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HYDROCARBON
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INTRODUCTION:
TAKING CONTROL OF
Süleyman Özmen
THE SULPHUR PARADOX
Refiners globally will continue to experience numerous challenges in examples of how refiners are responding to increasingly
the coming years. Principal among these is the sulphur paradox, stringent environmental specifications as they relate to
which is a reality that refiners increasingly face: more sulphur is sulphur and other emissions using the Pentagon Model.
coming into the refinery as the availability of sweet crudes
We then provide insight into the key technologies that help
diminishes, but less sulphur must leave the refinery within the finished
refiners execute on their sulphur management strategies.
products or as harmful emissions.
The Shell Global Solutions Sulphur Technology Platform, a
Indeed, the need to meet changing product specifications and focal point for integrated and customised sulphur
emissions legislation will continue to be a key focus for refinery solutions, helps refiners process heavier, sourer crudes,
managers as the global population rises and demand increases. whilst meeting stringent emissions and product
For example, the economy in Russia remains extremely tight and, requirements. In addition, distillate upgrading and catalyst
despite financial constraints, refiners must meet Euro 3 technology enables them to take their Ultra-Low sulphur
transportation fuel regulations this year and be prepared for Euro diesel (ULSD) units to the next level by improving product
5 by 2015. In terms of local product specifications, export markets quality or yield flexibility in revamp applications. JsC
can bring different demands. With the Middle East, for example, Ukrtatnafta’s Kremenchug refinery highlights the success of
now providing significant product to Europe, South America and these technologies, which helped them improve the quality
other regions, refiners must comply with the 10 weight parts per of their transportation fuels and improve their margins.
million (wppm) sulphur transportation fuels specification even
Ultimately, innovative process and catalyst technology
though it is not required for the domestic market. In developing
solutions are required for processing heavier, sourer crudes
markets, tighter specifications for motor gasoline (mogas) or diesel
whilst meeting emissions and clean transportation fuel
will also be imposed.
specifications, specifically in relation to sulphur. By using
During the next five years and beyond refiners must look forward integrated technology solutions to optimise sulphur
to find more viable solutions. There is never a simple single management strategies, we can face today’s refining
solution. A flexible and tailored approach is necessary to account challenges head on to survive and thrive!
for individual circumstances. Intelligently applied, integrated
Süleyman Özmen
technology and a robust sulphur management strategy are
Vice President, Refining and Chemical Licensing,
important now more than ever.
Shell Global Solutions International B.V.
In this supplement, we showcase the thinking and technologies,
which facilitate the effective management of sulphur in any form,
as refiners face processing heavier, sourer crudes despite more
stringent product specifications and emissions legislation.
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HYDROCARBON
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Energy scenarios Within the boundaries of our Three Hard Truths, society and
Shell has been using energy scenarios for almost forty years governments exercise choices, leading to many possible outcomes
to explore possible developments in the future of energy and for the energy system. Our scenarios explore two very different
to test strategies against those shifts. Decision makers use possibilities:
these scenarios to gain insight into the uncertainties ahead
Scenario one: Scramble
that concern them most, and explore the ways in which
Scramble represents a world where action takes place on a national
discontinuities might unfold. Scenarios enable better
level, with each government focused on securing energy for their
decisions today which will drive better performance in the
own particular needs over concerns relating to the impact of energy
midst of greater uncertainty.
on the environment and society. The choice of the term Scramble for
this scenario is significant as it highlights how the world is always
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trying to catch up with growing energy demand by pursuing the primary means of abating the effects of CO2 from fossil
easiest, cheapest and most plentiful resources available. fuel energy. The majority of coal and gas plants will have
carbon capture and storage associated with them, either
With a pervasive short-term mindset, the demand for readily-
installed new or retrofitted. Technologies like the Sulphur
available coal continues to grow very quickly. However, as the
Technology Platform provided by Shell Global Solutions
emissions challenge becomes more extreme, people are inevitably
also enable refiners to manage the ever-growing level of
forced to consider other energy sources. At this point the next area
sulphur produced in refining processes despite processing
of growth will be biofuels, since the technology is mature and can
ever-heavier crudes. By employing such solutions, it is
be implemented relatively quickly at a time when fast solutions are
easier for refiners to measure reactions. As a result,
required, although that may have unintended consequences.
