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5 Vasnat Kumar PDF
5 Vasnat Kumar PDF
“HYDROCRACKER OPERATION”
Presented by
V.Vasant Kumar
Chief Manager- Process Engineering
RESOT Centre
z Chemistry of Hydro-cracking.
z Process Configurations.
Topics for discussion (Contd.)
z Process descriptions- General
z Process Variables
z Emergency handling
z Modifications&operational Improvement
done in CPCL – OHCU.
z Case study –CPCL –OHCU.
z Hydro-cracking Licensors
Process Units
Unit Licensor Capacity
Amine Treating :
a) Fuel gas treating EIL 35,000 TPA
b) LPG treating EIL 60,000 TPA
z
z In
In 1995,
1995, UOP
UOP Bought
Bought Unocal
Unocal Technology,
Technology, and
and
Now
Now Have
Have 2/3
2/3 of
of the
the World’s
World’s HCRs.
HCRs.
z
z Other
Other Licensors
Licensors (Minor
(Minor Players).
Players).
–– IFP
IFP (Subsidized
(Subsidized by
by French
French Government)
Government)
–– MAKFina
MAKFina (Mainly
(Mainly Compete
Compete inin Mild
Mild HCR)
HCR)
–– Shell
Shell Global
Global (Several
(Several Captive
Captive Shell
Shell Units,
Units,
Criterion
Criterion Cats)
Cats)
Chemistry of
Hydro-cracking
Chemistry of Hydrocracking
Typical Hydro-processing & Hydro-cracking
Reactions:
1. De-metallization.
2. De-sulphurization.
3. Denitrification.
4. Olefin Saturation.
5. Aromatics Saturation
6. Hydro-Cracking
7. Sulphiding
8. De-methalization - Thermalcracking
9. Heat Release
Desulphurisation Reaction
R C CH R
HC CH + 4H2 Catalyst CH 3 CHCH 2CH 3 + H2S
S
Thiophene Branched Paraffin
R
R CH SH+ H2 Catalyst R CH2 R + H2S
Straight-Chain
Thiol Paraffin
Paraffin of paraffin of
z
zSingle
Single Stage - for 100% conversion of feed
into products.
z
zSingle
Single stage - Once -Through operation
Once-Through
–– CPCL ’s design
CPCL’s design configuration
configuration
z
zSingle
Single Stage Recycle
- CPCL
CPCL’s’s initial operation configuration
z
zTwo
Two Stage Recycle
Single -Stage Once
Single-Stage -Through
Once-Through
(SSOT) Hydrocracking
zFeatures
– Low Investment
– Low Hydrogen Consumption
– Very Flexible Plant, Handles a Variety of
Feeds
– Can Handle High End Point, High N
Feeds
– Pretreats VGO for FCC Feed
– Produces High VI Lube Base Stocks
Single Stage (SSOT)
CPCL SSOT YIELDS
CPCL SSOT YIELDS
Advantages :
1. Substantial increase in LPG and Gasoline yields.
2. Reduction in CLO and Coke yields.
3. Better quality products with very low sulphur content (MS ‘S’ <10 ppm,
RON 91 and TCO ‘S’ content <100 ppm).
4. Reduction in SO2 emission due to lower sulphur content in feed.
Single -Stage Recycle (SSREC)
Single-Stage
Hydrocracking
Product
Fresh
Gas
Feed
Recycle
Gas
Light
Naphtha
Heavy
Naphtha
Kerosene
Diesel
First-
First-Stage Second-
Second-Stage Product
Product
Hydrocracking Configurations
Summary
z
z Single-Stage,
Single-Stage, Once-Through-Liquid
Once-Through-Liquid (SSOT)
(SSOT)
–– Low
Low Conversion
Conversion (35-70%)
(35-70%)
–– Minimal
Minimal Quality
Quality Products
Products (UCO
(UCO toto FCC
FCC UU as
as Feed)
Feed)
–– Relatively
Relatively Low
Low Investment
Investment
z
z Single-Stage
Single-Stage Recycle
Recycle (SSREC)
(SSREC)
–– High
High Conversion
Conversion (90+%)
(90+%)
–– High
High Quality
Quality Products
Products
–– Moderate
Moderate Investment
Investment With
With Easy
Easy Feeds
Feeds
z
z Two-Stage
Two-Stage Recycle
Recycle (TSR)
(TSR)
–– Full
Full Conversion
Conversion
–– Very
Very High
High Quality
Quality Products
Products
–– Moderate
Moderate Investment
Investment With
With Difficult
Difficult Feeds
Feeds
Product Qualities
Single vs Two stage hydro-cracker
z
zStraight run gas oil.
z
zVacuum Gas Oil (LVGO & HVGO ).
z
zDe-asphalted Oil (DAO).
z
zFCCU cycle oil.
z
zCocker gas oil.
z
zDistillates.
z
zExtracts.
HYDROCRACKER FEED STREAMS -
CPCL
z HVGO Stream from Ref-II and Ref-III
z DAO
– dist 95%@585°C, vis 33 – 36cst @100°C, asp < 100 ppmw
z Foots Oil
– CCR 0.4%wt, Asp – 40-50 ppmw, Metals*– 3 ppmw
z Slack wax
– CCR - <0.1% wt, Asp – 90 ppmw, Metals – 1 ppmw
z Lube distillate & Lube slop
-CCR – 0.6% wt, Asp – 70 ppmw, Metals – 3.5 ppmw
z VB-VGO
(* Metals = Ni+V+Fe+Na)
Products from hydro-cracker
z HYDROCRACKER UNIT PRIMARY PRODUCTS:
Hydrocracking
ICR 126 Cylinder 951 2.54 113,348 116 667
CONFIDENTIAL
Property of Chevron
To be Reproduced and Used only in
accordance with written permission of Chevron.
