Technical Information Package for Shell Thermal Conversion Technologies Proposal No. 3-3676 ABB Lummus GlobalABB Lummus Global B.V. TECHNICAL INFORMATION PACKAGE a Index 2A 22 23. 2a 25 26 ar aa 32 InLkODUGHIUN \VISBREAKER HISTORY AND DEVELOPMENTS. CHEMISTRY CF VISBREAKING. ‘CONVERSION AND VISCOSITY REDUCTION PRODUCT PROPERTIES AND USE TECHNOLOGY OVERVIEW INTRODUCTION ‘SHELL SOAKER VISBREAKING TECHNOLOGY ‘VACUUM FLASHER TECHNOLOGY SHELL DEEP "HERMAL CONVERSION TECHNOLOGY SHELL THERMAL. GASOIL PROCESS UPGRADING POSSIBILITIES FOR THE VISBREAKER UNITS. PLANT AVAILABILITY COMPETITIVE ADVANTAGES ‘COMPARISONSHELL SOAKER VISBREAKER VS, COI VISBREAKER TECHNOLOGY LICENSING FROM ABB LUMMUS GLOBAL EXPERIENCE SUMMARY LICENSE SUMMARYABB Lummus Global B. ‘TECHNICAL INFORMATION PACKAGE : 1. Introduction VISBREAKER HISTORY AND DEVELOPMENTS ‘Thermal crackrg units bull before 1980 were plagued wih coking and mechanical prob- Jems. In these units, cracking was iilated in a hater and completed in a soaking drum. uns were shor, largely because the important parameters of cracking were not well under. stood ‘Because of the problems with coke formation in the soaking drum, vsbreakers after 1933 wore the coll cacking typo. Tha soaking drum was eliminated and the heater outlet tom- perature increased, so tha all cracking coud take place in the heater. Improved heaters and heap fuel largey contributed to this change. ‘Thorefre, it wes natural to build this same lype of visbreaker when visbreakers became popular in Europe after 1960. One advantage was thatthe higher cult temperature perme fed deep flashing of visbreaker efluent without the application of high vacuum, so that in ad lion to middia ditlato a heavy gas ol could be produced. This could be cracked to yield ‘datonal middle dstilates, ‘The depth of flashing was, however, not very impressive: and whenever larger quantities of thermal cracker feedstock were required, a vacuum flasher for the residue was necessary. Most ofthe Vsbreskers bull between 1960 and 1975 were combined with heavy dss thermal eracking units, ‘These combination units wore particularly usoful in reducing the heavy uel pour point wien waxy feedstocks were processed, such as those originating from Libyan crude os ‘The thermal cracking residues from these feedstocks have pour points which can be 1510 20°C lower than those ofthe comesponding heavy gas ol feedstocks. ‘AL about the sae time that ABB Lummus Global started to design and construct several \sbresking unis for Shel, a separate program was launched by Shell intomational to oa Vert some old thermal cracking units into soaker-type visbreakers. The fst of these units was started up in 1962 in Curagao. twas soon folowed by other units. “The main abjectve was fo achieve @ maxinum visbreaking copay fr a yi esi |t'soon appeared thatthe soaking units had a number of additonal advantages. ‘Since the oll cris in 1973, these advantages became so pronounced that Shell started to Convert its existing visbreaking-thermal cracking unit into soaker4ype visbreakers. Vacuum flashers were aided to increase the production of thermal cracker feedstock. All now vis- breakers bul by Shell are ofthe soaker ype Refining developments have also played a role in the expansion of vsbreaking. tn the refin- ery configuration which has developad over the last 10 years the catalyc cracker has played 2 predominant ole In meeting gasoline requirements. This and cat cracker demands on ‘vacuum gas ol, combined with te reduced demand for heavy fuel ol, has led to the present LUpsurge nthe construction of vibreakere for heavy vacuum reigues,ABB Lummus Global ‘TECHNICAL INFORMATION PACKAGE 1. Introduc! 12 In addition, visbeakers have been buit or planned for long reside feedstock forthe simpler hyroskimming refineriss. ‘These units can be bull as single stage visbreakers wit soakars ‘ras combination units with an addtional thermal cracker heater for heavy gas ol. Alter rately, the heary gas ol can be used as feedstock for the catalytic cracking uni (CHEMISTRY CF VISBREAKING ‘A residual ol can be described as colloidal system in which the dispersed phase consists ‘of micalle contaning asphaltenes and high molecular weight aromatic malthenes. The can- tinuous phase contains the balance ofthe malthenes. Asphaltenes are, in general, very complex hghmolecular weight hydrocarbons containing very ite Rydragen. ‘They also contain sullur, nitrogen, and oxygen, and hava a stfong aro ‘matic characte and aliphatic side chains. They are very soluble in carbon ttrachorde, car- bon disulde, nd aromatic hydrocarbons, but notin Fgh, parafirichytrocarbons. Malthe es are solublein al kinds of hyérocarbons and in carbon dls, ‘The micelle consists of a core of asphaltones to which high-molecular-welght aromatic Iy- rocarbons from the malthene racion are absorbed, To these high-molecular-welght aromatic hydrocarbons, other hydrocarbons with a some- ‘what higher hydrogen content are absorbed, unl the micelle at ther periphery contain fy- Grocarbons wih a hydrogen content about equal to that ofthe eantinuous malthene phase. Ina stable ol, he system of absorbed malthanes is such that all absorption forces are satu rated, The micale is then in physical equilibrium with the surounding of phase. In other ‘words, the aspaenes are peptized “The absorption equlbium can be csturbed in several ways, for instance, by adding hyteo- catbors with a high hydrogen content (aliphatic hydrocarbons) and by Increasing the tem- perature. Part of te absorbed compounds then dissolve inthe continuous malthane phase, ‘hereby the asphaltene cores precipitate. During the vistreaking process, the continuous oll phase is cracked to smallor molecules. ‘Also, new asphaltenes are formed from malthenes, and the malthene phase compostion changes in character. Eventually the equilorim between asphaltenes. and malfones is disturbed to such an extent that part ofthe asphaltenes flocculate. AL thal pol, the cracked ue ol becomes unstable, “The cracking reactivity ofthe various hydrocarbons difers forthe various classes of hycko- ‘carbone, and deereasae Inthe flowing order aap Paget‘ABB Lummus Global 3.V. ‘TECHNICAL INFORMATION PACKAGE 1. Introduction = Nomat pans = Isorparating | Cycloparatins = Aromatics fm Naphthones 8 Polynucear aromatics, Paaffins aro mestly cracked to smaller paraffins and olefins. Practically no carbon and ty ‘regen are formas, 80 that no coke formation takes place inthe primary cracking reaction, {An olefin Is racked to form ether two smaller olefins or olefin plus diolefin. The cileins ‘usually have shot chains, and the amount formed is less at lower cracking lomperatures. 