security of supply is more easily assured as demand is
Shortly after, there will be a recognition that nuclear is probably better managed on a global basis.
the best solution for electricity supply. However, as nuclear power
Preparing for the future
takes time to build and is relatively expensive by comparison, there
Today, the fundamental long-term energy drivers and
will be an energy supply crunch in which countries are forced to
uncertainties remain largely as anticipated. However,
take action to manage demand, by imposing taxes and mandates
when we consider all the factors together and impose on
to reduce energy consumption.
them the enduring economic uncertainty, it’s clear that the
Scenario two: Blueprints energy system will be even more volatile over the next
Blueprints represents a world where a patchwork of solutions to three to five years and possibly beyond, impacting refiners
tackle energy demand, supply and climate stresses emerge at a along the way.
local and regional level and coalesce into mainstream solutions.
There will be new competition from other energy sources
It is a world in which people think more strategically about global
for transport fuels - although this will not happen
energy needs and plan for a future that includes taking action in
consistently across the world - raising challenges in terms
relation to climate change and more efficient use of energy.
of refinery footprints and also in meeting demands for
In a Blueprints world, less coal is used in favour of cleaner natural specific products and increasing trade.
gas resources and renewable energy sources are developed and
Transition is inevitable in the world energy system as we
deployed more quickly.
strive to provide more energy using sources that produce
Investment in technology and market-based systems continues to less SOx, COx, and NOx emissions. However, there are
help increase the number of emissions reduction schemes and also real opportunities for positive change if we can
build on the success of carbon capture and storage projects as the begin to use energy more efficiently. Overall, 30 per cent
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HYDROCARBON
PROCESSING®
mb/d
it from source to a state where it can actually meet
energy demand. 100
Scenario planning enables refiners to navigate the energy 1990 2000 2010 2020 2030
landscape, but the next step is to provide refiners with a
template, enabling them to help improve operations and Natural gas liquids IEA estimate 24 mb\d
of supply will need
meet the challenges presented by the sulphur paradox. replacing by 2015
Non-conventional oil
This is explored in the next article, which demonstrates
how theory can be put into practice. Crude oil – yet to be developed (inc. EOR) or found
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HYDROCARBON
PROCESSING®
Short-Term =
Just Surviving
Operational
Improvements Short-to-Medium-Term=
Survive/Starting to Thrive
Short-Term Long-Term=
Revamp Thrive
Solutions
Phased
Investments
Over
Health, safety and environmental Long-Term
issues are of great importance to
Shell GS and thus central to all
pentagon options
Third pentagon: Phased investment revamps. They can then use their increased margins for the phased
To succeed long term, refiners must continue investing in investment programme in the long-term, enabling them to
phases as part of the third pentagon. For example, if they implement effective strategies for dealing with sulphur and other
want to maximise their diesel production with the right by-products and emissions.
product combination, they will need to install using deep
It is crucial refiners invest now and continue to do so in order to
flash technology with the hydrocracker and/or build light prepare for an inevitable surge in demand and more stringent
cycle oil (LCO) hydrotreaters to enhance production of diesel. emissions legislation and product specifications. Refiners can use the
There are environmental benefits to phased investment as lessons learned from the recent economic crisis to avoid the ‘stop
well. Refiners with a typical crude distillation unit and high and go’ behaviour of past crises in which refiners ceased investing
vacuum unit can invest in new technologies as part of the in new projects through a multi-platform approach.