Quench Make-up H2
H2 Gas compressor
Recycle gas
3 Off-gas to PSA
Feed 2,10,489 nm / hr.
(for
VGO preheating Reactors HP H2 recovery)
feed and Furnace
172.5 Kg/cm2
249.2 filtration gas separator
m3/hr. 3780C
LP
Liquid hydrocarbon gas separator
Heavier
hydrocarbons Kerosene / ATF 67.2 m3/hr..
3600C
Furnace Fractionator
Diesel 59.8 m3/hr..
Fractionator
feed furnace
Off-gas to
sponge-oil absorber
and then to FG header
2147 nm3/hr.
CW
Fuel gas
and CW
Fuel oil
Kero. P/A
Diesel P/A
Diesel R/D
MPS 59.8 m3/hr.
•
Cold High Pressure Separator
(CHPS)
z Cold High Pressure Separator (CHPS), - Separates the reactor effluent
into hydrogen-rich vapor, water, and hydrocarbon liquid reaction
products.
z The CHPS hydrogen-rich vapor steam (recycle gas) is sent to the high
pressure centrifugal separator to ensure no liquid entrainment.
Hydrocarbons make amine foam.
z The relief valve for the high pressure loop is located on the CHPS. The
set pressure of this pilot-operated relief valve is 5% greater than the
normal operating pressure of the CHPS .
z HP H2S Absorber, 207-C4 - Scrubs H2S from the recycle gas stream by
contact with lean amine to help maintain high H2PP.
z The temperature of the lean amine must be maintained 5°C hotter than the
feed vapor temperature to prevent and condensation of the vapor on
contacting the lean amine. (This is critical in preventing foaming in the
absorber.)
HSD
STRIPPER
Operating condition
Fresh Feed Rate, BPOD (112% of 37,400
Design)
Fresh Feed Rate, MM MTPA 1.85
LHSV, 1/Hr (Note 1) 0.8
Gross Conversion, Vol % 54
Total Catalyst Life, Yr 5 (With Regeneration)
207-R1 207-R2
2
Reactor Pressure, kg/cm (g)
SOR/EOR
Inlet 172.5/176.0 167.4/167.4
Outlet 169.0/169.0 163.9/163.9
Average Hydrogen Partial Pressure, 145 135
2
kg/cm (a)
Reactor Temperature, ºC
SOR/EOR
Inlet 378/396 378/396
Outlet 411/429 411/429
Maximum 440 440
3 3 845
Gas to Oil Ratio at Reactor Inlet, Nm /m
Number of Reactors 1 1
MAKE-UP H2 PURITY 99.5%
CHEMICAL H2 CONSUMPTION 262nm3/m3 of feed
HYDROGEN BLEED nil
Process variables
Process variables
1. FEED EFFECTS.
2. HYDROGEN EFFECTS.
3. CATALYST EFFECTS.
1. Reactor temperature profile.
2. Catalyst Average Temperature.
4. REACTION SECTION OPERATING
EFFECTS.
5. FRACTIONATION AND LER OPERATION
EFFECTS.
Process variables
- Feed effects
FEED EFFECTS:
1. LIQUID HOURLY SPACE VELOCITY
(FEED RATE)
2. NITROGEN.
3. ASPHALTENES.
4. METALS
5. POLYCYCLIC AROMATICS
6. SULFUR
7. CHLORIDES
Process variables- LHSV
Liquid Hourly Space Velocity (LHSV)
CONFIDENTIAL
Property of Chevron
To be Reproduced and Used only in
accordance with written permission of Chevron.
Naphthenes, LV % 32 62
(Estimated)
Aromatics, LV % (Estimated) 2 8 22
Note: Co- more than 30ppm and reactor temp less than 200°c, the
chances of nickel corbonyl formation is more. Which is highly toxic
Example: Effect of Increased Make-Up
Make-Up
Hydrogen Purity on Product Properties
and Cycle Length
SSOT Operation, System Pressure= 169 kg/cm2
2 2 2
Make -Up Purity, % 85 96 99.9
Recycle Gas Purity, % 75 86.5 90
Hydrogen Partial Pressure, 125 136 140
kg/cm 2G
Jet Smoke, mm 18 20 21
Diesel Cetane Number 50 53 55
Cycle Length, Months 14 24 29
Process variables:: Recycle
Recycle Gas
Gas Rate
Rate (Gas/Oil
(Gas/Oil
Ratio)
Ratio)
z
z Effects
Effects of
of High
High Recycle
Recycle GasGas rate
rate (Gas/Oil
(Gas/Oil Ratio)
Ratio)
z
z Decreases
Decreases Catalyst
Catalyst Fouling
Fouling
z
z Maintains
Maintains High
High Hydrogen
Hydrogen Partial
Partial Pressure
Pressure inin Reactors.
Reactors.
z
z Providing
Providing aa heat
heat sink
sink for
for high
high heat
heat of
of reaction
reaction in
in the
the
bed.
bed.
z
z Helps
Helps Distribution
Distribution ofof Reactants
Reactants Over
Over the
the Catalyst
Catalyst
Bed.
Bed.
z
z Limits
Limits Bed
Bed Temperature
Temperature Rise.
Rise.
z
z Increases
Increases Catalyst
Catalyst Activity
Activity
z
z Minimizes
Minimizes "Overcracking"
"Overcracking" of of Products
Products by
by carrying
carrying
them
them out
out of
of the
the reactors
reactors before
before they
they can
can re-crack.
re-crack.
(Higher
(Higher Liquid
Liquid Yields)
Yields)
Process variables:: Recycle
Recycle Gas
Gas Rate
Rate
(Gas/Oil
(Gas/Oil Ratio)
Ratio)