'Naphthenes and aromates with ong sie chains are mainly cracked so that the side chains fare shortened to methy! of ethy groups. Cracking of naphinene rings usually does not start al temperatures below 480°C. ‘Apart rom exacting reactions, several ther reactions take place, particularly when aromatics ‘and polynuclear aromatics are present. For instance, inter and intramolecular condensation cam take place as showin Figure 1 ‘Aromatic and Polynuclear Reactions ‘Condonsation Reactions "22 paphltene Formation 000-600-090, oO Figure 1ABB Lummus Globa B.V. ‘TECHNICAL INFORMATION PACKAGE rN PA 1. Introduction “The condensation reactions are argely responsible forthe formation of asphaltenes which, at increasing conversion eventually leads asphaltenes to precipitate and, therefore, produces Unstable fue ol ‘The concept of stability and how itis affected by visbreaking is Hustated by Figure 2. In tis cliagram, the comers represent three components of a residue: asphaltenes, parafis, and ‘aromatics. An area of immiscibly exists Btwoen the asphaltenes and para, as already implad by the defntton of asphaltenes, namely the material preciptated rom an oll product by the additon of heptane ar pentane, Stability of Residues Asphatene arate ‘aromate Points x igi Reskve Figure 2 ‘Suppose a restlue has a composition represented by point A, which is in th stable region, DDutng the vsbreaking process, asphaltenes are formed af the expense of aromas, so that the composition moves ino direction B. At to high a conversion, the composton can move int the unstabls region, In practice, a safe margin should always be Kept to account for disturbances in the colloidal sucture bacatse of prolonged storage at elevated temperature, oxidation by a and other factorsABBLummusGlobalBV. TECHNICAL INFORMATION PACKAGE FADED 1. Introduction 13 ‘Also, adaing ctterstock to obtain a spectied viscosity may have a negative effect on the stabilly, depencing on the nature af the cutlerstock. Possible effects of cutterstockadtion fare shown in Fgura 2. The stably can ether be Improved or impaired as movement occurs ‘way fom or towards the region of immiscibilly. Figure 2 only gives a qualitative insight into the stabilty phenomena because aromatic is rat the only yaristick forth sulabilly of cutterstock. A more quantitative insight can only be ‘biained by long term practical expenence and laboratory testing CONVERSION AND VISCOSITY REDUCTION “The effect of vibreaking operation can be expressad in terms ofthe conversion or yield of light products. Atrnatly, it can be expressed asthe reduction in vscosty of the product “The maximum allowable conversion is the amount of light material formed below a certaln ‘tue boling port (TBP) cat point; the remaining heavy material above that cut point i just stable For the Shell Thermal Conversion (SSVB) process, a cut point of 165°C is the normal refer- ‘ence point. The conversion by this definition is liferent for various feedstocks because of the “lerences In chemical and colloidal nature, as has been noted 1 viscosity redustion is used as a yardstick, it refers tothe viscosity ofthe materia boiling Above 168°C inrelation ta the feedstackviscosty ‘A ew points should be made regarding the terms conversion and vscosiy reduction: 41. Conversion at 165°C dies from actual conversion because the feedstock is also can- verted int ight and heavy gas cll an one hand and asphaltenes on the other. 2. The stably requirement may difer from case to case. When th fuel oil has tobe kept in storage fra tong ime, the limits are much more stingent than when the fuel ols UUsoa immsdatoly ter has been produces. Also, manne dleselInsialatons are ‘uch more sensitive to plugging than large uly bole. Therefore, the conversion to be appliedin practice depends largely onthe cumstances, 3, The stably may change ater the requited cuterstock, but the fuel must be sil stable Parieular care should therefore be exerise in cases where the qualty and quantiy of culterstock are not known beforehand. This is often the caso in coastal refineries, vere proiucts are shipped without knowing th final destination. This is an addtional actor tobe taken into account in the day-o-day operation of a visbraaker. ano rT SSR sama FbaleABB Lummus Global B.V. TECHNICAL INFORMATION PACKAGE - 1. Introduction 4, The comersion of a visbreaker, infact, s expressed inthe amount of unwanted prod Luc because the goal isto reduce the viscosy of the 165°C-plus product. In other ‘words, fo reduce the viscosity of the combined distilate and residual fue, the simulta. neous preducton of gas and gasoline is necossary oul 5. A perhaps more useful way to express the effect of visbreaking is the amount of a ‘standard eultortack needed to blend the vishroken residue to No, 6 Fuel Ol viscosity (0f 3,500 Sec. Redwood | (RI) at 100°F compared to the amount ofcutestock needed forthe feodstock In Figur 3 this cutlorsock quantly is given as a function of the can ‘The reduction in cttestock snot proportional to the conversion, but the effect b= comes less as the conversion increases. Cutterstock Required as a Function of Conversion Taaamn anaABB Lummus Global B.V. TECHNICAL INFORMATION PACKAGE 1. Introduction 14 PRODUCT PROPERTIES ANU USE ‘As has beon mentioned, the