Presented by ABB Lummus Global B V Frank
Presented by: © ABB Lummus Global B. V. Frank Hollander & Maurice Korpelshoek Shell Thermal Conversion Technologies for Crude Oil Residue ABB
Introduction ABB / Shell Thermal Conversion Technologies © ABB Lummus Global B. V. - 2 Technology Application Economic Evaluation ABB
© ABB Lummus Global B. V. - 3 The ABB Group 1, 000 companies operating in more than 100 countries with 157, 000 employees and revenues of $24 billion USD ABB
The ABB Group Process Industries Chemical, marine, turbocharging, metals, minerals, mining, cement, pulp, paper and printing industries Utilities Electric, gas and water industries Oil, Gas and Petrochemicals © ABB Lummus Global B. V. - 4 Manufacturing and Consumer Industries Automotive industries, telecom, product manufacturing, electronics, airports, parcel and cargo distribution, public and commercial buildings Automation Technology Products, systems, software and services for the automation and optimization of manufacturing operations Oil and gas drilling onshore and offshore, offshore production installations, refineries and petrochemical plants Financial Services Financing, sales support, risk management services and insurance for internal and external customers Power Technology Products The entire spectrum of power technology products for power transmission and power distribution ABB
ABB Oil, Gas & Petrochemicals © ABB Lummus Global B. V. - 5 Being a world leader in providing technologies, products, systems and complete project and plant services for offshore and onshore oil and gas production, refining and petrochemicals ABB
Industries Served & Services Industries Oil & Gas Offshore Oil & Gas Onshore Refining Chemicals/ Petrochemicals Pipelines © ABB Lummus Global B. V. - 6 Services Process Evaluations Conceptual Design Studies FEED Packages Detailed Engineering Procurement Construction Start-up/Training Project Controls/Planning Project Management Heat Transfer Technology Financial Services ABB 02 -04 -
ABB Oil, Gas & Petrochemicals Services EPC Projects Refineries Petrochemical Plants Power-Cogeneration Offshore Platforms Subsea Production Floating Production © ABB Lummus Global B. V. - 7 Project Management Consulting Project Business Planning & Scheduling Project Execution Plan Project Control Technology Licensing Basic Design (Economic) Studies Refining Technologies Petrochemical Technologies Services After Market and Full Life Cycle Support Financial Structuring and Project Financing ABB
Introduction Technology Licensing © ABB Lummus Global B. V. - 8 Shell Thermal Conversion processes for crude oil residue / heavy gasoil Residue processes based on Shell (Soaker) technology Developed by Shell Licensed by Shell and ABB Lummus Global ABB
Shell/ABB Relationship © ABB Lummus Global B. V. - 9 ABB Lummus Global B. V. Shell Global Solutions International B. V. Licensing Research & Development Feasibility Studies Design & Engineering Operating Experience Project Management Operational Feedback EPC Services Upgrading of Technology Technical Services ABB
History and Experience © ABB Lummus Global B. V. - 10 Development of Shell Soaker Visbreaker Technology First Shell Visbreaker built in 1920’s Soaker Internals developed in 1970’s ABB Lummus Global design and engineering since 1960’s with Shell authorized licensor since 1979 Advanced technologies Shell Vacuum Flasher Technology Thermal Distillate Cracking Technology Deep Thermal Conversion Technology ABB
