Modern lube refining technology - Part 2

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Concept of Shape-Selective ZSM-5 Dewaxing Catalyst. Cracking High-Pour Paraffins into Naphtha and Gas. Reduction Coking Propensity through Reactant-Shape Selectivity

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Nội dung Text: Modern lube refining technology - Part 2

____________________________ MODERN LUBE REFINING TECHNOLOGY ________________________________________ MLRT Le Ngoc Quang, PhD HANOI UNIVERSITY OF TECHNOLOGY MLRT-LNQ Hanoi University of Technology 1
Trends in Lube Refining  Lube Crude Supply  Processing MLRT-LNQ Hanoi University of Technology 2
Lube Crude Supply Trends  Premium Crudes Declining  Increasing Effort to Obtain and Approve Replacements MLRT-LNQ Hanoi University of Technology 3
Future Lube Processing Objectives  Improve Yields of Lube on Crude  Make Acceptable Lubes from Lower Quality Crudes  Replacing Solvent Refining Steps With Catalytic  Processes Can Help Meet These Objectives. MLRT-LNQ Hanoi University of Technology 4
Major Processing Trends (cont’ d)  Mobil Lube Dewaxing (MLDW) - Catalytic Dewaxing to Replace Solvent Dewaxing  Wax Hydroisomerization (MWI) - Extra-High VI Base Stocks - Production of Group III Stocks  Severe Lube Hydrotreating – LHDT - Replacing Furfural Solvent Extraction - Group II Stocks Production  Lube Hydrocracking  Group II-III Stocks Manufacture MLRT-LNQ Hanoi University of Technology 5
M L D W Mobil Lube DeWaxing Catalytic Replacement for Solvent Dewaxing MLRT-LNQ Hanoi University of Technology 6
Lube Oil Base Stock Manufacture: MLDW Catalytic Dewaxing Process VACUUM WAXY DEWAXED LUBE BASE NEUTRAL DISTILATTION DISTILLATES RAFFINATES OILS STOCKS FURFURAL MEK CLAY 1 SOLVENT 1 SOLVENT 1 OR 1 EXTRACTION DEWAXING HYDROGEN FINISHING 2 2 2 2 ATMOS. FURFURAL WAX 3 RESID 3 3 3 EXTRACT (FOOT OIL) 4 4 4 Propane Light Hydrocarbon De - DE-ASPHALTED asphalt 4 CATALYTIC OIL DEWAXING ASPHALTS VACUMM RESID. * Tanks Represent Different Viscosity Grades MLRT-LNQ Hanoi University of Technology 7
MLDW Flow Diagram MLRT-LNQ Hanoi University of Technology 8
MLDW Operating Conditions H2 Partial Pressure: 400 psig H2 Circulation: 2500 SCF/B H2 Consumption: 100 – 250 SCF/B Space Velocity: HDW 0.3 – 1.0 LHSV HDT 1.0 LHSV Operating Temperature: HDW 520 – 675oF HDT 450 – 525oF MLRT-LNQ Hanoi University of Technology 9
MLDW Catalyst: ZSM-5 Zeolite Note: Zeolite Synthesized by Mobil (ZSM) MLDW Catalyst: 10-Member Ring Structure Medium Pore Zeolite - 65% ZSM-5 on Al2O3 Pore Dimension - 1- 4 wt% Ni 5.3 x 5.6 A0 Straight Channel 5.1 x 5.5 A0 Sinusoidal Channel MLRT-LNQ Hanoi University of Technology 10
MLDW Dewaxing Principles  Concept of Shape-Selective ZSM-5 Dewaxing Catalyst  Cracking High-Pour Paraffins into Naphtha and Gas  Reduction Coking Propensity through Reactant-Shape Selectivity  Resistance to Poisoning of Bulky Nitrogen Compounds  Utilization of Hydrogen Reactivation Method (High Temperature H2 Reduction) MLRT-LNQ Hanoi University of Technology 11