product propertis fr col vsbreaking and the Shell Soakor Vis- breaker process are, fr all practical purposes, the same. The ony pronounced diference is Inthe degree of saturation ofthe ight components “The Ce fraction fom a Shell SoakerVisbreaker unit, fr instance, contains abaut 35 percent ‘lfc materials, whereas forthe cal process this runs from 40 1 50 percent, “his diference reflects the ference in cracking temperature. The quantities of gas pro- ‘duced, about 2 at. porcent on feedstock, usually do not warrant the recovery of LPG. Most ‘often, afer remcval of hydrogensulde, this gas is used as fuel gas. ‘The average properties of gasoline and gas ol produced by the Shell soaker visbreaker are listed in Table 1 ‘Table 1: Typical Soaker Visbreaker Product Properties Gasoline (C5-165°C) Specie gravity o74 Ft lear 7 + 1.5 mI TELigal 7 F2dear ow +1.5 mI TELgal cy Nitrogen, ppm 50 Bromine number, a/100 9 CF Gas 011 (165-350°C) Specie gravy osr Bromine number, 9/100 g 25 Diesel index (ater Hydrotreating) 50 Because the gasoline is olefnic, sensitviy and lead susceptibity are rather poor and so Is the octane number. To improve the octane number, the heavy portion ofthe gasoline can be treated na caliyic reformer after having been hycrrested frst for saturation of olefins nd removal of sulABB Lummus Global TECHNICAL INFORMATION PACKAGE 7 Ah aD PADD 1. Introduction Ifa mulimetalle catalyst is used in the reformer, the iragen content must be reduced to @ level oft ppm by the hydrotteater. This may require a rather high reactor pressure and the Use of penal catalysts. ‘The light poten of the gasoline, which has a research octane number (RON) of about 80, can also be add to the gasoliie pool afer Merox teating. Sometimes te total visbreaker [pasoine is reprocessed in a cat eacker, which improves the sab to such an extert that ‘only a sweetening step is required for mereaptan removal ‘The visbreaker gas oll as it comes from the unit isnot color stable. Therefore, it should be hydrotreated te make it sutable for dstilate fuel oll use unless the quantty inthe total fuel pool is intod. When the gas ols used as residual fuel cutterstoc, the hydrateating step an be omitted unles itis required for desulturizaton. ‘The most important propery ofthe vsbroken residue isis viscosity in connection with ts stabilly. The viscosity reduction that can be achioved isa function of the nature ofthe food sock, which determines the maximum possible conversion and feedstock viscosity. For the final product specications, other properties (Ike specie gravity, sulfur content, and Conrad ‘son carbon corten) are of interest. But these again depend onthe feedstock characteris, For a typical Middle East residue, vsbroken residue properties ae given in Table 2 “Table 2: Typical Feed Residue Propertos (Middle East Crude) Feedstock Visbroken Residue 550°C us 350°C pus Speci graviy 1.008 11038 ‘Suu, wt percent 35 37 Viscosity @ 53°C, St 48,000 16,000 CConradson cabon, wt percent 170 ae “The resi is nostly used as a heavy {yl oll component. in some refineries the residue is subject to vacuum flashing fo oblain a ditllate for use as supplemental cat cracker foed- Stock. Part of he eyele al produced inthe cat cracker fs then used as a cullersock forthe vvacuum-fashed residue, ‘Another posstility Ist utize visbroken residue as feedstock for a paral oxidation uni for bhyerogen or synthesis gas production. In this case, here are no stringent stably requ ‘mens fr the vsbroken residue, so that substantially higher conversions are possible. ‘Shell Thermal Sonversion processes are ideally suited for such an operation because any Coke formed as a result ofthe high conversion wil not deposit onthe heater tubes where the ‘conversion f 8 within acceptable lis,ABB Lummus Global B.V. TECHNICAL INFORMATION PACKAGE 1. Introduction In rotneros with lube of feces, the propane or butane asphalt from deasphaltny opera- tions can also be used as foadsiack toa visbreaker, Because of ther extremely high viscos- ly, these asphelts are usually cracked in admixture with straight run residues. Visbroken residues fom pure solvent asphall would not meet some ofthe current uel ol specications, Ty FasoABB Lummus Globa BV. TECHNICAL INFORMATION PACKAGE 2. Technology Overview ‘The three main configurations of Shell ermal conversion technologies are ‘= Shall Socker Vebreaker without Vacuum Flasher Shell Sccker Viebroaker wih Vacuum Flasher ‘5 Shell Socker Visbreaker wih Vacuum Flasher and Distllate Conversion (Shell Thermal Gasol Prcess) “The main difersnces between the three configurations ae the products they delve. The bar sc Sholl Soaker Visbreaker without Vacuum Flasher praduces gas, naphiha, and gasol addtional prodiis. The Shel Soaker Visbreakor with Vacuum Flasher has an adlional heavy (or Vacuum) gas ol produc. In the Sha Thermal Gasol process, the adcional heavy ‘gasol product thermally converted to lighter gasal “The ferent technologies are deserbed in more detalin the paragraphs tha flow. RSE aR PapaABB Lummus Global B.V, ‘TECHNICAL INFORNATION PACKAGE 2. Technology Overview 224 SHELL SOAKER VISBREAKING TECHNOLOGY OVERVIEW ‘The Shell Soaker Visbreaking process is ideally suited for the reduction of heavy fue oll product via resi! vsooslty reduction and maximum production of dsllates. Typical appica. tions include almospheri: and vacuum resids and solvent deasphaltr pich, The Shall ‘Soaker Visbreabng process is oily Hoansed by Shell and ABB, ABB and Shell rave extensive technical and commercial experiance in soaker visbreaking, ‘which results in highly efficient and reliable units. Over 80 Shell Soaker Visbreaking unis have been bull 3r converted ram cal vibreakers and crude units. (Over 70% of te total visbreaking capacity bull during the last 10 years was based on this, Shel technology. It offers demonstrated advantages that include significantly lower fuel me (quirements, incteased heater run length, and higher conversion operation with