History and Experience © ABB Lummus Global B. V. - 11 World Leader 102 projects Shell / ABB 92 Licenses worldwide 80 Operating units 70% of Visbreaker capacity installed ABB
History and Experience 15 450, 000 12 360, 000 9 270, 000 6 180, 000 3 90, 000 0 1952 1957 1962 1967 1972 1977 Year 1982 1987 1992 1997 Cumulative Capacity, MTSD © ABB Lummus Global B. V. - 12 Units Licensed Cumulative Capacity 0 2002 ABB
© ABB Lummus Global B. V. - 13 History and Experience ABB
Heavy Residue Upgrading Capacity By technology Residual Hydrocracking Coking 7% 47% Visbreaking and Thermal Distillate Cracking 46% © ABB Lummus Global B. V. - 14 Shell Thermal Conversion Technologies 70% Others 30% ABB
Heavy Residue Upgrading Capacity By region Delayed Coking Thermal Cracking & Visbreaking Residual Hydrocracking © ABB Lummus Global B. V. - 15 Capacity, MM BPSD 2 1. 5 1 0. 5 0 USA, Canada Latin America Europe FSU Asia, Pacific Africa ABB
© ABB Lummus Global B. V. - 16 Shell Thermal Conversion Licensees ABB 01 -07 -19
Features and benefits Shell & ABB’s long-term partnership is unique in the Refining Industry. . . Shell Leading technology experience ð Results in lowest cost of production Vast operation experience ð Licensees benefit from wealth of operating knowledge and experience ð Results in best-fit of technologies available © ABB Lummus Global B. V. - 17 ABB world market leader in refining technology ABB world class basic design, ð Provides safe and proven design engineering, procurement, construction ABB
Shell Thermal Conversion Technology Portfolio: © ABB Lummus Global B. V. - 18 Residue Upgrading Shell Soaker Visbreaking (SSVB) Shell Vacuum Flasher (VF) Shell Deep Thermal Conversion (SDTC) Distillate Cracking Shell Thermal Distillate Cracking (STDC) ABB
Shell Thermal Conversion Technologies CDU VDU STDC SSVB VF © ABB Lummus Global B. V. - 19 CDU = Crude Distillation Unit VDU = Vacuum Distillation Unit SSVB = Shell Soaker Visbreaker VF = Vacuum Flasher STDC = Shell Thermal Distillate Cracker SGP = Shell Gasification Process This may also be any other Gasification technology. ABB
Shell Thermal Conversion Technologies CDU VDU STDC SSVB SDTC VF © ABB Lummus Global B. V. - 20 CDU = Crude Distillation Unit VDU = Vacuum Distillation Unit SDTC = Shell Deep Thermal Conversion STDC = Shell Thermal Distillate Cracker SGP = Shell Gasification Process This may also be any other Gasification technology. ABB
Shell Soaker Visbreaking Mechanism Continuous oil phase (Malthenes) cracked to smaller molecules Paraffins mostly cracked to smaller paraffins and olefins Conversion to gas, naphtha, light and heavy gasoil © ABB Lummus Global B. V. - 21 Focus on conversion to ‘wanted’ products, i. e. 165+ C. Reduction of cutter stock requirement ABB
Shell Soaker Visbreaking © ABB Lummus Global B. V. - 22 Fuel Oil specification: Viscosity Sulphur Density Cutter stock added to meet Fuel Oil specification ABB
Shell Soaker Visbreaking Cutterstock Gain as function of Conversion © ABB Lummus Global B. V. - 23 Cutterstock Gain (%) 70 60 50 40 30 20 10 0 0 5 10 15 Conversion (%) ABB
