the reflux pump. About 14,836 BPSD kerosene product from Kerosene
Stripper C-203 is cooled by E-209, generating 50 psig steam , followed by air cooler E-210. The
diesel product, about 13,461 BPSD from Diesel Stripper C-204 is cooled by generating 150 psig
steam at E-211, followed by air cooler E-212 to 160°F and sent to OBL.
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Table 2
STREAM FLOWS
CAPACITY: 1372 MILLION LB/YR
Total, lb/hr 13,165 471,625 1,129,831 1,601,861 1,601,861 19,867 947,305 82,000
Total, kg/hr 5,972 213,925 512,483 726,592 726,592 9,012 429,690 37,195
Total, lb/hr 82,000 Trace 541 1,109,031 21,246 674,423 473,473 714,189
Total, kg/hr 37,195 Trace 245 503,048 9,637 305,913 214,764 323,951
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Table 2 (Continued)
STREAM FLOWS
CAPACITY: 1372 MILLION LB/YR
Total, lb/hr 42,302 481,698 190,836 183,246 181,646 35,000 1,730 479,858
Total, kg/hr 19,188 218,495 86,562 83,119 82,393 15,876 785 217,660
Total, lb/hr 4,000 26,185 13,610 3,826 3,911 462,542 157,767 105,177
Total, kg/hr 1,814 11,877 6,173 1,735 1,774 209,805 71,562 47,707
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Table 2 (concluded)
STREAM FLOWS
CAPACITY: 1372 MILLION LB/YR
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Table 3
MAJOR EQUIPMENT
CAPACITY: 1,372 MILLION LB/YR (622,000 T/YR)
DIESEL FUEL
AT 0.96 STREAM FACTOR
EQUIPMENT
NUMBER NAME SIZE MATERIAL OF CONSTRUCTION REMARKS
------------------- ---------------------------------------------- ---------------------------------------- ---------------------------------------------------------- ----------------------------------------------------------------------------------
REACTORS
COLUMNS
C-101 AMINE ABSORBER 8 FT DIA SHELL: C.S. 15 VALVE TRAYS, 24 INCH SPACING
36 FT TRAYS: C.S.
C-201 LPG STRIPPER 10 FT DIA SHELL: C.S. 24 VALVE TRAYS, 24 INCH SPACING
60 FT TRAYS: C.S.
C-202 PRODUCT FRACTIONATOR 16 FT DIA SHELL: C.S. 50 VALVE TRAYS, 24 INCH SPACING
120 FT TRAYS: C.S.
C-203 KEROSENE STRIPPER 6 FT DIA SHELL: C.S. 8 VALVE TRAYS, 24 INCH SPACING
25 FT TRAYS: C.S.
C-204 DIESEL STRIPPER 7.5 FT DIA SHELL: C.S. 10 VALVE TRAYS, 24 INCH SPACING
33 FT TRAYS: C.S.
COMPRESSORS
K-101A-C H2 MAKE UP COMPRESSORS 3,500 BHP C.S. 3 STAGES EACH, RECIPROCAL; MOTOR DRIVE.
2 OPERATING, 1 SPARE.
K-102 H2 RECYCLE COMPRESSOR 4,025 BHP C.S. 1 STAGE, CENTRIFUGAL; TURBINE DRIVER
HEAT EXCHANGERS
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Table 3 (Continued)
MAJOR EQUIPMENT
CAPACITY: 1,372 MILLION LB/YR (622,000 T/YR)
DIESEL FUEL
AT 0.96 STREAM FACTOR
EQUIPMENT
NUMBER NAME SIZE MATERIAL OF CONSTRUCTION REMARKS
------------------- ---------------------------------------------- ---------------------------------------- ---------------------------------------------------------- -------------------------------------------------------------------------------
PROCESS FURNACES
TANKS (OFFSITE)
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Table 3 (Concluded)
MAJOR EQUIPMENT
CAPACITY: 1,372 MILLION LB/YR (622,000 T/YR)
DIESEL FUEL
AT 0.96 STREAM FACTOR
EQUIPMENT
NUMBER NAME SIZE MATERIAL OF CONSTRUCTION REMARKS
------------------- ---------------------------------------------- ---------------------------------------- -------------------------------------------------------- -------------------------------------------------------------------------------
PRESSURE VESSELS
MISCELLANEOUS EQUIPMENT
M-101 FRESH FEED FILTER SYSTEM CARBON STEEL 100 MESH SS SINTERED, BACKFLUSH
M-201 UCO FILTER SYSTEM CARBON STEEL 100 MESH SS SINTERED, BACKFLUSH
SPECIAL EQUIPMENT
PUMPS
22
PEP REVIEW 98-7
Table 4
UTILITIES SUMMARY
CAPACITY: 1,372 MILLION LB/YR (622,000 T/YR)
DIESEL FUEL
AT 0.96 STREAM FACTOR
PEAK DEMANDS
COOLING WATER GPM 7,992 4,488 3,504
PROCESS WATER GPM 96 96 --
STEAM, 50 PSIG M LB/HR 34 -- 34
STEAM, 150 PSIG M LB/HR 5 -- 5
STEAM, 600 PSIG M LB/HR 86 42 44
23
PEP REVIEW 98-7
COST ESTIMATES
The capital investment and production costs for hydrocracking as oil produced from Arabian
Light crude oil for the production of jet and diesel fuels are presented. Costs are based on an
U.S. Gulf Coast location for the second quarter of 2000. Overnight construction is assumed (ie,
the cost of funds spent during construction are excluded).