better viscos- iy reductionABB Lummus Global B.V. TECHNICAL INFORMATION PACKAGE - 2. Technology Overview 222 “The technology provides retiers with the means to conserve valuable cuter stock while st producing high qualty, stable ful ol, This conservaton of valuable ctler stock, cambined With fue savings derived from the technology, offers an overall cst advantage thal leads to project payouts of one to two years, SShelfe viebreaking pracess can be tallord to meet the refines’ specific needs. A vacuum ‘lasher can be added to obtain increased distilate recovery. Incorprating two-stage cracking in-combination with a vacuum Rasher wil increase conversion an dstilate recovery. With typically 20% ofthe vacuum resi fed converted to dilate and lighter products, Shell ‘Soaks Visbrerking i ane ofthe lowest east canversion process optons, PROCESS DESCRIPTION Rosid food is pumped through prebeal exchangers before entering the visbreaker heater, ‘where the resi is heated to the required cracking temperature. The high effciency heater i also utlized fo superheat sipping steam. Heater ofuent i sent tothe soaker drum where ‘most ofthe theme cracking and viscosity reduction takes place under controlled conditions Soaker drum effluent is flashed and then quenched in th fracionator. Heat inlogration is ‘maximized in der to keep fuel consumption toa minimum. The flashed vapors can be frac- tionated into ges, gasoline, gasol and visbreaker residue Liquid visbreater residue is steam-stipped in the bottom of the fractonator and pumped through the cosing cicult to baler limits. Visbreaker gasol, which is drawn off as a side ‘steam, is stear-sipped, cooled and sent to battery limits. Atematly, the gasol fraction ‘can be included withthe Visbroaker effluent. It is also possible to obtain a heavy vacuum ‘gasol fraction by adding a vacuum fasher downstream of the fractionator, Cutter stocks, suchas ight cyte ol or heavy atmospheric gasol, may be added fo the vis- breaker residucigas oll mixture to meet the desired fuel ol specication PpsABB Lummus Global B.V. TECHNICAL INFORMATION PACKAGE 2. Technology Overview Products yiekls are dependent on feed type and product specications. Typical product elds for Middle East crude are given below Feed vacuum resue Mile East Viscosity, eSt @ 100°C 77 Products in % wt on feed 8 23 gasoline ECP 165°C 47 jgasoll ECP 350°C 140 residue ECP 359°C + 70 Viscosity 165°C pus, cSt @100°C ora 224 ECONOMICS ‘The investments inthe order of 1000 - 1200 USS/bb installed excluding treating facies ‘and depending on capaci Utiities,typicalper bbl @ 180°C: fuel, Meal 16 clectrity, kWh os net steam production, kg 18 ‘coating water 010ABB Lummus Globa B.V. TECHNICAL INFORMATION PACKAGE 2. Technology Overview 23 23. VACUUM FLASHER TECHNOLOGY ‘OVERVIEW ©0000 ‘The steady diep in heavy fuel ol demand has asked for further developments in Vsbceaker ‘Technology. Stell Global Solutions has developed the Vacuum Flasher Technology, for ‘hich ABB Lurmmus Global ats as the authorized leensor. ‘Vacuum Flasher Technology has two major advantages when added to @ Shell Soaker Vis- breaker LAddtonal dlstiiate products are belng produced which are sutable for thermal crack- ing, cata eracking or hycacracking to improve the overall performanoa of tha rin: en IL Ihproduces a heavier, more viscous residue, which i stil suitable for fuel blending or \which can be gasiied to produce hydrogen and can be used as ful fora power plant directABB Lummus Global B.V. TECHNICAL INFORMATION PACKAGE 2. Technology Overview 292 “The shell propretary design oF me transfer ne between the axmospheric Fractonator anc the Vacuum Flasher and of the Vacuum Flasher internals minimizes coke formation and hence maximizes te runlength This design also ensures a maximum yield of dstilte prod: ucts while entranment of heavy residue is avoided. ‘large number of Vacuum Flashers downstream of viebraakers and thermal gesol units are in operation. Shall Soaker Visbreaker unis have successfully been revamped with the ada- tion ofa Vac Flasher. IMPLEMENTATION When a refinery has a Visbreaker unit in operation, its worthwhile to investigate whether additonal distlate processing capaci is avalable If his isthe case, revamping the Vis~ breaker unit using Vacuum Flasher technology wil result in more dstllate products, and thus improved merging. \With a liited émount of investment, Vacuum Flashing technology offers two advantages, ‘over Visbreaker uns without a Vacuum Flasher: 18 Adltonal state products ae produced which are sutable for thermal cracking, ‘cata ecacking or hycrocrackin. Ths resuls In improve economies ofthe refinery. = Itproduces a heavier, more viscous residue, which sil suitable for blnding int fuel cl and canbe bummed inthe refinery ful system. Asan alterative, this residue stream ‘can be gasitiod ta produce hydrogen and is then used as fuel for a powerplant crecty \When a Vacuum Flasher is added to a Visbreaker unit, only minor modifications to the Frac- ‘nator system are required. The feed preheat train and product rundown wil ypically be ‘checked forthe Yew situation, “The Vacyum Fsher concept has evolved from the crude J vacuum column dosign. In a ‘Vacuum Flashar th following products are produced! Hssvy Gx Oi (H00) Vacttim Ges 0 (G0) '= Vacuum Fashed Visbreaker Residue “Typlal product yllds (nwt % on total feed to the Visboaker unt for moderate conversion rates are: 60 1.2% ‘utpoint 350 - 365 °C veo 11-15% cutpoint 365-520 °C VE Residue 65-70% —cutpoint 20°C plus‘ABB Lummus Global B.V. TECHNICAL INFORMATION PACKAGE 2. Technology Overview 2a3 By-Products: VF off ga: ome VF SourWater 20k % Stops o1-02m% EcoNowics ‘A calculation has baon dona fora typical visbreaker unit witha capacity of 4000 Usd, proc- ‘essing Middle East Vacuum residue witha viscosity of 3900 cSt at 100 °C. Below, the cifer- ‘ence In blending ofa vsbreaker unit and a visbreaker unt with Vacuum Flasher has been n= ‘Seated, es ors, seeg) VBP ym [VBR 