Sulphur Technology Platform and thereby decrease their Efficient and continuous project management is a necessity in a
energy use by approximately 25 per cent by integrating challenging, cyclical business environment. With the Pentagon
their technologies. This not only helps refiners reduce capital Model, refiners will enhance their existing assets to meet the
investment, it can also help them achieve energy efficiency growing energy demand by implementing appropriate sulphur
and CO2 reduction as well. management technologies such as the Sulphur Technology Platform
and, at the same time, increase their margins. By adopting the
A multi-platform approach to sulphur
Pentagon Model now, refiners will be in a better position to survive
Each of the three pentagons enables refiners to improve
and thrive in the short and long term.
operations and adapt to changing emissions and product
standards. During implementation of the first pentagon, Süleyman Özmen
refiners are able to make enough operational Vice President, Refining and Chemical Licensing,
improvements to gain savings for further investment in Shell Global Solutions International B.V.
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n F ront-end development to optimise process design and The objective of the phase II revamp was the installation of
technology selection; a second stage dewaxing section to achieve a further cloud
point reduction of 20˚C and thus produce a winter diesel
n Implementation support, such as project management support product for the local market.
and contractor management to ensure budgets and schedules The diesel hydrotreater was designed to process straight
are met; and run diesel and kerosene with a maximum sulphur content of
50 to 350 wppm. A maximum capacity testrun showed that
n tart-up and commissioning services to reduce implementation
S
the unit was capable of operating at 115 per cent of the
time and organisational effectiveness reviews throughout the
design throughput at the premised feedstock, having a
project lifecycle.
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HYDROCARBON
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sulphur content of about 100 wppm in the diesel product. Catalysts & Technologies ASCENT™ platform DN-3531 and DC-2531
The premised feedstock is a blend of 85 per cent wt straight in a sandwich structure was proposed. The nickel molybdenum
run diesel and 15 per cent visbreaker gasoil and light (NiMo)-based catalyst was applied to reduce the residual nitrogen
catalytic cracked cycle oil (LCO). The unit was further to low enough levels for the (future) second stage noble metal
constrained in terms of a maximum pressure differential hydro-isomerisation dewaxing (HDW) catalyst. The cobalt
across the reactor section, set by the fixed speed recycle molybdenum (CoMo)-based catalyst had been included to meet
gas compressor capacity and heat integration limitations. the diesel sulphur specification but minimise hydrogen consumption.
To achieve a diesel product sulphur content of less than 10 As an opportunity to minimise investment for the dewaxing expansion
wppm, the installation of an additional reactor downstream in phase II of the revamp project, the heat integration of the reactor
of the existing HDS reactor was required, while the section was optimised by the installation of a new hot high-pressure
increased feed rate would require the installation of a separator (HHPS) scrubber as part of the application of the third
maximum diameter impeller for the diesel hydrotreater feed pentagon. This combination would make substantial heat available
charge pump, together with the replacement of the pump from the new HHPS pump to be used for feed preheat, while at the
driver. This solution was a minimum capital expenditure same time reducing the condensing duty requirement of the high
(capex) solution for the refinery, meeting the premised Euro pressure vapour condenser. The pump around could also be used as
5 diesel specifications and the target capacity increase of liquid quench in between the catalyst beds of the new reactor.
30 per cent compared to design.
For phase II of the revamp project, the hydro-isomerisation
Processing of gas oils, especially when containing LCO, to dewaxing technology was applied, because of yield advantage
very low sulphur levels requires hydrogenation of the difficult over catalytic cracking dewaxing, and integrated within the existing
sterically-hindered sulphur species (dibenzothiophenes) found HDS reactor section. The concept of isomerisation dewaxing is
in the heavy end of the feed. In order to achieve the required based on a catalyst having a zeolite structure, impregnated with
sulphur in product, a catalyst system based around Criterion noble metal platinum (Pt).
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The feasibility study resulted in several benefits to the refinery’s The assessment demonstrated that in an integrated HDT/
revamp project. By applying the Pentagon Model, the refinery HCU configuration, the unconverted oil bleed from the
experienced a capacity expansion of 30 per cent and diesel common fractionation section to the FCC and the
product that met Euro 5 standards through phased capital remainder recycled to a hydrocracker unit (operating at
expenditure without replacement of capital-intensive equipment. higher conversion), would not be feasible at any of the
The refinery also produced winter diesel grade with a cloud point three investigated pressure levels. This was because the
specification of -25˚C. Lastly the refinery achieved increased diesel sulphur content of the middle distillate (kerosene and
yield (optimisation of gasoil stripper in work-up section) and diesel combined) could not meet the 10 wppm sulphur
increased unit reliability (reinstate wash water application). specification. Even at the 120 bar pressure level the
S-slip in ULSD was estimated at 65 wppm.