Cutterstock Gain Visbreaking Gasoline © ABB Lummus Global B. V. - 24 Atm. or Vacuum Residue (VB Feed) Fuel Oil Gasoil + Visbroken Residue Cutterstock Gain ABB
Shell Thermal Distillate Cracking Liquid phase thermal cracking of Heavy or Vacuum Gasoil Elevated pressure and temperature Furnace cracking Two year run-length Lighter 150 -180 o. C LGO © ABB Lummus Global B. V. - 25 320 - 370 o. C HGO or VGO Residue 520 - 600 o. C ABB
© ABB Lummus Global B. V. - 26 Vacuum Flashing of cracked materials No Furnace required High recovery of Vacuum Gasoil Severe conditions: Coke formation Heavy fouling Polymerisation Despite severe conditions: Two year run-length Design criteria and internals ABB
Shell Thermal Conversion Technologies Application Grassroots © ABB Lummus Global B. V. - 27 New Residue Upgrading facilities in new or existing refineries Revamp of existing refineries Revamp of existing coil Visbreakers Revamp of Visbreakers that have no other residue upgrading facilities ABB
© ABB Lummus Global B. V. - 28 Thermal Conversion Technology Fit ABB
Technology Application SSVB STDC VF SSVB STDC SSVB + VF STDC + VF © ABB Lummus Global B. V. - 29 STGP SDTC High Conv SDTG High Conv ABB
Overview Thermal Conversion Applications SSVB + VF Shell Soaker Visbreaking SSVB + Vacuum Flasher STDC + VF Shell Thermal Distillate Cracking STDC + Vacuum Flasher STGP = SSVB + STDC +VF © ABB Lummus Global B. V. - 30 Shell Thermal Gasoil Process SDTC SDTG = SDTC + STDC + VF Shell Deep Thermal Conversion Shell Deep Thermal Gasoil Process ABB
© ABB Lummus Global B. V. - 31 Shell Soaker Visbreaking ABB
Shell Soaker Visbreaking : Objective : Viscosity reduction of (vacuum) residue Minimize fuel oil production Lower residue viscosity Minimize blending with cutter stock Production of light distillates (350 ºC minus) Production of heavy gasoil © ABB Lummus Global B. V. - 32 Gas, naphtha, light gasoil Supplementary feedstock to STDC or Hydrocracker or FCC ABB
Shell Soaker Visbreaking : Characteristics © ABB Lummus Global B. V. - 33 Thermal Conversion by residence time, temperature Lower temperature gives better selectivity to gasoil / kero End of Run conditions determined by Heater tube wall temperature (650 ºC / 1200 ºF) Soaker Drum downstream Heater Direction : Upflow Patented internals Provides additional variable to control (pressure) ABB
Shell Soaker Visbreaking : Features © ABB Lummus Global B. V. - 34 Important Features Low temperature Long residence time Low pressure drop Patented Soaker Internals ABB
Shell Soaker Visbreaking : Benefits Important Benefits Lower investment Longer run length Lower fuel and power consumption © ABB Lummus Global B. V. - 35 Smaller amount of (low level) steam generated Better flexibility and operability Better Gasoil yield Smaller Heater ABB
Shell Soaker Visbreaking : Fit in Refinery 100 Feed 0. 7 23. 1 15. 0 11. 3 CDU Gas Naphtha Kero Gasoil 6. 5 LVGO 49. 9 Atm. Residue 22. 7 HVGO VDU 0. 4 Gas 0. 8 Naphtha 20. 7 SSVB Vacuum Residue ~ 1000 c. St @ 100 C 2. 4 Gasoil 17. 1 © ABB Lummus Global B. V. - 36 Visbreaker residue CDU = Crude Distillation Unit VDU = Vacuum Distillation Unit SSVB = Shell Soaker Visbreaker 23. 0 Fuel oil ~ 500 c. St @ 100 C 5. 9 ~ 26 c. St @ 100 C Cutterstock Total 165+ C ~ 120 c. St @ 100 C Typical Ural Crude ABB