5 we a or) (6ASOL wo or A ot “Teme vepe a Figure 4: Blerding example ‘The dilerence in gross margin between a Shall Soaker Visbreakor and a Shel Soaker Vis- breaker with Vacuum Flasher is approximately $5 per ton of residue feed. For 8 4000 T/SD \Visbreaker, the advantage Is $ 66 Millon per year. The difference in investment cost for the ain of 9 Versnam Flashor Is anpeimatly 86 klion. The pay out iene for Shel Vasu Flasher technology i thus less than 1 year, ‘Actual pay out time depends on the locaton, product prices, design conversion, feedstock specifications, ateABB Lummus Global B.V. TECHNICAL INFORMATION PACKAGE 2. Technology Ove! 234 PROJECT EXECUTION ABB Lummus Global has history of executing various visbreaker revamp projects. A typical revamp project would start with assessment of operating data of the existing visbreaker plant, folowed by a feasibility study phase, where diferent revamp options are evaluated in ‘rare dota Rests fom the feasibly study ae discussed with the client and a plan wil be ‘made forthe next phase of the project which isthe preparation ofthe basic design package. ‘The basic design phase vl be flowed by the dataled enginoerng “The Vacuum Flasher section can be bul in @ modular way and added next tothe visbresker plot, Given below is an example ofa 3-D madel ofa visbreaker unit which was originally bit by Shell and for which a Vacuum Flasher was aded later on. The Vacuum Flasher saction thas been highighte. 20 model of visbreaker unit with Vacuum Flasher RET EER TRS asABB Lummus Global B.V. ‘TECHNICAL INFORMATION PACKAGE 2. Technology Overview 24a [SHELL DEE [NERMAL CONVERSION I oveRVIEW @ woes © comer ® @ crore ® ‘The Shell Deep Thermal Conversion races fils the gap between vebreaking and coking. ‘was developed based on many years of experience uh tne Shell Soaker Visbreaking prac ss. The process yields a maximum of distillates by applying deep thermal conversion ofthe ‘vacuum residue feed and by vacuum lashing of the cacked residue. High distilate yields Bare obtained wile stil producing a stable iqud residual product, refered to. a8 Vacsum ‘ashed cracked reside. This sream, which isnot suitable for blending to commercial fuel, i vader specily protic, geniicaon err combustor 1 generate power andr ge ‘The Shel Deep Thermal Gasol process is @ combination ofthe Shell Deep Thermal Conver- sion and the Shell Thermal Gasol processes. Inti alterative high conversion scheme, the heavy gasol (GO) from the atmospheric Fractionator and the vacuum gaol (GO) fam ‘he vacuum flasher are converted Ina dstilate thermal conversion healer into lower Boling point gasolABB Lummus Global B.V. TECHNICAL INFORMATION PACKAGE 2. Technology Overview 243 PROCESS DESCRIPTION Deep Thermal Conversion Preheated vacuum residue is charged tothe visbreaker heater and fom there fo the soaker, ‘where the deep conversion takes place. The conversion is maximized by controling the Op: tating tomperure and pressure. The soaker effluent i routed la a eyelane ane the eyone ‘overheads are charged tothe flash zone of the atmospheric Fracionatr to produce the de- Sed products ke ges, LPG, naphtha, kero and gasol. The fraconalor batlome are routed to a vacuum flasher, which recovers addlional gasol and vacuum gasoll (GO). Vacuum flashed cracked residue is routed fr further processing depending on the end use. Deep Thermal Gasoil ‘The heavy gascl from the atmosphers Fractonator and the VGO ftom the Vacuum Flasher fro cracked in a dilate thermal conversion heater. The produc fom the thermal conver- ‘sion heater i rosto to the Fractonatr, YIELOs Products yields are dependent on feed type and product specications. Typical product Yel for Middle East crude are given below Feed vacuum residue idea East Viscosity, eSt @ 100°C 770 Products in wt on feed os 40 gasoline ECP 165°C 80 jgasoll ECP 950°C 184 waxy dstilate ECP 520°C 25 residue ECP 527°C + 474 “aan EDT)ABB Lummus Global B.V. ‘TECHNICAL INFORMATION PACKAGE 2. Technology Overview 244 ECONOMIES ‘The investment amounts to 1300 - 1600 USB/tb installed excluding treating feces and depending onthe capac and configuration Uiities, pica per bbl @ 180°C: fuel, Meat By lectrciy, kWh os net steam production, kg 2 coating water, n® 015ABB Lummus Global B.V. TECHNICAL INFORMATION PACKAGE 2. Technology Overview 25 SHELL THERM. GASOIL PROCESS 251 OVERVIEW OOO0000 [ABB offers the Shell Thermal Gasol process to upgrade atmospheric residue and waxy dis Uilate. Orginaly developed in the 1960s, contiwed improvement in the Shel-designed soaker drum ard heater designs resulted in the present Thermal Gasoll technology, a cam- bination of tree mature, well proven Shel technologies: Soaker Visbreaking Vacuum Flashing = Thermal Gracking ‘Shell was the fst to develop and employ soaker vsbroaking technology. The soaker drum, with patontd internals, achieves higher conversion and improved viscosly reduction com ared to other vsbreakng technologies. Ta PanaABB Lummus Global B.V, TECHNICAL INFORMATION PACKAGE : 2. Technology Overview 282 ‘ABB and Shell have extensive experiance in the design of thermal conversion processes, ‘With continual feedback from operating uns, we are able to provide advanced designs and practical advice on operational matiers. Shells engoing research and development in ther- mal cracking technology and equipment design assures the avaiablty of the most up. dale know-how this fale PROCESS DESCRIPTION ‘Atmospheric residue Is pumped through feed preheat exchangers, where the feed is heated ‘agaist cracked residue, and then routed to the visbreaker heater. In the heater, the feed Is heated tothe required cracking temperature and routed tothe soaker where tha majorly of the thermal crzcking occurs under controlled condtions. The soaker effuent is routed to a ‘clone andthe cyclone overhaads are charged to the fash zone ofthe atmosphere rac- tionatr. Inthe top secton of the Fractonator, the soaker effluent Is spit into four factions: heavy