Investment Costs
Table 5 sets forth the total fixed capital (TFC) investment for a 35,000 B/SD HyCycle
hydrocracking unit. The costs are calculated at a PEP Cost Index of 624. The design has not
been fully optimized either for equipment size or energy consumption. Owner’s costs such as
cleared land are excluded. Licensing or royalty fees are regarded as proprietary and are not
included in these costs.
The boundary limit installed costs was $151 million before contingency. This cost is 14%
lower than the corresponding cost of the conventional VGO middle distillate hydrocracker
evaluated in PEP Report 211. Both units cracked Arabian Light gas oil. The conventional unit
operates at 2645 psi compared to 1910 psig in the HyCycle process. The lower pressure
reduces the reactor cost and hydrogen compressor cost. UOP has estimated a 5% capital
reduction compared to “previous offerings” due to these factors [R98-007-001]. Table 6 shows
the investment costs broken down by section. The major items are the reactors and initial
catalyst charge and the hydrogen compressors. The estimated cost of catalysts, about $10 MM,
is based on generic industry data from hydrocracking projects. Because of the large size
hydrocracking reactors and the subsequent portion of capital cost attributed to these reactors, it
should be noted that the process specifications of these items could be highly influenced by site
specific factors such as transportation local construction capability. Material of construction
design codes, desired run length on the catalyst could be subject to operator’s preference and
would affect capital investment. Adding 15 or 25% contingency to the current estimate results in
a boundary limit investment of 174 million $ or 189 million $ respectively.
Offsite investment before contingency (Table 5) totals 21 million $. The offsite investment is
relatively small percentage of the boundary limit investment due to the high cost of the reactors
and credit for steam generation within the boundary limits. The cost of the offsite is based on an
assumed generic integration with other refinery units such as crude distillation, vacuum distillation
sulfur recovery, waste water treating, spent catalyst, and intermediate storage. Offsite
investment includes the incremental cost of utilities and storage. Gas oil feed and product
storage are based on 3 days production (except fuel oil, 5 days). The allowance for general
service facilities includes a control room, roads, fire protection and equipment. The cost of rich
MDEA stripping is included in the waste treatment investment. The allocation also covers the
flare and relief system and incremental additions to the water collection and treatment system.
Contingencies of 15 or 25% bring the total offsite investment to 23.8 million $ or 26.5 million $
respectively.
The total fixed capital cost or boundary limits investment is 198 million $ including a 15%
contingency or 216 million $ when including a 25% contingency.
Production Costs
Table 7 lists the unit cost and consumption factors used in estimating the value of
feedstocks, products and utilities included in the production cost. By-products are shown as a
credit (negative). Feedstock and product values are mid-2000 values determined by PEP. The
24
PEP REVIEW 98-7
gas oil feed is based on 10 vol% atmospheric gas oil and 90% vacuum gas oil. The on stream
factor is 0.96.
Raw material cost of 24.51 ¢/lb of diesel fuel includes catalyst replacement every three
years (UOP expects 4 years catalyst life with their new catalysts [R97-07-001]. By-product sales
and credits of mainly jet fuel and full range naphtha offset most of the raw material cost. Utility
costs, 0.52 ¢/lb of diesel, are relatively low due to credit for steam generation.