Integrated MHC/HDS Complex
In an example of the application of the third pentagon (“long-term For both the single-stage full range MHC and the
options”), an integration of mild hydrocracking and diesel integrated MHC/HDS configurations, the cetane number
desulphurisation units helped to add value to an existing refinery specification could not be achieved at the lower pressure
generating Euro 5 diesel quality products and feedstock for the levels of 80 bar and 100 bar. The density specification of
fluid catalytic cracking (FCC) unit. The main objective of the < 845 kg/m3 could only be met at SOR conditions for the
configuration review was to upgrade heavy gas oil single-stage full range.
(HGO)/vacuum gas oil (VGO) to diesel while still producing
At the highest pressure level of 120 bar, all diesel
unconverted oil (UCO) as feedstock to the FCC. Another business
specifications could be met for both these configurations.
driver was to hydrotreat excess light gas oil (LGO) to produce
The middle distillate yield from the single-stage full range
diesel. The challenge was to determine the most economical,
MHC configuration compared with the integrated MHC/
reliable and robust solution through co-processing or post
HDS is around 5 per cent lower due to extra cracking of
treatment while meeting diesel Euro 5 specification.
the LGO feed. Although the single-stage full range MHC
Fresh gas
From HMU
HDW
CHPS
Pass 2-4
HDS Reactor#2
CHPS
To HLPS
A/B/C/D
Feed / Effluent
Exchanger Interstage Stripper
HDW Feed
HHPS / Effluent
RG / Reactor Exchanger
Effluent Exchanger
HDW Effluent
KO Drum
HDW Feed Pump
A/B To HLPS#2
HHPS pumparound
Pump HDW Liquid
Feed Surge Drum M
New HHPS
Feed Charge Pump Pumparound Wash water
Exchanger
HHPS Liquid
To HLPS
A/B A-D
Feed / HDW Feed oil / Product Drier bottoms
Liquid Exchanger
Exchanger
Final Diesel Hydrotreater Flow Scheme post revamp with Dewaxing technology
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HYDROCARBON
PROCESSING®
LPG
LPG treating
Gasoline
Naphtha
Naphtha hydrotreating Gasoline
Catalytic reforming Benzene
Toluene
Atmospheric column
Xylene
Kerosene Kerosene wet treating
Kerosene/Jet
Crude oil
Kerosene hydrotreating
FCC gasoline selective Gasoline
Diesel
hydrodesulphurisation
VGO hydrotreating
Diesel
LVGO
Vacuum column
Hydrocracking
FCC
Organic S H2S
Residue upgrading
HVGO
On-specification SOx/NOx
Furnaces, boilers
- Visbreaking product or emission
and turbines
- Residue hydroconversion Mercaptan/COS S
- Coking
- Solvent deasphalting SO2
would have the higher operating flexibility of independent The right solution for managing sulphur should develop out of
turnarounds for maintenance and/or catalyst change deliberate evaluation of the application of technologies and their
compared with the HDS from MHC functions in the integration within a refinery. There are multiple options to deal
integrated MHC/HDS configuration, the higher capital with sulphur throughout the refinery. Flexibility within an overall
cost involvement for the two MHC reactors versus the refinery approach can increase capability to respond to market
HDS and MHC reactors will justify the loss in operating variation and clean fuel legislation or more stringent product
flexibility. specifications. Depending on the refiner’s business goals and the
existing refinery configuration, unique technical solutions are
The integrated configuration consists of a single-stage mild
available at every step of the Pentagon Model that encompass
hydrocracker (MHC) reactor in once-through operation
the whole refinery or focus on individual units.