Shell Soaker Visbreaking : Feed/Products © ABB Lummus Global B. V. - 37 Visbreaker Feed Atmospheric and / or Vacuum Residue Solvent pitch Products Offgas to Fuel system or LPG recovery Gasoline (C 5 - 165 ºC) to Gasoline pool, after Hydrotreating Gas Oil (165 - 350 ºC) to Hydrotreater, or use as Cutterstock Visbroken Residue to Fuel Oil Blending or Refinery fuel - ABB
© ABB Lummus Global B. V. - 38 Shell Soaker Visbreaking : Recent Projects ABB
© ABB Lummus Global B. V. - 39 Shell Soaker Visbreaking + Vacuum Flasher ABB
SSVB with Vacuum Flasher : Characteristics Objective of Vacuum Flasher: Maximize distillate recovery from residue Production of heavier residue © ABB Lummus Global B. V. - 40 Further separation of Visbreaker residue Less Residue Design robust to fouling Layout of internals and transfer line prevents coke build-up Runlength of Vacuum Flasher longer than Visbreaker Good fit for revamp of existing Visbreaker ABB
SSVB with Vacuum Flasher : Fit in Refinery 100 Feed 0. 7 23. 1 15. 0 11. 3 CDU Gas Naphtha Kero Gasoil 6. 5 LVGO 49. 9 22. 7 HVGO VDU Atm. Residue 0. 4 Gas 0. 8 Naphtha 20. 7 Vacuum Residue SSVB 2. 4 Gasoil 17. 1 CDU = Crude Distillation Unit Visbreaker residue © ABB Lummus Global B. V. - 41 VDU = Vacuum Distillation Unit VF 3. 8 Vacuum Gasoil 20. 2 13. 3 SSVB = Shell Soaker Visbreaker Vacuum flashed residue VF = Vacuum Flasher Typical Ural Crude Fuel oil 6. 9 Cutterstock ABB
SSVB with Vacuum Flasher : Feed/Products Visbreaker Feed © ABB Lummus Global B. V. - 42 Vacuum Residue Products Offgas to Fuel system or LPG recovery Naphtha (C 5 - 165 ºC) to Gasoline pool after hydrotreating LGO (165 - 350 ºC) to Hydrotreater, or use as Cutterstock HGO (350 - 520 ºC) to STDC, Hydrocracker or Catcracker Vacuum Flashed Cracked Residue - to Fuel Oil Blending or Refinery fuel - ABB
© ABB Lummus Global B. V. - 43 SSVB with Vacuum Flasher: Recent Projects ABB
© ABB Lummus Global B. V. - 44 Shell Thermal Distillate Conversion ABB
Shell Thermal Distillate : Characteristics Objective of Shell Thermal Distillate Cracker: Cracking of Vacuum Distillate products to maximize gasoil yield Heavy distillates are recycled to Cracking Furnace Optimize conversion through recycle ratio © ABB Lummus Global B. V. - 45 High recycle ratio, Low press, Low temp Higher Gasoil yield Design robust to fouling ABB
Shell Thermal Distillate : Fit in Refinery 100 Feed 0. 7 Gas 23. 1 Naphtha 15. 0 Kero CDU 1. 4 Gas 11. 3 Gasoil 49. 9 Atm. Residue VDU 6. 5 LVGO 22. 7 HVGO STDC 2. 5 Naphtha 7. 9 Gasoil 10. 9 Residue 20. 7 © ABB Lummus Global B. V. - 46 Vacuum Residue CDU = Crude Distillation Unit VDU = Vacuum Distillation Unit STDC = Shell Thermal Distillate Cracker Typical Ural Crude ABB
Shell Thermal Distillate : Feed/Products Feed: Vacuum Distillate, Atmospheric Distillate © ABB Lummus Global B. V. - 47 HGO, LGO Products Offgas to Fuel system or LPG recovery Naphtha (C 5 - 165 ºC) to Gasoline pool after hydrotreating Gas Oil (165 - 350 ºC) to Hydrotreater, or use as Cutterstock Tar - to existing Visbreaker - to fuel oil blending - ABB
© ABB Lummus Global B. V. - 48 Shell Thermal Distillate : Recent Projects ABB
© ABB Lummus Global B. V. - 49 STDC + Vacuum Flasher ABB
