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2012 Internation Pet Refining Journal India Lube Paper-TECHNOLOGY UOP Oct12
2012 Internation Pet Refining Journal India Lube Paper-TECHNOLOGY UOP Oct12
2012 Internation Pet Refining Journal India Lube Paper-TECHNOLOGY UOP Oct12
The worldwide demand for lubricants is expected to increase by Lube basestocks are broken into a number of categories
2.6 percent annually through 2015(1), with Asia predicted to (Groups I to IV – as shown in Figure 1). Group I typically are
remain the fastest growing region. Lubricant demand in the conventional Solvent Refined lube basestocks. Groups II and III
Asia pacific region is ~39 percent of the total world demand. were added to lubricant classifications in the early 1990s to
India individually holds a major market position as the sixth represent low sulfur, low aromatic, and high Viscosity Index (VI)
largest lubricant market in the world and third in Asia. Motor lubricants with good oxidative stability and soot handling. The
vehicles are the largest market for lubricants, and growth will be reduction of wax content in the lubricants also improves the
led by strong gains in the developing Asian countries due to operating range and engine, low temperature performance via
exponential growth of motor vehicles, particularly in China and improved pour and cloud point.
India.
Figure 1 Base Oil Classification (API)
Engine components are subjected to enormous thermal and Group I Group II Group III Group IV
mechanical stresses during operation; hence lubricating oil plays 80 < VI < 120 80 < VI < 120 VI > 120 PAOs
an important role in internal combustion (IC) engines for % Sat <90%
% S > 0.03
(Group II + > ~ 110) (Group II + > ~ 130)
% Sat <90% % Sat <90%
Chemical RX
increased efficiency, higher performance, trouble free % S < 0.03 % S < 0.03
operation and durability. Further, in the wake of pressures to Solvent Refining Catalytic Hydroprocessing Single
Component
reduce vehicle emissions and cutting edge technological
developments in IC engines, the role of automotive lubricant Very Wide Group V
Chemical Spectrum Others
has become vital to meeting future demands being placed on IC (E.g. Synthetic Esters)
engine design. Chemicals RX
31
TECHNOLOGY
Figure 2 Global Basestock Lube Production Figure 3 History of UOP's Hydrocracking &
1000 EMRE's Hydroisomerization Progress
UOP & UOP &
Group III Albemarle enter EMRE
750 UOP alliance enter
Group II UOP HC Unicracking alliance
KBD
8
4
6
2
200
200
199
199
200
200
199
199
1960 Process
1950 (hydroisomerization)
Assessment of Industra Data EMRE MLDW™
Process
(lube dewaxing)
overview of some of the main technology advancements both EMRE HYDROFINING™
Process
companies have introduced since the 1950s. (wax and lube)
The catalysts used play a critical role in the economic production The UOP and EMRE Alliance mentioned above was formed in
of the high Viscosity Index (VI) lube basestocks required by the July of 2011. After one year of the Alliance, four projects are in
market. The first step is hydrocracking and/or severe the execution phase. One of these projects is for the production
hydrotreating to remove sulfur and nitrogen from the feed, of Group III lube base oil, two projects are for fuels using the
which are poisons to the downstream catalysts. Also important hydroisomerization platforms, and one has elements of both. In
is the reduction of aromatics via both saturation and boiling one case, MIDW and Unicracking technologies are used to
range reduction due to dealkylation and ring opening which in significantly improve diesel yields. In the second and third
effect raises the VI of the unconverted oil sent to the hydroisomerization platform cases, high-cetane ULSD and high-
hydroisomerization unit. The unconverted oil (UCO) from the quality kerosene that meet a very low cloud point will be
hydrocracking unit or the product from the hydrotreating unit produced. The combination of the Unicracking and lubes
can be processed over the hydroisomerization catalyst which finishing technologies provides customers with the optimum
will isomerize the n-paraffins while saturating the remaining route to high quality API Group III Lube basestock.
aromatics. EMRE's MSDW™ technology is well known for this
kind of chemistry and utilizes the MSDW catalyst. Several There are a large number of operating units in the world
generations of MSDW catalysts have developed over the years making lube basestocks. These applications span the world, but
resulting in both improved stability and yield (Figure 4). a number are concentrated in the Gulf Coast of the United
States and East Asia (Figure 5).