and in parallel a single-stage hydrodesulphurisation (HDS)
reactor in once-through operation. Both reactors operate Shell Global Solutions, together with its various alliances, has
at the same pressure level. The configuration features developed and applied a broad portfolio of integrated and
common high pressure gas and recycle section, common comprehensive technology solutions that refiners can implement.
cold separation section and common work-up section. Enabling refiners to increase margins and prepare for more
stringent emissions regulations, the Sulphur Technology Platform
The configuration assessments and optimisation studies
allows refiners not only to survive, but also to thrive.
resulted in several benefits to the refinery project. The
refinery achieved its highest diesel and kerosene yields, Yvonne Lucas
while meeting Euro 5 standards and producing Licensing Technology Manager, Refining,
unconverted oil requirement as feed for FCC. The project Shell Global Solutions International B.V.
utilised low capex involvement whilst optimising energy
efficiency and reliability of operations.
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Responding to
Platform enables proper amine hygiene, ensuring that the
treating solvent a refiner is using matches what the system
was designed for. It also ensures that the type of amine
increasingly molecule and the amount of amine circulating solution is
correct, so that all the amine molecules are able to pick up
stringent the acid gas components. Most gas streams contain some
contaminants that degrade amine over time and form, for
What Shell does in its own refineries every one to two years
is to clean up the amine, bringing in outside truck-mounted
systems to take out these contaminants so that the amine can
be restored to its full capacity.
The sulphur paradox is resulting in refiners being squeezed from Applying the first pentagon can help refiners get five to 10
both sides by tighter product specifications and increasing per cent more capacity out of the assets that they already
emissions legislation. have without making significant equipment changes. Before
Although there are several technologies that take out the sulphur and making a new investment, refiners that thrive are making sure
nitrogen molecules from the hydrocarbons, these molecules then end they are getting the maximum out of what they have while
up in some of the streams that must be cleaned up. Sulphur, mostly as they plan for any future additions and operational changes.
hydrogen sulphide (H2S) is removed from the above streams using Second pentagon: Debottlenecking the amine system
treating solutions. The treating solutions are then regenerated, thereby When applying the second pentagon, refiners implement
creating a H2S rich stream that must be handled. Refiners are not short-term solutions or revamps, allowing investments to be
permitted to just send this stream to an incinerator, burn it to SO2 and made during a normal turnaround.
emit it into the atmosphere. They must convert the H2S to something
else; a by-product that can be used, such as sulphur, or disposed of Many new amine solvents available today are more
as non-hazardous waste. How can refiners manage all of this? energy-efficient and have higher capacity. As a result,
change out of a solvent during a turnaround can help a
A range of investments through application of the Shell Global refiner get more capacity in the system. For instance, a plant
Solutions Pentagon Model can help refiners meet future regulation in the northern part of the US was using diethanolamine
and environmental issues that deal with handling sulphur as a (DEA) as the solvent, and the inlet gas rates were about to
by-product. A portfolio of technologies as part of Shell Global increase by about 30 to 35 per cent. Shell Global Solutions
Solutions’ Sulphur Technology Platform can help remove refinery studied the facility and recommended changing the refining
emissions, enabling refiners to manage the sulphur paradox. process to the Sulfinol-X1 process. The plant was able to
First pentagon: Handling more H2S boost capacity by 30 per cent and save energy for
With refiners faced with doing more with less, the first step is to make regeneration without making any hardware changes.
sure they are getting the maximum use out of the assets they have The plant was able to lower its circulation rate due to the high
before they start making new investments or wholesale changes to capacity of Sulfinol-X and the smaller heat of regeneration
refinery operations. This process of going back and looking at requirements.
refinery assets based on current and anticipated concerns is known Another refinery was adding a new hydrotreater unit (DHT)
as the first pentagon. It is the starting point in the journey to improved and wanted help with optimising their amine system. They
operations, which continuously adapt to changing product needed amine for the recycle hydrogen scrubber in the new
specifications and emissions standards. DHT, and wanted the same amine for use in other parts of
the refinery. The facility still needed to meet the sulphur
specifications on the low-pressure fuel system. Shell Global
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HYDROCARBON
PROCESSING®
Solutions evaluated the system and changed the coming from the sulphur plant. The tail gas coming from the sulphur
monoethanolamine (MEA) process that they were using to the plant contains many sulphur species. In a tail gas treating plant, all
Shell Global Solutions’ ADIP-M (aqueous MDEA) process. these sulphur species are converted to H2S, which is then picked up
In addition, Shell Global Solutions recommended acid aided by an amine system and recycled to the front end of the Claus unit.