Plant cash costs total 4.48 ¢/lb of diesel fuel. Adding depreciation at 10%/yr of total fixed
capital of $216 million (including a 25% contingency) and an allowance for general
administration, sales and research expenses gives a net production cost of 6.15 ¢/lb. At a 25%
contingency factor, the product value is 9.51 ¢/lb of diesel fuel.
Product value of units of 0.5 and 1.5 times the base case capacity were also calculated at a
0.96 on stream factor and a constant 25% ROI. With a 25% contingency, the product value from
the half capacity plant is 11.49 ¢/lb, 14% higher than the 10.08 ¢/lb of the base case. Increasing
capacity to 150% of the base case reduces the product value 4.6% to 9.62 ¢/lb. With a 15%
contingency, the respective product values at 0.5 and 1.5 times the base case capacity are 10.81
and 9.07 ¢/lb of diesel fuel.
With 25% contingency, reducing the time on stream factor to 0.92 from 0.96 reduces the
production of diesel fuel to 1315 million lb/yr (12,342 B/D) from 1,372 million lb/yr (12,878B/D).
Plant cash costs increase to 4.55 ¢/lb from 4.48 ¢/lb of diesel. Net production cost becomes 6.29
¢/lb, up from 6.15 ¢/lb. The total product value at 25% ROI rises to 10.39 ¢/lb from 10.08 ¢/lb.
Similarly, with 15% contingency, the base unit’s total production cost decreases to 10.21 ¢/lb of
diesel with less time on steam.
Profitability
Based upon a total fixed capital cost (included 25% contingency) of $216 million and a 0.96
operating factor, the total return on investment (ROI) before income taxes, was an attractive
29.3% at the mid 2000 prevailing diesel fuel market value of 10.77 ¢/lb. When the plant capacity
is half the base case capacity, the ROI reduces to 21.1%. Increasing capacity to 1.5 times the
base case increases the ROI to 32.7%. Similarly, but with a 15% capital cost contingency, the
base case unit’s ROI increases to a very attractive 33.6%, the half capacity case returns 24.7%
and the 1.5 times case return rises to 37.4%.
At a 0.92 operating factor instead of 0.96 and a product value of 10.77¢/lb of diesel fuel, the
base case unit’s ROI decreases 2.1 percentage points to 27.2% with a 25% contingency and
rises 2.0 points to 31.4% with a 15% contingency. At 25% contingency, the 0.5 and 1.5 times
capacity plants' returns are 19.2% and 30.5% respectively. Also with a 15% contingency, the 0.5
and 1.85 times plant capacity plants returns are 22.7% and 34.9% respectively, down 2.0 and 2.5
percentage points when the time on stream is reduced to 0.92.
25
PEP REVIEW 98-7
Table 5
CAPACITY
EXPONENT
COST --------------------------
($1,000) UP DOWN
------------ ---------- ----------
BATTERY LIMITS EQUIPMENT, F.O.B.
REACTORS 24,383 0.98 0.90
COLUMNS 1,373 0.95 0.81
VESSELS & TANKS 1,834 0.84 0.97
HEAT EXCHANGERS 5,666 0.78 0.63
FURNACES 5,897 0.82 0.82
COMPRESSORS 9,921 0.76 0.76
SPECIAL EQUIPMENT 10,000 1.00 1.00
MISCELLANEOUS EQUIPMENT 700 1.00 1.00