Figure 4 UOP/EMRE Value
UOP Unicracking Catalyst Continuous EMRE Lube Processing
Improvements
HC-310LT
And Getting Better
HC-205LT 1920 1930 1940 1950 1960 1970 1980 1990
2nd Stage HC-215LT 2000
HC-120LT • MSDW-2
1981 2001
DHC-2 HC-130LT 1920 • Lube Dewax ing (MLDW) • MAXSAT-1
DHC-8 • Lube Hydroc racking
HC-115LT Naphtha
DHC-32LT HC-140LT 2005
DHC-39LT 1953 1973 • New MSDW
DHC-41LT HC-43LT • Wax HYDROFINING™ • White Oils
HC-150LT
Distillate Selectivity
HC-53LT
1954
• Lube HYDROFINING™ 1989 2003
HC-185LT • Fuels HDC BTMs to Lubes • M WI
HC-175LT
Max Diesel Distillate Flexible HC-26L 1991 2008
HC-24L HC-29LT • Wax Hydroisomerization • M AXSAT-3
1997
• MSDW-1
Activity
1999
• Raffinate Hydroconversion 2006
Optimized (targeted) hydrogen addition • M AXSAT-2
32
TECHNOLOGY
There are three predominant routes to making Group II and III An alternate route is to mix Group I solvent based plants with
base oils (Figure 6). The route of using lube hydrocracking, Group II catalytic approaches. In this case the extraction unit
MSDW, and MAXSAT technologies to produce lube base oil does part of the hydrocracking work by removing the poor VI
usually produces a Group II basestock simply because the Lube components and some of the nitrogen and sulfur poisons. A
hydrocracker conversion is typically low. This route often significant amount of hydroconversion across a raffinate
produces heavier Lube basestocks. The second approach is with hydrocracking unit (RHC) is still needed to complete
a fuels hydrocracking unit, usually operating at higher the removal of poisons and raise the VI for the MSDW process.
conversion and typically producing light neutral base oils with A more detailed look at the processing steps and chemistry
high VI. occurring in each step during production of the lube oil
basestock using catalytic routes one or two described above are
Figure 6 Typical Catalytic Routes shown in Figure 7.
Lube HC Bottoms The feed represents a typical Arab Gulf VGO type feed. After
Hydrocracker MSDW/MAXSAT hydrocracking, the aromatics are reduced via conversion (ring
opening and dealkylation) and saturation along with sulfur and
Distillate/DAO
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TECHNOLOGY
15 Group III
= Solvent Extraction
13 l Old technology
11 l Limited feed flexibility
9 Group IV / PAO’s
l Medium to low quality feeds require high
7 solvent ratios for higher quality Base Oils
5 l Lower yields of Base Oils
3.5 4 4.5 5 5.5 6 6.5 7 7.5 8 8.5
Viscosity @ 100°C, cSt = Hydrocracking
Lower Noack Volatility for Group II and III l Works with wide variety of feeds
l Converts undesirable compounds into
acceptable lube oil constituents
The Unicracking process, the hydrocracking technology licensed l Hydrogenation reactions without yield loss
by UOP, is the leading technology for conversion of low value l Hydrocracking reqctions resulting in VI
feedstocks into high-value transportation fuel and/or premium improvements
quality lube oil basestocks. Application of the Unicracking
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TECHNOLOGY
HDS HDS
HDN Isom
Ring-Sat. Cracking
Ring Open
Olefin-Sat.
The Unicracking technology embodies a broad portfolio of several of the lube properties improve as indicated in Figure 10.
commercially proven flow schemes and advanced catalysts Pour point reduction and further quality improvement is
(shown in Figure 4). This enables a tailored solution to maximize achieved by using hydroisomerization processes like the MSDW
lube basestock production or economically co-produce lube and MAXSAT technologies.
basestock and high-quality transportation fuel to meet the
refiner's objectives. Hydroprocessing in general is a well suited As feed is processed in the hydrocracking unit, contaminants
process technology to impart molecular transformation like sulfur and nitrogen are removed, aromatics are saturated
required for production of high-quality lube basestock as and the boiling point of the hydrocarbon shifts; thus viscosity
indicated by types of reactions (Figure 9) that are an integral reduces and VI increases as indicated in Figure 11.
part of the Unicracking technology.
Hydrocracking catalyst design requires a fundamental Figure 11 Lube Basestock from Hydrocracking
understanding of reaction mechanism. Hydrocracking catalysts 150 250
are bi-functional catalysts containing both metal and cracking
functions. The balancing of acid and metal functions is key for 140 200
Normal Praffins R - C - C - C - R
R The Unicracking catalyst portfolio (Figure 12) offers a wide
Isoparaffins R - C - C - R
Oxidative Stability
R
Pour Point
Volatility
Solvency
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TECHNOLOGY
Figure 12 UOP Hydrocracking Catalyst Portfolio HC - 115, DHC - 32 LT and DHC - 39 LT produce high-quality lube
HC-310LT
base oil while maximizing yield of distillate fuel. These catalysts
HC-205LT
are capable of producing waxy VI in excess of 135+(Figure13).
nd
2 Stage HC-215LT
HC-120LT
DHC-2
DHC-8
HC-130LT Figure 14 presents VI and viscosity data from a commercial
HC-115LT
DHC-32LT HC-140LT
Naphtha
Unicracking unit producing high quality lube basestock for
DHC-39LT
DHC-41LT HC-43LT
HC-150LT
multiple cycles using DHC - 32 LT and HC - 115 LT catalysts.