regeneration additive that was needed to keep the fuel gas
The Shell Claus Offgas Treatment unit (SCOT) is a low sulphur,
H2S specification low. This helped increase the sulphur
low-temperature tail gas treating unit that allows refiners to achieve >
handling capacity from 167 t/d to 290 t/d (almost double the
99.9 per cent sulphur recovery. This particularly helps refiners meet
capacity of the system), supply amine to new DHT recycle gas
the fluid catalytic cracking (FCC) consent decree, whereby refineries
scrubber and maintain low fuel gas H2S specifications without
are expected to reduce sulphur emissions, or at least hold the sulphur
adding a whole new unit.
emissions at the levels at which they were at before, whilst the feed to
Even simple, small changes and investments can get refiners the FCC is increasing in sulphur content.
anywhere between 15 to 30 per cent more capacity in the
In the new Shell Global Solutions designs, the amine unit, the sulphur
existing assets.
plant and the tail gas treating units are all completely integrated so
Third pentagon: Achieving very low sulphur emissions refiners can thrive by achieving very high (>99.9 per cent) sulphur
Refiners ultimately look to implement long-term solutions or recoveries and low emissions. Shell Global Solutions, along with its
schedule phased investments as part of the third pentagon. The various alliances, offer the extremely robust Sulphur Technology
Sulphur Technology Platform provides a range of technologies Platform that covers all facets of refinery operations where sulphur or
that can help refiners focus on long-term improvements while nitrogen is present in any form, allowing refiners to respond quickly
meeting product and emissions standards at the same time. and effectively to changing environmental specifications.
For example, the Claus, SuperClaus and EuroClaus units can
take a refinery up to 96 to about 99.3 per cent sulphur Pervaiz Nasir
recovery. However, if a refinery needs to go beyond this, Regional Manager Gas/Liquid Treating and Sulphur Processes,
they would need to add tail gas treating to the tail gas Shell Global Solutions (US) Inc.
2
6 in wt. eq.
sulphur emitted
Reduce SOx
and NOx
in emissions
Produces more
elemental
sulphur
91 in wt. eq.
sulphur
converted into
elemental
sulphur
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Beyond ULSD:
Refiners implement
tomorrow’s distillate
upgrading technology t
The global distillate market is expected to remain tight over the next designs, customised catalyst solutions and process
few years, which will continue to encourage refiners to favour diesel configurations from the Sulphur Technology Platform,
production over gasoline. Complicated further by the sulphur refiners are able to not only survive but thrive in this
paradox, senior refinery managers are asking themselves how they volatile environment.
can maintain efficiency, throughput and margins in this challenging
A strong ULSD catalyst portfolio
environment.
A strong ULSD catalyst portfolio is a key enabler for
Although redirecting heavy naphtha is a way to generate additional upgrading diesel quality while meeting sulphur
diesel barrels, a greater incentive exists to increase the endpoint of specifications. A robust and flexible portfolio maximises
diesel streams or upgrade more fluid catalytic cracking light cycle activity to reduce the volume of catalyst necessary to
oil (FCC LCO) from the heating or fuel oil pool into on-road diesel. achieve ULSD targets. This frees up reactor volume for
For example, since 2005, when Euro 4 ULSD specifications took other upgrading catalyst system options. The catalyst
effect in Europe, the value of diesel over lower quality dispositions portfolio provides a range of nickel molybdenum (NiMo)
has increased by a factor of three to five times. With more stringent and cobalt molybdenum (CoMo) catalysts to control
legislations cropping up all over the globe, refiners have hydrodesulphurisation (HDS), hydrodenitrification (HDN)
considerable economic incentive to upgrade heavy diesel molecules and aromatic saturation (ASAT) thus improving the quality
or convert LCO to ULSD product now and for the foreseeable future. of the feed flowing to the catalyst systems. Offering the
flexibility to modify hydrogen consumption and offset
The challenge will be to adopt more innovative ways of thinking
hydrogen requirements associated with additional
about meeting long-term product standards and emissions
upgrading requirements, the ULSD catalyst portfolio also
legislation in order to maximise diesel volume. The good news is
provides a flexible set of products that can be
that refiners can optimise operations and meet these requirements
presulphurised, activated and regenerated to meet unit
through the multi-platform Shell Global Solutions Pentagon Model.