gasol, gaso, naphtha and offgas. The gasol Is taken from the Fractionator as a draw of, stear-strippedin aside stipper to inprove the ash pont, and sent tothe battery leit The Cverhead vapo's are condensed in a two-stage condensing system: in the frst stage, only the refux Is Condensed; In the second slage, the naphtha product's condensed. From the ‘overhead system, the offgas and naphtha are sent tothe battery limit Inside the Fracionaor, the quid is quenched to prevent futher cracking and then sleam- ‘lipped. The hot Fractonator bottoms, together withthe cycone bottoms, are routed to te ‘vacuum flasher where the vacuum gasoil (VGO} is recovered. The VGO is sent, togethar With the heavy gasol from the atmospheric Fracionator, to a dstilate thermal conversion heater where ts partly converted ints lower boing fractions, The heater eluents routed to the fash zone of he atmospherc Fracionator. The unconverted heavy gasol is reeavered in the Fractonato: and Vacuum Flasher and is recycled back to the distilate thermal conver sion heater to maximize the gasl yield, “The vacuumfashed restive Is cooled against the VGO and then by steam generation. The cooled residue sent fo fue ail blending whee itis blended with gasol product andlor other eatlerstocks tomes the specifi fuel ol viscosity a aE aaa TenaABB Lummus Global B.V. TECHNICAL INFORMATION PACKAGE a 2. Technology Overview 253 YIELDS Depend on feed type and product specifications, Feed atmospheic residue Middle East Viscosity, St @ 100°C at Products in % wt. on feed was 64 gasoline ECP 165°C 129 gasoll ECP 360°C 386 residue ECP 52°C + 4A Viscosity 165°C pus, cSt @100"C wW 254 ECONOMICS The investment amounts to 1400 - 1600 USSibbI Installed excluding treating facts and pending an capaciy and configuration Utilities, typical per bbl @ 180°C: ful, Meal 4 electricity, Wn os net steam production, kg 9 coating water, oa?ABB Lummus Global B.V. ‘TECHNICAL INFORMATION PACKAGE 2. Technology Overview 26 264 POSSIBILITIES FOR THE VI upcran REAKER UNITS Three welkproven advanced technologies from Shell are now available fr llcensing ftom ABB Lummus Global, that provide an economical feasible extension and upgrade of the \Vebreaker Unit [SHELL VACULM FLASHER TECHNOLOGY “The Vsbreaker residue sil contains a considerable amount of heavy gasoil (TBP range ap- proximately 350-500 °C} that can be used as an alratve supplementary feed to further ‘grading processes such as catalytic cracking or hydrocracking. Heavy gasollis recovered by ‘Yacuum flashing ofthe atmospheric visbreakor residue. Shell has accumulated avast wealth ‘of rasoarch and operational experince In visbreaker residue vacuum flashing. She's Vao~ ‘uum Flasher technology is available for licensing through ABB Lummus Global. The main {features ofthe Shell Vacuum Flasher Technology ae: '§Excallentlstilate yield, combined with high product qualtes of vacuum flasher dit- lates. 1 Superir‘unlenath, when compared to conventional, open art, vacuum flashers. © vere © oven © rerun © came © seuvrcamnusierABB Lummus Global B.V. ‘TECHNICAL INFORMATION PACKAGE 2. Technology Overview zee 263 [SHELL THERMAL GASOIL TECHNOLOGY ‘Shell Thermal Gasol Technology is utlized forthe production of middle dstilates from t- 'maspheric reside by a combination of visbreaking and distilate thermal conversion. Heavy latilatos withdrawn from the Visbreaker atmospheric Fractonator and vacuum flasher are further cracked in.a separate thermal conversion fumace. This process combines the a. vantages of Shel's visbreaker process with ditilate conversion fumace design. The Shell ‘Thermal Gasol Technology provides an excelent low cast soliton for reducing fuel ol pro= diction. The dillale Thermal Conversion Technology (based on converting dstilate feed) ‘can aso be lcersed separatly, ®00000 ‘SHELL DEEP THERMAL CONVERSION TECHNOLOGY ‘She's latest development in the area of Thermal Conversion is the Shell Deep Thermal Conversion Tecmology. Bue to the increase in nor uel oll outlets of thermally converted residues, new apporuniies. have arson for thermal conversion. The use of undiluted ther- ‘mally converted residues removes the usual stably consrant alowing subetantally f- {eased conversion levels in the operation of a Thermal Conversion uni. In practoe how fer, the maximum achievable conversion levels are often imited by the rapidly decreasing Unit run length. Shell has been able to improve the design and operation ofthe Unit such that high conversion eves can be achieved wile maintaining long rn lengths.ABB Lummus Globa BV. ‘TECHNICAL INFORMATION PACKAGE 2. Technology Overview ‘This technology loses the gap between visbreaking and delayed coking, It realizes most of the delayed coking upgrading while avoiding the drawacks of solids handling. The residual product of Dsep Thermal Conversion remains iquid and is refered to as vacuum flashed (racked residus ‘The main characteristics ofthe technology ae sted below: Can bo eppliod to both Visbreaking as wel as Thormal Gasoll unis. Includes Shel Soaker Visbreaking technology, Includes Shell Vacuum Flasher technology. “Typically 45-55 Sout of Vacuum Residue Is converted to ditilate products Revamp af an existing units possible UUguid reseal proctuct Includes 2ath design and operational know-how, ‘The main benefts of Shell Deep Thermal Conversion technology compared to ‘high conver son’ operation on tradtonal thermal conversion technology can be summarized 28 oloWs: Substantial higher conversion. Longer run length and higher an stream Ume, Higher cstat yields from Vacuum Flasher, Lower casita expenditure. ‘Adéitiond gasol from Vacuum Flasher Improved operability due to use of pressure and temperature as contol variables. (On tha other ste the main benefits of Sell Deap Tharmal Conversion technology compared to delayed coking technology can be summarized as flows: Sight lenor conversion Better quality products Higher sclectity to gasoit Substantaly lower capital expenditure 1 