Verdana 30 pt - ASSOCIAZIONE ITALIANA · PDF fileEni Slurry Technology (EST) is a new...
Transcript of Verdana 30 pt - ASSOCIAZIONE ITALIANA · PDF fileEni Slurry Technology (EST) is a new...
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EST technology:
an advanced way to upgrade the bottom of the barrel
G. Rispoli
OMC 2015 WORKSHOP: ADVANCED PROVEN TECHNOLOGIES INCREASE PRODUCTIVITY QUALITY, SAFETY AND SECURITY Ravenna, 26th March 2015
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EST: the answer to market needs 1
EST results and operation experience 3
First EST Commercial Unit at eni’s Sannazzaro Refinery 2
Conclusions 4
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H/C 1.3 H/C 1.9
Current C-rejection technologies (i.e. Coking) do not provide complete bottom of the barrel conversion
+ 4% wt. Hydrogen
- 24% wt. Carbon
Over 100 million tons of petroleum coke produced annually world-wide
Bottom of the Barrel conversion
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EST (Eni Slurry Technology) is a proprietary new
process for heavy feedstock conversion & upgrading
Petroleum Residues
Heavy Oils
Tar Sands Bitumen
EST
Bottomless
Syncrude D API > 20
What is EST ?
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EST is a hydrocracking process based on two unique features:
1. Nanodispersed (slurry) non ageing catalyst
2. Homogeneous & isothermal slurry bubble column reactor
The recycle of unconverted heavy ends
allows the total conversion of the bottom of the barrel to good quality
middle distillates (feedstock conversion >97%)
H2
Refined products
(SCO)
Gas
Slu
rry R
eacto
r
Feed
Purge
Fracti
on
ati
on
S
yste
m
Cat prec
Catalyst & Residue
Recycle
H2 Rec.
Reaction Products
EST can easily handle very heavy feedstock
What is EST ?
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Eni Slurry Technology (EST) is a new technology for the full conversion of the bottom of the barrel to distillates The availability at industrial level of EST enables the oil industry to solve crucial needs:
Meet the declining demand of Fuel Oil converting surplus of Refinery Residues into Distillates (Zero Fuel Oil - zero coke Refinery)
Meet the increasing demand of cleaner distillates without increase of the CDU capacity
Increase the refinery flexibility to supply of heavier crudes In this context, EST allows a better use of the conventional oil resources and promotes the use of non-conventional oil resources such as heavy and extra-heavy oils and oil-sands bitumen
EST Meets Fundamental Needs of Refining Industry
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March 2014: the SECAs established to limit SOx and particulate matter emissions are:
1. Baltic Sea area – as defined in
Annex I of MARPOL 2. North Sea area (including the English Channel) – as defined in Annex V of MARPOL 3. North American area (entered into force on 1st August 2012); and 4. United States Caribbean Sea (entered into force on 1st January 2014)
Marine fuels Sulphur standards : key steps
Sulphur in Marine Fuels: towards new specifications
New maritime regulations coming into effect starting in 2015 significant reduction of residue demand
(Source: MARPOL 73/78, Annex VI Regulations for the Prevention of Air Pollution from Ships)
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EST Sannazzaro: the industrial project
Diesel
LPG
Gasoline
Kero
O
I
L
M
o
v
e
m
e
n
t
HDS1/2
HDS3
Reformer2/3
TIP
ALK MTBE
O.C.
Bitumen
Pitch
T
o
p
p
i
n
g
HDC1/2 VACUUM 1/2
FCC
VSB
IGAS
Syngas
ROSE
EST
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Integration of EST Complex in the Sannazzaro Refinery: Total refining capacity 11Mt/y
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Auxiliaries units: -H2 unit 100 kNm3/h -(running since Jan 2013)
-SRU 160 t/d
Bunkerized control room (in operation since Jan 2013)
Slurry reaction unit 23000 bbl/d
Upgrading process unit
PTU
EST Complex Lay-out
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EST Sannazzaro today
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EST start-up and first year of operation
The EST hydrocracker unit has successfully and safety begun operations and is producing high quality distillates (oil-in: 2013, October 14th)
Syncronized start up / operation of all the auxiliary facilities associated with the Unit
First results confirm the proper design of the plant:
major equipments provided the expected performance (as per design)
some minor adjustments in order to improve the global EST plant performance
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EST first results
Slurry reactors: perfectly isothermal and homogeneous (axial DT <2°C and radial DT <0.1°C)
Gas/liquid separation: High efficiency of gas-liquid separation (no foaming occurrence)
Conversion: EST plant has run at nearly 70-80% of design capacity (there are market constraints related to the reduction of purge volume accepted by cement factories compared to the their planned absorption capacity). Feed conversion up to 95-96% without coke formation
Product slate and quality: Results are in good agreement with the expected product distribution as calculated by process simulation (based on EST Demonstration plant data). Euro V diesel yields is higher than 40 wt.%
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EST results: Slurry reactors temperature profile
410
415
420
425
430
435
18/10/2014
20/10/2014
22/10/2014
24/10/2014
26/10/2014
28/10/2014
30/10/2014
01/11/2014
03/11/2014
05/11/2014
07/11/2014
09/11/2014
11/11/2014
13/11/2014
Temperature
[°C
]
T int. Liv. A [TXI-468] T int. Liv. B [TXI-467] T int. Liv. D [TXI-465] T int. Liv. E [TXI-464]
T int. Liv. G [TXI-462] T int. Liv. H [TXI-461]
DT=2°C
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0
5
10
15
20
25
30
35
40
45
Expected EST Unit Data
wt. %
C1-C2 LPG Naphtha Diesel VGO Purge
EST results: product yields
Typical EST Feed
d15°C: 1026 g/cm3 C5-Asph: 15.4 wt.%
S: 2.9 wt.% Ni: 88 ppm
N: 0.6 wt.% V: 199 ppm
CCR: 20.1 wt.% Fe: 41 ppm
Euro V diesel
Desulphurized
naphtha
Cat feed 0.1% S
(or marine fuel 0.1% S)
Pitch
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EST second run
A power failure occurred in Sannazzaro refinery (about 3 months after start-up), causing the upset of Steam Reformer plant
Following this event, the decision of EST shutdown was
taken, also supported by the following reasons:
the adverse scenario for cement industry that limited EST
maximum production (due to reduction of purge volume accepted by cement industry whose capacity in Italy dropped by 40% in the last few years)
the opportunity to take advantage of maintenance activities to improve plant reliability, efficiency and operating procedures
New start up of EST unit: June 2014 Unit operating in a very stable mode Still present constrains in cement market Part of the pitch is sent to Sannazzaro existing gasification unit
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The first EST hydrocracker Commercial unit is in operation at eni’s
Sannazzaro refinery
Key success factors:
Demonstrated reliability
High conversion to valuable products
No coke formation/production
Option to convert the Bottom of the Barrel overcoming conversion limitations
Environment-friendly technology
High energy efficiency
Excellent option for natural gas valorisation
Further improvements of the technology are in the pipeline as a
result of first year of operation
Now, since the successful start up of the Unit, eni has started to
license EST technology
Conclusion
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Thank you for your attention
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