STDC + Vacuum Flasher : Characteristics Objective of Shell Thermal Distillate Cracker: Cracking of Vacuum Distillate products to maximize gasoil yield Heavy distillates are recycled to Cracking Furnace Optimize conversion through recycle ratio © ABB Lummus Global B. V. - 50 High recycle ratio, Low press, Low temp Higher Gasoil yield Design robust to fouling Objective of Vacuum Flasher: Maximize distillate recovery from thermal cracked tar Gasoil recovered in Vacuum Flasher is recycled to Thermal Cracker ABB
STDC + Vacuum Flasher : Fit in Refinery 100 Feed 0. 7 Gas 23. 1 Naphtha 15. 0 Kero CDU 2. 0 Gas 11. 3 Gasoil 49. 9 Atm. Residue 6. 5 LVGO VDU STDC 22. 7 HVGO 3. 8 Naphtha 12. 3 Gasoil 20. 7 Vacuum Residue VF © ABB Lummus Global B. V. - 51 CDU = Crude Distillation Unit 4. 6 VDU = Vacuum Distillation Unit Vacuum Flashed Residue VF = Vacuum Flasher STDC = Shell Thermal Distillate Cracker Typical Ural Crude ABB
STDC + Vacuum Flasher : Feed/Products Feed : Vacuum Distillate, Atmospheric Distillate © ABB Lummus Global B. V. - 52 HGO, VGO Products Offgas to Fuel system or LPG recovery Naphtha (C 5 - 165 ºC) to Gasoline pool after hydrotreating Gas Oil (165 - 350 ºC) to Hydrotreater, or use as Cutterstock Vacuum Flashed Tar to fuel oil blending - ABB
© ABB Lummus Global B. V. - 53 STDC + Vacuum Flasher : Recent Projects ABB
© ABB Lummus Global B. V. - 54 Shell Thermal Gasoil Process ABB
© ABB Lummus Global B. V. - 55 Shell Thermal Gasoil : Characteristics Objective of Visbreaker + Thermal Conversion Unit : Maximize Gas Oil yield, reduce residue Two-stage cracking of atmospheric or vacuum residue No Vacuum distillation required Low cost option for residue upgrading ABB
Shell Thermal Gasoil : Fit in Refinery 100 Feed 0. 7 23. 1 15. 0 11. 3 CDU Gas Naphtha Kero Gasoil VDU 49. 9 Atm. Residue LVGO HVGO 3. 2 Gas 6. 4 Naphtha 19. 3 SSVB Gasoil VF STDC © ABB Lummus Global B. V. - 56 CDU = Crude Distillation Unit VDU = Vacuum Distillation Unit SSVB = Shell Soaker Visbreaker 21. 0 Vacuum flashed residue VF = Vacuum Flasher 32. 0 Fuel oil 11. 0 Cutterstock STDC = Shell Thermal Distillate Cracker Typical Ural Crude ABB
Shell Thermal Gasoil : Feed/Products Feed © ABB Lummus Global B. V. - 57 Atmospheric Residue, Vacuum Residue Products Offgas to Fuel system or LPG recovery Naphtha (C 5 - 165 ºC) to Gasoline pool after hydrotreating Gas Oil (165 - 350 ºC) to Hydrotreater, or use as Cutterstock Vacuum Flasher Cracked Residue - to Fuel Oil Blending or Refinery fuel - ABB
© ABB Lummus Global B. V. - 58 Shell Deep Thermal Conversion Process ABB
Deep Thermal Conversion: Characteristics Objective of Deep Thermal Conversion: Very high conversion of Vacuum Residue to distillate products Operation at high conversion level © ABB Lummus Global B. V. - 59 Stable liquid plant residue No commercial fuel production Closing gap between Visbreaking and Delayed Coking Visbreaker : Fuel Oil product Delayed Coking : Coke product Deep Thermal Conversion : liquid residue product Design robust to fouling ABB
Deep Thermal Conversion: Characteristics Closing the Gap Shell Soaker Visbreaking Shell Deep Thermal Conversion Delayed Coking Yield, wt. % 70 Better Yield towards distillate products 60 50 40 30 20 © ABB Lummus Global B. V. - 60 10 0 C 4 -Minus C 5 -350°C 350 -520°C Fraction VFCR/Coke Unwanted Yield to Gas ABB