Distillate Selectivity
HC-53LT
HC-215LT
• DHC - 8
HC-120LT – Diesel selective
– Large pore structure and saturation activity
• Well suited to feeds with high coking tendency
DHC - 8
HC - 115LT • HC - 115LT, DHC-32LT, DHC-39LT
DHC - 32LT – Maximum H2 addition
– Maximum converted product quality
• Kerosene smoke point – Diesel cetane
DHC - 39LT – Saturation of UCO
• High VI lube base oil
– HC - 115LT first choice for lube base oil
production
36
TECHNOLOGY
Quite a broad range of feedstocks have been processed in The catalyst cycle life of these units is quite long if reasonable
MSDW units ranging from hydrocracker products, raffinate care is taken with the catalysts. The hydrocracking catalysts
products and slack wax from solvent units. The MSDW process typically last 2 to 5 years depending on the feed and design. The
makes all types of lube basestock products ranging from 2 MSDW catalyst typically lasts 4 to 10 years, again dependent on
centistokes light neutral lube basestock through high viscosity the design. There are units that have even achieved 12 year
Bright Stocks (BS). Unit operating pressure varies greatly catalyst lives. The key to long cycle life is feed preparation. One
dependent on the types of feed and product desired. advantage of the EMRE MSDW technology is that the catalyst
has been developed to give a fairly robust sulfur/nitrogen
tolerance. This tolerance enables the catalyst to be less
susceptible to unit upsets and can survive such events with
greater certainty. This greater reliability is critical to maintaining
lube basestock supply to the customer.
37
TECHNOLOGY
M/U H2 Amine
Feed Experience Separator Liquids
• Distillate/LHDC to HP Stripper
NNF S/U Line Product Qualities
• HDC Btms
• HDT Raffinate (VGO/B.S.) • Vis range 2, 3, 4, 5, 6, 8, 10 cSt. to B.S
• VI’s from Grp II 95 VI to Grp III+ 145
• HDT Slack Wax • LN’s Low CCS <1500 cP at -30 C
• Blocked and Broad Cut
S/U – Internal Liquid Recycle
6 Kinetic Control
Equilibrium Control 800
Saturates, Wt-%
4 80 400 psig, H2
0
0 20 40 60 80 60 Increasing Pressure
Relative Temperature
200 240 280 320 360 400
Temperature, °C
38
TECHNOLOGY
Figure 18 South East Asia (SEA) Lube Complex Includes a Unicracking and MSDW Plant
Lubes Stock
Unicracking Lubes
VGO Unconverted
Oil EMRE Lubes
Distillation
Vacuum
Atm
Resid
DAO
The Alliance has been awarded four projects already, including The objective of this complex is to produce lube base oil and fuel
Lubes and Fuels projects, as listed in Table 2. in blocked out mode. The lube block will process a blend of feed
that contains vacuum gas oil (VGO), 100N wax, 400N wax and
Table 2. Alliance Projects since Summer 2011 BSHVI wax from an existing MEK unit. The quality of the feed
blend for the Unicracking Unit is in Table 3.
= Lubes
l South East Asia - Lubes and Fuel Table 3 Unicracking Unit Feed Properties
l Europe - Group III Plant
Property
= Fuels Gravity, API 19.01
l Central Asia (70 KBD+) Specific Gravity 0.9402
l Russia (30 KBD +) Sulfur, Wt-% 2.88
Nitrogen, Wt-ppm 1030
The Lube projects include a South East Asia (SEA) lube complex Distillation D-1160
project and a European project to make Group III lube IBP, °C 505
basestocks. The SEA project under design is a grass roots project
that includes a Unicracking Unit and a MSDW Unit. 5% 407
50% 497
95% 566
FBP 714
39
TECHNOLOGY
The MSDW unit will process UCO from the Unicracking unit for Figure 20 MIDW Catalyst Operates with
the production of high-quality Group II Base Oils. The primary Excellent Diesel Selectivity
target is to maximize the production of 500N and 100N lube 100
base oils and meet the Group II quality target listed in Table 4. MIDW Operating “Range”
90
Table 4 Lube Product Specifications
40