MLDW Advantages over Solvent Dewaxing Lower Investment (80%)  Lower Operating Cost (15%)  Higher Lube Yields  Cracked By-Products Primarily high Octane Naphtha  Equivalent Base Stock Quality  Low Pour Point Specialty Products (less than conventional 200F) MLRT-LNQ Hanoi University of Technology 12
MLDW: Other Considerations  Lower VI from Equivalent Feed  Eliminates Separate Lube Hydrofinisher  Full Range of Charge Stocks to produce LN, HN and BS  Higher Viscosity from Same Boiling Range Feed  Eliminates Wax Production MLRT-LNQ Hanoi University of Technology 13
Commercial MLDW Performance 3-Bed Reactor: Yield & VI Comparison MLDW ∆ (MLDW-SDW) Yield VI Yield VI 200 SUS Automotive 77 101 -2 -7 650 SUS Automotive 79 94 +8 -5 150 SUS Turbine 69 104 -4 -4 600 SUS Turbine 78 93 +9 -6 150 Bright Stock 86 96 +9 0 (Data Based on 1st Cycle Results for Isthmus Crude) MLRT-LNQ Hanoi University of Technology 14
Lube Unit Operating Costs ( US$/bbL) Finished Lubes Unit Charge SDW MLDW Vacuum Distillation 1.02 4.47 4.32 Propane Deasphalting 4.44 5.52 4.92 Furfural Extraction 2.67 5.63 5.39 Solvent Dewaxing 9.79 12.59 Catalytic Dewaxing 2.94 3.60 Tankage (Inventory) 3.17 3.40 Total 31.38 21.63 Basis: 5,000 B/CD Lube Plant In N.W. Europe (Arab Light Crude) 100” 300” 700” BS Production (B/CD) 430 2065 1205 1300 Pct of Pool 9 41 24 26 MLRT-LNQ Hanoi University of Technology 15
Improved MLDW Commercialization through Catalyst & Process Technology Discovery of ZSM-5 in Late 1960s ZSM-5 Patent in 1972 MLDW Process Development in 1970s 1992 1993 1981 1996 MLRT-LNQ Hanoi University of Technology 16
Commercial MLDW Performance TOST Performance on Base Stocks MLDW SWD Spec, Hr LN Turbine 4,000 4,000 4,000 LN >2,000 >2,000 1,000 HN >1,000 >1,000 1,000 MLRT-LNQ Hanoi University of Technology 17
LHDT Process Background  Chemistry Turbine Oil Stability Improves with Reduced -Polynuclear Aromatics (PNA’s) -Total Aromatics -Sulfur and Nitrogen  Operating Conditions Hydrogen Partial Pressure 2200 psig Reactor Temperature 600 – 675oF Liquid Hourly Space Velocity 0.3 – 0.6 Hr -1 MLRT-LNQ Hanoi University of Technology 18
Performance of Lube Hydrotreating Statfjord 300 SUS Arab Light Automotive Turbine 300 SUS Turbine Charge Product Charge Product Charge Product Properties KV at 40oC, cSt 61.2 50.9 56.5 48.2 54.0 37.3 Viscosity Index 97 102 103 107 103 115 Pour Point, oC -12 -11 -12 -10 -13 -9 Sulfur, ppm 1900 3 1200 1 6000 2 Aromatics, Wt% 17.5 4.3 10.8 1.9 25.6 3.6 Performance (XRL-1509) OCST (3 Days at 150 oC) D8 2.5 - 2.5 D8 2.5 RBOT, Min 325 440 - 390 330 415 MLRT-LNQ Hanoi University of Technology 19
MLDW Turbine Oil Upgrading Commercial Demonstration Conditions 650oF 0.3 Hr -1 2300 psig H2 (Outlet) Isthmus MLDW Turbine 200 SUS Properties Charge Product Viscosity, SUS at 100oF 201 165 Viscosity Index 97 104 Pour Point, oF 15 20 Sulfur, ppm 3100 3 Aromatics, Wt % 24 4 Performance (RL-1442) OCST (3 Days at 150oC) D8 2 RBOT, mm 305 450 TOST, Hrs MLRT-LNQ Hanoi University of Technology 2200 On-Going 20