SLOVNAFT LCF Operation experience

Transcription

1 45 th International Petroleum Conference June, 2011 BRATISLAVA SLOVNAFT LCF Operation experience Robert ŽAJDLÍK, Ján GAZDÍK

2 LC- Finer, SLOVNAFT general data License ABB LUMMUS GLOBAL Inc. USA July 1995 Fluor Daniel & Mitsubishi Heavy Ind. June 1996 Start of construction June 1997 End of construction September 1999 Start-up on Vacuum Residue March 8th 2000 Performance test August 24th-27th,2000

3 LC-Finer unit Main objectives VR Conversion 565 degc+ Reactor Temperature 416 C Reactor Pressure 18 MPa Conversion 62% (design 65%) Desufurisation VR ( wt%) Denitrification VGO ( wtppm) Demetalisation VGO, VR (0.1 wtppm; 100 wtppm) MCRT Reduction VGO, VR (0.4 wt%; 22 wt%) Other...

4 LC- Finer, SLOVNAFT feed, products & yields Feed Vacuum residue 155 t/hr Diluent LCO 15 t/hr Diluent MCB 10 t/hr Make-up Hydrogen 22 kg/t Feed % Vacuum Residue 86 MCB 8 LCO 6 Total Product % Gases 4 Naphtha fraction 6 Diesel fraction 24 VGO 28 Vacuum Residue 38 Total 100.0

5 LC- Fining family Build Company VR [t/hr] Bottom product 2010 GS Caltex 400 Stable FO 2013 Northwest Upgrading 193 IGCC 2010 Shell Canada 291 Stable HSSC 2007 Neste Oil 267 Fuel Oil 2003 Shell Canada 527 Stable HSSC 2000 Slovnaft 155 Stable LSFO 1998 AGIP Petroli 167 Stable LSFO 1988 Syncrude Canada 267 Coker Feed 1984 BP-Amoco 500 Coker Feed + 7 H-Oil technologies worldwide, (e.g. PKN Plock)

6 Importance of LC Fining for the company Net Cash Margin ranking of the European refineries, 2008, Wood Mackenzie 20 Bratislava; Duna; NCM in USD/bbl 10 5 Rijeka; 5.92 Sisak; 4.42 IES Mantova;

7 SLOVNAFT s technological change over last decade Production (in kilotonnes) change Motor petrol % Motor diesel % Heavy fuel oil % Bitumen % Petrochemical and plastics % Other products % Total % Slovnaft now produces more valuable light products other 12% other 25% bitumen 5% bitumen 1% fuel oil 22% fuel oil 3% petchem 9% petchem 5% diesel 44% diesel 38% over USD 650 mn investments spent on change of product slate and fuels desulphurization light products > 85% of total production all motor fuels can be produced with 10 ppm quality petrol 18% 1998 before upgrade petrol 25% 2007 after upgrade

8 LC Finer - part of the complex EFPA Preparation: Building: Gases Gases Vacuum Resid Gases LCF VGO Refinery LN HN MD VGO HDS VGO LN HN MD VGO Resid. FCC MEROX LPG MEROX GAS MD C 4 Resid. Refinery Gases Natural Gas HP ETBE ALK C 4 from SC SH Gasoline

9 Flow Diagram... LC-Finer unit

10 100% Capacity utilisation LCF unit utilisation over decade Relative on stram factor Relative on stram factor, Capacity utilisation [%] 90% 80% 70% 60% 50% 40% 30% 20% 10% 0% Year

11 100.00% 90.00% 80.00% 70.00% 60.00% 50.00% 40.00% 30.00% 20.00% 10.00% 0.00% Yields (product rate/total liquid feed rate] VR VGO Gas Oil Kerosene H Naphtha L Naphtha yield on feed [kg/kg]

12 Raw 565 C+ conversion Net conv. Raw conv. 565C- in VTB 565C- in VR Conversion / 565C- in VTB [wt%]

13 Sulfur in heavy products Slufur content [%wt] 565 C recovery VTB [%w] S in VGO S in VTb S in VR 565C- in VTB

14 Nitrogen in heavy products Nitrogen content [%wt] Nitrogen content [wtppm] N in VTb N in VR N in VGO

15 Problematic issues Feed quality changes Sulfur and Nitrogen content Density MCRT Metal content Fouling of key equipments LP/HT separator and downstream HEX (E101) Atmospheric tower Vacuum column heater Vacuum column HEX train Mechanical issues (will not be discussed)