Deep Thermal Conversion: Characteristics Closing the Gap Shell Soaker Visbreaking Shell Deep Thermal Conversion Delayed Coking Fraction of Feed Hydrogen, % 70 60 50 40 30 20 © ABB Lummus Global B. V. - 61 10 0 C 4 -Minus C 5 -350°C 350 -520°C Fraction VFCR/Coke ABB
Deep Thermal Conversion: Fit in Refinery 100 Feed 0. 7 23. 1 15. 0 11. 3 CDU 49. 9 Atm. Residue Gas Naphtha Kero Gasoil 6. 5 LVGO 22. 7 HVGO VDU 20. 7 SDTC © ABB Lummus Global B. V. - 62 Vacuum Residue CDU = Crude Distillation Unit VDU = Vacuum Distillation Unit SDTC = Shell Deep Thermal Conversion 9. 7 Vacuum flashed residue SGP = Shell Gasification Process Hydrogen Typical Ural Crude SGP 0. 8 Gas 1. 8 Naphtha 4. 1 Gasoil 4. 3 Vacuum Gasoil Fuel oil Power ABB
Deep Thermal Conversion : Feed/Products Feed © ABB Lummus Global B. V. - 63 Vacuum Residue Products Offgas to Fuel system or LPG recovery Naphtha (C 5 - 165 ºC) to Gasoline pool after Hydrotreating LGO (165 - 350 ºC) to Hydrotreater, or use as Cutter stock HGO (350 - 520 ºC) to STDC, Hydrocracker, or Catcracker Vacuum Flasher Cracked Residue - Gasification - Cement Kiln - Conversion Unit (Coker, LC-Finer) - Uncut refinery fuel - ABB
© ABB Lummus Global B. V. - 64 Deep Thermal Conversion : Applications ABB
Deep Thermal Conversion : Plant Availability Conversion (wt%) Plant Availability 12 8 6 100 4 95 2 90 Before Revamp 0 1989 1990 1991 1992 1993 1994 After Revamp 1995 1996 1997 1998 1999 2000 Plant Availability (%) © ABB Lummus Global B. V. - 65 Conversion (wt% 165 minus) 10 85 Year ABB
Deep Thermal Conversion : CRC Litvinov Vacuum Flasher Fractionator Soaker Drum © ABB Lummus Global B. V. - 66 Heater ABB
© ABB Lummus Global B. V. - 67 Shell Deep Thermal Gasoil Process (SDTG) ABB
© ABB Lummus Global B. V. - 68 SDTG : Characteristics Objective of Thermal Cracker: Maximize distillate yield Gasoil recovered in Vacuum Flasher is recycled to Visbreaker/Thermal Cracker Design robust to fouling ABB
SDTG : Fit in Refinery 100 Feed CDU 0. 7 23. 1 15. 0 11. 3 Gas Naphtha Kero Gasoil 3. 2 Gas LVGO HVGO VDU 7. 3 Naphtha 22. 6 49. 9 SDTC Atm. Residue © ABB Lummus Global B. V. - 69 CDU = Crude Distillation Unit VDU = Vacuum Distillation Unit 16. 3 Vacuum flashed residue Gasoil STDC Fuel oil SDTC = Shell Deep Thermal Conversion STDC = Shell Thermal Distillate Cracker SGP = Shell Gasification Process Hydrogen Typical Ural Crude SGP Power ABB
SDA Integration : comparison © ABB Lummus Global B. V. - 71 VDU + SDA DAO to Hydrocracker SDA Pitch to Bitumen or Gasifier VDU + SDTC VGO to Hydrocracker DTC already upgrades residue Liquid Residue to Gasifier DAO to Hydrocracker > VGO to Hydrocracker VGO quality better than DAO SDA Pitch to gasifier > Liq. Residue to Gasifier SDA/HC $$ > SDTC/HC $$ ABB
SDTG : Feed/Products Feed © ABB Lummus Global B. V. - 72 Atmospheric Residue, Vacuum Residue Products Offgas to Fuel system or LPG recovery Naphtha (C 5 - 165 ºC) to Gasoline pool after Hydrotreating Gas Oil (165 - 350 ºC) to Hydrotreater, or use as Cutterstock Vacuum Flasher Cracked Residue - Gasification - Cement Kiln - Conversion Unit (Coker, LC-Finer) - Uncut refinery fuel - ABB
© ABB Lummus Global B. V. - 73 Economic Evaluation Low to Modest Investment Attractive revamp options Short pay-out time (less than 1 year) ABB