PUMPS 2,670 0.79 0.74
---------
TOTAL 62,444 0.90 0.85
OFF-SITES, INSTALLED
CLARIFIED WATER 578 0.74 0.64
COOLING WATER 1,284 0.92 0.92
PROCESS WATER 302 0.62 0.62
BOILER FEED WATER 2,695 0.52 0.39
STEAM 2,739 0.48 0.00
TANKAGE 6,662 0.65 0.65
---------
UTILITIES & STORAGE 14,261 0.62 0.47
26
PEP REVIEW 98-7
Table 6
OFFSITES, INSTALLED
CLARIFIED WATER 309 0.74 0.64 269 0.74 0.64
COOLING WATER 721 0.92 0.92 563 0.92 0.92
PROCESS WATER 130 0.62 0.62 102 0.62 0.62
BOILER FEED WATER 1,028 0.51 0.34 1,667 0.53 0.42
STEAM 258 0.48 0.00 2,481 0.48 0.00
TANKAGE 2,772 0.65 0.65 3,890 0.65 0.65
--------- ---------
UTILITIES & STORAGE 5,219 0.66 0.58 8,972 0.60 0.41
27
PEP REVIEW 98-7
Table 7
PRODUCTION COSTS
PEP COST INDEX: 624
VARIABLE COSTS
CONSUMPTION
UNIT COST PER LB ¢/LB
------------------------- -------------------------- ----------
RAW MATERIALS
FRESH FEED 10% AGO 6.442 ¢/LB 2.89017 LB 18.62
HYDROGEN 99.9% 73.21 ¢/LB 0.07717 LB 5.65
CATALYST & CHEMICALS 834 ¢/LB 0.000292 LB 0.24
MDEA 183 ¢/LB 0.000002 LB NEGL
---------
GROSS RAW MATERIALS 24.51
BY-PRODUCTS
C1 FUEL GAS 7.806 ¢/LB -0.01012 LB -0.08
C2 FUEL GAS 11.11 ¢/LB -0.01156 LB -0.13
C3 FUEL GAS 12.05 ¢/LB -0.03757 LB -0.45
C4 FUEL GAS 11.55 ¢/LB -0.05491 LB -0.63
FULL NAPHTHA 13.13 ¢/LB -0.64451 LB -8.46
KEROSENE(JET FUEL) 11.12 ¢/LB -1.09191 LB -12.14
H. FUEL OIL 7.671 ¢/LB -0.04335 LB -0.33
---------
TOTAL BY-PRODUCTS -22.22
CONSUMPTION CONSUMPTION
UNIT COST PER LB PER KG
------------------------- -------------------------- --------------------------
UTILITIES
COOLING WATER 7.45 ¢/MGAL 2.45 GAL 20.4 LITERS 0.02
PROCESS WATER 1.101 $/MGAL 0.0294 GAL 0.245 LITERS NEGL
STEAM, 600 PSIG 5.72 $/MLB 0.172 LB 0.172 KG 0.10
STEAM, 50 PSIG 3.5 $/MLB -0.453 LB -0.453 KG -0.16
STEAM, 150 PSIG 4.51 $/MLB -0.239 LB -0.239 KG -0.11
ELECTRICITY 4 ¢/KWH 0.0648 KWH 0.143 KWH 0.26
NATURAL GAS 3.24 $/MMBTU 1,260 BTU 698 KCAL 0.41
---------
TOTAL UTILITIES 0.52
28
PEP REVIEW 98-7
Table 7 (concluded)
PRODUCTION COSTS
PEP COST INDEX: 624
-----------------------------------
* OF DIESEL FUEL
# BASE CASE
29
PEP REVIEW 98-7
CONCLUSION
If the high yield of diesel product would represent a desired product slate, the preliminary
conclusion about the HyCycle(TM) Unicracking technology is very positive. This preliminary
conclusion could be enforced by confirmation of the assumption made during the course of this
evaluation, in terms of reactor operating conditions, vapor product separation conditions, and
product yield. It is recognized that a non-disclosure agreement with UOP would have been
required in order to further establish the technical integrity of the above report.
FOOTNOTES
(1) Cetane Index. A Nomograph for calculating Cetane Index is presented in Standard
Methods For Analysis and Testing of Petroleum and Related Products. 1988 issue British
Institute of Petroleum. Vol 1 218-3. API gravity and 50% boiling point by ASTM distillation is
needed.