16 Nitrogen and Sulfur in VR feed Sulfur [wt%] Nitrogen [wt%] Sulfur Nitrogen

17 Density and 10% BP of VR-feed Feed density Feed 10% BP Feed density [kg/m3] Feed 10% BP [ C]

18 MCRT in VR-feed MCRT Recovered at MCRT [wt%] Recovered 565 C

19 Metals in VR feed V Ni metals content [mg/kg]

20 Catalyst addition rate CAR on VR+MCB CAR 7 day average CAR CAR [kg/ton]

21 Invitation Sustainable development and HSE Aspects of Refinery and Petrochemical Operations Miestnosť: Hall B June 13, 2011 (Monday), 16:20 PROCESS OF WASTE CATALYST RECOVERY FROM RESIDUE HYDROCRACKER POLC, R.*; VDOVJAK, L.; DIKÁCZOVÁ, Z.

22 Fouling Critical Fouling Locations 22

23 Fouling Limitations Unit is stopped every 6 11 months, sometimes VT bypass needed Shutdown duration from 5 to 14 days Main reasons for S/D: Vacuum heater limits reached - either pressure in the passes or skin temperature in convent section VTB pumps suction loss 11E101 H2 preheat high delta p Roughly at about 40 tones of coke removed from equipments Vacuum bottom exchangers cleaning frequency: 11E302A/B - once per month 11E308 LP steam generator once per 5 weeks 11E309 once per 6 weeks 23

24 Modifications done Atmospheric bottoms (ATB) circuit installed Main goal to remove coke from the ATB ATB increased suction VTB increased suction 11E308 increased tube ID 11E101 modification increased tube ID and construction material changed, wash oil (HCO) Introduction of new low sediment catalyst Wash oil withdrawal downstream the exchangers Antifouling chemicals dozing Excessive test dome with several chemicals suppliers Vacuum furnace operation strategy Steam flow Decreased outlet temperature to 376 C Considering installation of spiral exchangers 24

25 VTB LP/HT V103 E309A E309B ATM C201 VAC C301 E308 C201 C301 Wash-oil P305 E302A E302B H301 VAC Heater H301 C301 bottom P304

26 Atmospheric tower bottom Temperature [ C] Total feed [t/h] Operating days 80

27 LC Finer, SLOVNAFT

28 Thank you for your attention

29 Other achievements Hydrogen partial pressure treat gas purity make-up H2/feed hydrogen purity [%vol] H2 make-up/feed rate [Nm3/m3]

30 Feed rates VR+LCO+MCB VR LCO MCB 25% 20% 15% 10% 5% 0% Total Feed and VR rates [kg/hr] LCO/total feed and MCB/total feed fraction

31 1030 VTB density and viskosity and VR-density VTB density VR feed density VTB viskosity VTB density [kg/m3] VTB viskosity [mpa.s]

32 100% 95% 90% 85% 80% 75% 70% 65% 60% 55% 50% Sulfur removal efficiency Normalised conversion (410 C, 170 t/hr) Conversion normalised conv S Conversion [%w]

33 HDN Normalised conversion (410 C, 170 t/hr) Conversion normalised conv. 50% 45% 40% 35% N Conversion [%wt] 30% 25% 20% 15% 10% 5% 0%

34 120% 100% 80% 60% 40% 20% 0% -20% HDV removal efficiency conversion V est. on cat k0 2.0E E E E E E E E E E E V conversion and estimated V on catalyst(bfc) [%w] k0 activity factor

35 HDNi removal efficiency 100% conversion V est. on cat k0 2.0E E+09 Ni conversion and estimated Ni on catalyst(bfc) [%w] 80% 1.6E E+09 60% 1.2E+09 40% 1.0E E+08 20% 6.0E E+08 0% E+08 k0 activity factor -20% 0.0E+00

36 Sediment - SHFT Sediment [%wt] MCRT in Feed [wt%] Sediment in ATB Sediment in VTB MCRT

37 Sediment - SHFT Sediments [%w] TI Feed [%wt] Sediment in ATB Sediment in VTB TOLUENE Insoluble

38 Location of SKIN temperature measurement points for fouling control of BRHCK key equipment. TI3394 ATM C201 VAC Heater H301 TI3305 TI3307 TI3314 TI3372 VAC C301 TI3398 TI3396 TI3312 TI3311 TI3395 VTB P205 TI3319 TI3333 P304 TI3374 TI3397

39 LC Finer overall on-stream performance Year VR Processed On-stream t hr TA year TA year TA year total

40 Feed deterioration impact on RX exotherms Reactor exotherms R101 R102 R103 cummulative dt H2 Make-up Exotherm [ C] Hydrogen make-up rate [Nm3/m3 feed]