Nosolidshanding RO rT aR aE Toa PanaABB Lummus Global B.V. TECHNICAL INFORMATION PACKAGE 2. Technology Overview 27 PLANT AVAILABILITY Propar dasign ofthe Visbroaker Heater utizing tho exportse of Shol/ABB Lummus Global and proper operon supension, results in an onstream time ofthese heaters of about 350 ‘days per yoar. The fractionation section, the soaker and the heat exchangers in the unt have far longer run lengths. The avalabilly of the Visbreaker Uni is expected to be as shown below Number of decoxing shutdowns per year 1 ‘Average length a decoking shutdown in day's 8 ‘Average total soreduled shutdown days per year’ 14 ‘Average unschaduled shutdown days per year 1 ‘Avalabe stream days per yar 360 Pant avai oa oar Onstream avalilty " pverage scheduled shutdown days pe yar ls based on one major tumaround every four years and ind de coking shutdownsABB Lummus Globa BV. ‘TECHNICAL INFORMATION PACKAGE 3. Compet 3a /e Advantages JREAKEN 1ECHNOU {OMPARISON {ELL SOAKEN VISUREAKING HL ‘The Shell Soacer Visbreaking Process Is low-temperature, long residence time cracking technique. It fers signifcant advantages over conventional heater cal cracking in oper tional flexbilty, Investment and operating cost. Developed by Shal, the Soaker Visbreaking Process fs avaiable worldwide fam ABB, Lummus Global ‘The Shell Soaker Visbeeaking process is a mature and proven technology. Its cuenty

Shel Sonar VatraerTechndagy_SDTE Sha Dany Therma GarsersionTooiogy STG» hal Teal Gc eccagy Fak Vacttm eer Tetcogy Geoamam masa aaa Sena aABB Lummus Globa BV. TECHNICAL INFORMATION PACKAGE 4. Experience Summary Licensee Refneria Ila Curazao SA, Emmastad, Curacao, Netvrlands Antiios Shell Canada Lid, Montreal, Canada Shell Canada Ld, ‘Samia, Canada ‘Shell Nederland Raffnaded - TCL, Pomis, The Netherlands ‘Singapore Petroleum Co. Lid, Pulau Merimaus, Singapore ‘Thal Ol Ref. Co, Ld, ‘Thaland Total SpA, gil, aly (Cie. de Rafnage et de Dstrbution Total France La Méde, France Lindsey Oil Refinery, Kilinghoime South Humberside, Unites Kingdom omvas, ‘Schwechat, Austia Orion Refining Corp, Goca Hope [Norco Louisiana, Unies States Shell Eastem Petroleum (Pe, Lie, Pulau Bukom, Singopore sieP, Aniwerp, Belgium Sa Soo Sater Vitor Toor sr ‘Set Thema! Gas Technology Year Licensed +980 1980 1980 1980 1980 1980 1980 1979 1979 1979 1979 1979 1979 ore oF Capacity, TID 7000 2700 570 4000 4800 4500 4000 4400 4500 7300 Technology Note SSVB Upgrade seve ‘88vB SSVB/SVF/ spTC 88vB sve sve SSvB/VF ssve sv SVF/ST@ Upgrade ‘88vB Sha baap Thermal Govern Teoma ‘Shel cium Flasher TcholonyABB Lummus Global B.V. TECHNICAL INFORMATION PACKAGE 4. Experience Summary Year Capacity, Licensee Licensed _MTID’ Technology Note BPPLC, 1978 500 SSVB//SVF Lavera, France DEA Minerloo! AG, 1978 300 ssve Wesseling, Germany Deutsche Shell AG, 1978 2500 SSVBIVE Herburg, Germany ‘Api Rafiera di Ancona SpA, ser 2000 SSVBIVE Faleonara, Hay Fortum Oll and Gas Oy, 1977 ‘200 ssvB "Nasntal, Finland Netherlands Refining Co. 1977 600 sve Rotterdam, The Netherlands Sto, des Potoles Shel, ser 4100 sve Bere FEtang, France Fortum Oi and Gas Oy, 1976 4800 ssvB Porve, Finland Potoplus, 1876 1900 © SVF/STG (Cressier, Switzerland ‘Shell and BP PLC Petroleum Refineries 1976 4600 SSVB/SVF Ply. Lid. (SAPREF), Durban, SouttAitica Cle, Rhenane de Ratfinage, 1974 3000 SVF/STG Roichstatt- Vendenhsim, France Shell 1974 4650 st Gothenburg, Sweden Shel, 1974 2000 sts. “Teespor, United Kingdom “SSS> Sha Sonar VatrnkerTechmaagy SDTE She Dany Tel Ganson Teadogy {S1G= She Tea ase Tectrlogy SF Shel Vasuen Fader TetnaonyABB Lummus Globa BV. TECHNICAL INFORMATION PACKAGE - 4, Experience Summary Year Capacity, Ucensee Licensed MTID’ Technology Note Shell Eastom Petroleum (Pe. Li. 1973 5500 SVF/STG. Pulau Bukom, Singapore Shell Cia, Argentina de Petroleo SA, 1970 +600 sve Buenos Aires, Argentina Philips 66, Wood River. I, 1968 2900 seve Unted States ‘Shel, Sta, 1988 4000 sts Nenway Deutsche Shell AG- TU2, 1986 2500 SVFYSTG Godort, Gamany [AS Dansk Shall, 1984 4400 VFISTG Upgrade Fredeviia, Denmark Ste. des Petroies Shel, 1963 000 SSVB/SVF Pit Couronne, France Deutsche Shell AG- TEU, 1901 2700 SF IST Godot, Germany Paraguana Refring Center- RV, 1988 000 ssve CardontJudibana, Falcon, Veneziela Paraguana Refining Center-RV2, 1958 5000 ssve Cardontludbana, Falcon, Venezuela Paraguana Ketning Center-RV3, 1958 4500 ssve Cardontiudbana, Falcon, Venezuela hal Grok Vsbaakar Teco SOTO Sha Dep Thana Conarson Techno Shall Theat Gael Tacha SF Shu Vacuum Pusher TeeblogyABD ABB Lummus Global Shell Global Solutions Opportunities for optimization of refineries using ‘Thermal Conversion technologies by F. Hollander, A. Keukens, M. van Es ‘ABB Lummus Global, The Hague, The Netheriands a B. Douwes ‘Shell Global Solutions, Amsterdam, The Netherlands Summary ‘Teena Canversion technologies remain dominant technologies in residue Upgrading In most pata of he word. Tel inpla base process yout has been mined fn econ years fo vera a elabie and ecovonle technology wih ithe advantages over more complex and high investment conversion lechndogles, Also forthe near fire Thenmal Conversion poceseos at txpeca pay a. kay rol. In refnery operations lying on fut Improvements in techrlogy operaton sna unt managemont. Russia and the OS Republes dopond heavy on ful ol and heavy dilate. Not Strpedngly, demand for slate-otho-at Thermal Conversion echnalogies ls {rows bath revamp stuatons and now ppicatan. Shel, wth ABB lms Gita! ee authorized hoansor, has developed innovate Thermal CCorwasion tochologies that la a lading oo in oda’ Yalu upareing ‘marel, bit also Ih the conven of heavy and ach gasll Thal leading role of Shall and ABE haa reultad In more than 0 eperaing Uns ‘trial. Based on he lates! projects, most of ham in assis and te CIS FRopubis, fret cace stds -incidng roving of existhg crude of ‘seating uns, ation othe Sha Vaculm Flasher and grass foots Shel ‘Sate Visbestng, Sho Terma Gasol Process an Shall Deep Thermal