(2) Per pass conversion: 100- 650°F+ material in distillate product (liquid volume)
650°F+ in (fresh feed + recycle)
(3) Overall conversion : 100- 650°F+ in distillate product (liquid volume)
650°F+ material in feed
30
PEP REVIEW 98-7
CITED REFERENCES
Literature
R98-07-001 Antos, G.J., et al., “Unicracking TM Innovations Delivery Profit,” National
Petrochemical and Refiners Association 2001 Annual Meeting, New Orleans,
LA, (March 18-20, 2001), Paper AM-01-30
R98-07-002 Lamourelle, A.P., et al., “Clean Fuels: Route to Low Sulfur Low Aromatic Diesel,”
National Petrochemical and Refiners Association 2001 Annual Meeting, New
Orleans, LA, (March 18-20, 2001), Paper AM-01-28
R98-07-003 Adler, K., “2001 In Review: Europe, Asia See Trends of Fuels Regulations,”
World Refining, 11,1 (January/February 2001), 36, 38-40
R98-07-004 Peckham, J., “Euro Commission Proposes 10 ppm ULSD Phase-in from 2007,”
Diesel Fuel News, 5, 5 (March 5, 2001), 11\
R98-07-005 Roj, A., “Fuel Quality for the Future—an Automotive Industry View,” Cleaner
Fuels for Europe workshop, Helsinki, Finland, (Nov. 23-23, 2000)
R98-07-006 U.S. Environmental Protection Agency, “EPA Gives the Green Light on Diesel-
Sulfur Rule,” News Release (R-30), (February 28, 2001)
R98-07-007 National Petrochemical and Refiners Association, “NPRA to Challenge Diesel
Sulfur Rule in Court: Decision Motivated by Supply Concerns,” News Release
(January 23, 2001)
R98-07-008 National Petrochemical and Refiners Association, “NPRA Files Petition for
Review of EPA’s Diesel Sulfur Rule,” News Release (February 2, 2001)
R98-07-009 National Petrochemical and Refiners Association, “NPRA Reaction to Reports of
Administration Decision on Diesel Rule,” News Release (February 28, 2001)
Patents
US 5885440 Hoehn, R.K., et al., (to UOP LLC), “Hydrocracking process with integrated
effluent hydrotreating zone,” U.S. 5,885,440 (March 23, 1999)
US 5980729 Kalnes, T.N., (to UOP LLC),”Hydrocracking Process,” U.S. 5,980,729 (Nov. 9,
1999)
WO 97/38066 Cash, I. R., (to Chevron U.S.A.), “Process for Reverse Staging in
Hydroprocessing Reactor Systems,” WO 97/38066 (application) (Oct. 16, 1997)
Reports
211 Chang, E.J., “Hydrocracking,” PEP Report 211, SRI Consulting, Menlo Park, CA
(April 1994)
212 Leiby, S.M., “Options for Refinery Hydrogen,” PEP Report 212, SRI Consulting,
Menlo Park, CA (February 1994)
216 Ma, J.J. “Acid Gas Treatment and Sulfur Recovery,” PEP Report 216, SRI
Consulting, Menlo Park, CA (November 1997)
31
PEP REVIEW 98-7
228 Nielsen, R. H., “Refinery Residue Upgrading,” PEP Report 228, SRI Consulting,
Menlo Park, CA (May 2000)
32
PEP REVIEW 98-7
Figure 1 (Sheet 1 of 2)
(TM)
HYCYCLE UNICRACKING HYDROCRACKING
FOR MIDDLE DISTILLATE
H2 COMPRESSION AND REACTOR LOOP
225 F
O
225OF 225OF 600 psig
640 psig 150OF 150OF 100OF 2050 psig Steam
100 F O
1130 psig
V-102 150OF 22
V-101 E-104 V-103
E-101 E-102 E-103 E-105
Make-up H2 K-102
1
K-101A K-101B K-101C
E-116
Vac.
Vent
Wash 2020 psig CW
Water 165OF
V-104 140OF
16
Atmospheric Gas Oil V-105 21
E-114
Vacuum Gas Oil
From Storage
18 To V-201
300OF
V-106
M-101 17 19
2
E-106 330OF 320OF E-113 130OF
Waste 1750 psig
E-107 Water 20
600OF
O
130 F
490OF E-112 15 C-101
4 BFW 700OF Lean MDEA
1910 psig
690OF
14 630 F
O
R-101 13
R-103
R-102
E-110 E-111
3 Rich MDEA
640OF 500 F
O
150OF
11 To V-201
6
E-115
O 625OF E-109 1800 psig
730 F O
BFW
725 F 10
1820 psig 695 F
O O
5 625 F 1860 psig
V-107
E-108 7
BFW 400OF
250OF 8
12
320OF
Unconverted 715OF 1860 psig
Oil from F-101 1950 psig
Section 200 Unconverted
36 9 Oil to E-204
V-101 R-101 F-101 V-104 M-101 A,B R-102 V-102 R-103 V-103 V-105 V-107 V-106 C-101 K-102
H2Co mpressor Hydrotreating Feed-Recycle Feed Fresh Feed Finishing H2Co mpressor Hydrocracker H2Co mpressor Cold Hot Flash Recycle Amine H2 Recycle
K.O.1 Reactor Furnace Surge Filter System Reactor K.O.2 K.O.3 Separator Drum Compressor Absorber
K.O.
K-101A,B,C
H2 Make up
Fuel
Gas V-203
18,000 lb/hr
Steam 50 psig
28,000 lb/hr
30
650OF, 30 psig
O
700 F
From V-107 E-204
625OF 35
9 Fuel
Oil
UCO to Fuel Oil
To R-103 650OF M-201
2200 psig
36 37