Thermal Conversion Economics © ABB Lummus Global B. V. - 74 Residue Upgrading advantage Reduce amount of Cutterstock (typically gasoil) Improve gasoil yield ABB
Thermal Conversion Economics Visbreaking Gasoline © ABB Lummus Global B. V. - 75 Atm. or Vacuum Residue (VB Feed) Fuel Oil Gasoil + Visbroken Residue Cutterstock Gain ABB
© ABB Lummus Global B. V. - 76 Thermal Conversion Economics ABB
© ABB Lummus Global B. V. - 77 Thermal Conversion Economics ABB
© ABB Lummus Global B. V. - 78 Thermal Conversion Economics ABB
© ABB Lummus Global B. V. - 80 STDC + Vacuum Flasher Economics ABB
© ABB Lummus Global B. V. - 81 Thermal Conversion Economics ABB
© ABB Lummus Global B. V. - 82 Thermal Conversion Economics ABB
Gasifier Economics Hydrogen Residue Oxygen Power Typical product margin IGCC: $ 100 - $ 150 /ton residue © ABB Lummus Global B. V. - 83 Gasifier Product margin $ 80 - 120 Million per year for 4000 t/d Thermal Conversion Unit ABB
Comparison Soaker Coil Visbreaker Proven advantages of SSVB: Capital Investment : 15% lower Smaller furnace Less heat exchange equipment Fuel saving up to 30% © ABB Lummus Global B. V. - 84 Due to lower Heater Outlet temperature Longer runlength Lower cracking temperature, so lower tube wall temperature Reduced coking , extended tube life Higher onstream time ABB
Comparison Soaker Coil Visbreaker Proven advantages of SSVB (cont’d): Enhanced Operating Flexibility High turndown ratio © ABB Lummus Global B. V. - 85 Heater outlet temperature and Soaker pressure are controlled Stable and controlled operation at 50% of design capacity 2% higher Gasoil yield Optimized flow pattern in Soaker, no back mixing Optimal residence time distribution ABB
Comparison Soaker Coil Visbreaker © ABB Lummus Global B. V. - 86 Coil Soaker ABB
© ABB Lummus Global B. V. - 87 Comparison Soaker Coil Visbreaker ABB
Comparison with other Technologies © ABB Lummus Global B. V. - 88 Other residue upgrading technologies available: Coking Hydrocracking Catcracking Shell Thermal conversion technologies achieve ~ 80% of the benefits at ~ 20% of the investment of a Hydrocracker Unit can be upgraded to other technology later Phased investment No regret investment ABB
Comparison with other Technologies 7000 90% 6000 80% 5000 70% Yield 60% 4000 50% 3000 © ABB Lummus Global B. V. - 89 40% 30% 2000 Gasoline Gasoil Fl. Dist Fuel/Coke Investment 20% 1000 10% 0% Investment US$/Bbl 100% Base Visbreaker Deep Thermal Conv. Delayed Coker Flexi. Coker 0 ABB
Investment New unit 3, 000 MTD capacity Ural crude US Gulf Coast SSVB +VF © ABB Lummus Global B. V. - 90 Feed VR TIC MM US$ 20. 6 Revamp 40 - 70% less STGP SDTC VR AR/VR VR 25. 5 28. 3 28. 2 ABB
Innovation © ABB Lummus Global B. V. - 91 ABB and Shell strive to implement most economic solution for refiner Innovative, tailor-made solutions Continue to develop technologies Examples Implementation of Deep Thermal Conversion technology Sasref integration Gas Turbine and Thermal Gasoil Unit ABB
© ABB Lummus Global B. V. - 92 Sasref Integration Gas Turbine & STGP First of its kind application Excellent energy efficiency Low Investment Cost Very long runlength ABB
© ABB Lummus Global B. V. - 93 Sasref, Saudi Arabia ABB
Sasref, Saudi Arabia Gas Turbine Combi Tower © ABB Lummus Global B. V. - 94 Vacuum Flasher ABB
© ABB Lummus Global B. V. - 95 ABB
- Slides: 93