CCorwssion uns "ae prosorted showing the epparunites for optimization of roreros using Thermal Conversion tochnolgis” Russian Refining Technology Conference 2001 Page 1 of24ABB Lummus Global Shell Global Solution: Introduction ‘The Shall Soaker Vibreaker procoes has 2 long and sucossl history. The felatonshipbotween ‘Shell ‘and ABE. Lummus Global te faid of breaking woe fest established in the omy sites, wt the canstucton of 2 nurbor of conventonal ot Wsbroskars Gy to ary 10706, tho Shall Sonler Vitreaker concept waa sufi developed Yo be commercialy appt. The procoss wos feensed forth fst me In 1977. At ts tino, Shall apponed ABB ae the authorized leancor forthe process end bocare mote deeply valved In serving thi echnaiogy. The Shel Saker Viebraker Teohnlogy hae eubeequenty becom one ofthe mara widely ‘pple retiing processes. The nue’ of leensad ul ls 90 wi taal ital capac of about 40,000 Tors per day. approxiaing o more than 70 povant ofthe wold’ vsbeakingexpacy i the last decade Uiereaing has shown to be a robust echnoogy in the dynamic rein ‘matket-Athough other compa procescos hae boon developed. Shel ‘Saker Visbeaking remains of ror Importance In th upgrading ef heavy Fesites. Tho ieatation of naw vbroakng plats nowedaye contest the stme pace as inthe 1980's. This succes = bazod on te fundamental Stronths ofthe procees. lt remains lw eat, high conversion. long "un Tengt process thst i very onbla wih regard to feadstok and cperaonsl changes while preducng vauabl ight products and stable ul ot ‘Over the years continued implementation of Improvements a the Sha Saker Vsbreaker process, have rosutod In designs gated to high rolablty and peromanco. She's continuous fot n the davetopment of new epic has resid in new thermal conversion lechnobogies such 1s vacuum flashing technology. deep tharmal cracking and therm gaso2 onvatlon. These new technologies. ate merging, wel-poven and il Wiser the choise of raiere 10 eplinize thr relney wih Thermal CConvrslonscutns “his paper dosoribes in bref our dient Shell Thermal. Conversion lechnaogis leonse by ABB ap authorized leonsor basod on the lost projods in Russia and the CIS’ Ropubles, the Gzach Republe, Germany, India and Saud) Arata. Diferent ase tudes = including revamping of trisirg eres, vacuum or visbreaking Uns, adaiion the Shall Vacuum Foster and. graseoots Shall Soskar Viereokng, "Shel! Thermal Goel Procas end Shell Daap Thermal Conversion unis re presets Fah Proseure Distista Conversion an technologies tha are developed © (co-jrocess slops and asphas. Thase echnaogies ee ame to ect the ‘tue gasal endplt and envionment! spoceaions Russian Refining Technology Conference 2001 Page 20124ABB Lummus Global Shell Global Solutions 2 ‘Techrologies| 24 ‘Shell Soaker Vsbresking Technology (SVB) ‘The Syl Soaker Visbeakng (SSVB) Technology has been developed by ‘Shatin he ate sevens, The tocinalogy has snes evolved her ane has ‘een teeeatly Heoneed and” ppled never 60 uns Wwovielde Sha ‘Soa Visbrakers sess for over 70% ofthe total Vieng capt batt eing bull as 10 years. This makos he moat sucoasstl and dey ape reve upgrading toehnaogy I the wor. ‘The main objective ofthe Shall Sosker breaker Is o reduce the viecosy cof Amspharc or Vacuum Resive, which sgniicanly reduces th need of futergock for blending to commercial fuel ol. Besides te. Visco Fedicton, valuable posucls Bee LPG, Naphiha and Gasol are produced (thar posal feedstocks thal can ba ised sre sepa and slop ‘By siting the majorly ofthe cracking process from the heater cols (2s in akcol designs) to the Soaker dum, prolonged restence ele achived, ‘toni alewor cracking fomperature I combination wth Sel patortod Sake" inamal this assures botiar solo. longer runing, lower ‘enor demand and lower capa invostront ‘The mala characters ofthe tachnology ae «"Typcal feedstock is Vacuum Residue 1 ge ocd stock next empact unit comprising a residue conversion and a fractionation eaten + Repleaton ofa soaking wos th propre inemals + The ameunt and to vzosty of the residue (and hange of the flo) _ae reduce, typical hel oF production resetons of 25% can Be soiowed ‘Tho benefits of tho Shall Soaker Visbroakng tochnolegy compared to tho carvertonal fumace (cl) ecking tecnalogy can be summetzed as ‘alow Lange un lngth and higher on steam tine Irroved Sloe towards Gasot Reduced tel and power consumton wer eal expect Iroroved operably due to use of pressure (Soaker) and tomperature (heaton 36 contelvorattos Figure 21 below presents the Shell Soaker Viebreskerprocass.Prehestod feslue feedstock Is charged to the Vsbreakr hasta (2) and fom tere 10 tha Stokor (2). Tho conversion takes place in both tha Restor and the Sooke’ The operating temperature and prossure are catald such 2610 ‘eodh he dased conversion lvel andor unt capac. Th cracked fede Russian Refining Technology Conference 2001 Page 3 of 24ABB Lummus Global Shell Global Solutions ‘hen charged to an atmosphere tactlonstr (3) to produce the deskes prodkst ke gas, LPG, napa, Keo, gacol and eracked rescue 3 a oat Figue 21 Simpliid Flow Scheme of Shall Soaker Visbroakar Unt Revamping of existing crude and (col) Vistreaker unis is possible, ABB has varied succesfully several existing cll vsbreakers and eude unt into ‘Sha Soaker Visboaker The Russian markat shows reat pont wih ‘growing number of crude and vsbreaking unis nang the ond of ir ‘Sone fe spn. Wits an foment of babweon 30% a 60% of new (g2s8 oot Ui revamping towards a Shell Sooke Vsbreakor fs fost and fw cost sluion to reduce the amount of ellatock requred for he prods of fel (Case: Grass-o0Is Shell Soaker Vsbreaker Unit ent ‘ichinstecrgsiniaz Projet’ ase Deulgn and Engineering Detaled Engineering Tine ‘04 200" Background: ‘The projet involved the implementation of row Shel Soaker breaker Unit Eonssing ofthe foaming elements 1+ Food heating nd reaction Frectonation and reais tipping 2 casal sipping Napa stabilzation 1 Orgas emine absorbe Russian Refing Technology Conference 2004 Page 4 of24