process and operations requirements.
The Pentagon Model can help refiners move “beyond ULSD” to
improve cetane, reduce aromatics, upgrade cold flow properties, Criterion Catalysts & Technologies’ portfolio is extensive,
improve density, reduce heavy diesel end point, process biodiesel reflecting the continuous innovation and commitment to
components and shift conversion between naphtha, kerosene and catalysis research and development across all
diesel. By employing the Pentagon Model with advanced unit hydroprocessing applications. The latest products allow
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HYDROCARBON
PROCESSING®
y today
ULSD to occur in a reactor volume that is only 60-75 per Shell Global Solutions HD-trays have been able to substantially
cent (~10-15°C more activity) of first generation ULSD improve performance of units by distributing gas and liquid more
products in the market. The CENTERA® products in widely over the catalyst bed. The robustness of these distribution
particular provide refiners with a great opportunity to trays combined with a high tolerance against tray tilt and a
reduce the amount of catalyst needed to make ULSD, boltless, weldless and ergonomic design, have made these trays a
freeing up space to utilise other upgrading catalysts in the desirable choice for refiners in application of the second
same reactor system. Both the CoMo DC-2618 at lower pentagon (revamps) and for new units. Over 1500 trays have
operating pressure and the NiMo DN-3630 at higher been supplied to customers in the last 10 years. Besides the
operating pressures offer considerable activity gains. HD-tray, the UFQ has been an integral component for higher
severity applications like ULSD and hydrocracking units, which
Reactor internals technology
have a large heat release and need of uniform temperature
Implementing the additional chemistries requires proper control from bed to bed.
control over the reaction environment, which in many cases
requires much finer control over gas and liquid flows as After implementing a strong ULSD catalyst portfolio and reactor
well as reaction temperatures. In fact, if proper mixing and internals technology, refiners looking to implement additional
redistribution does not occur, there can be a detrimental chemistries can choose from various types of upgrading that are
impact on the catalytic environment, which can reduce enabled by catalyst and reactor internals technologies; to operate
product quality or degrade yields. in the “beyond ULSD” mode. These include: ASAT, selective ring
opening (SRO), “mild” hydrocracking (MHC) and cold flow
Shell Global Solutions’ reactor internals technology improvement via catalytic dewaxing (CDW).
provides advanced vapour and liquid distribution and
Aromatic Saturation (ASAT)
optimised mixing of vapour and liquids. Two of the most
Refiners can choose from two catalyst plus process ASAT solution
widely known are the high dispersion distributor tray
options, depending on the degree of aromatic saturation required.
(HD-tray) and ultra flat quench (UFQ) assembly, both of
which are responsible for ensuring maximum contact of Single Stage – Enhanced Aromatic Saturation (EAS)
liquid and gas with the catalyst and uniform temperature EAS involves utilising a bed or two of a multi-bed ULSD unit for
control of both phases separately, as a result of excellent ASAT. In this scenario, all or most of the HDS and HDN reactions
mixing performance regardless of quench load. occur in the lead beds of reactor. The low levels of organic
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sulphur and organic nitrogen in the latter beds of the reactor Selective Ring Opening (SRO)
create an environment that is favourable for ASAT to occur. Diesel SRO can provide improved diesel product quality (density,
is then processed in the latter beds to meet cetane, density, and aromatics, cetane) with a distillate selective reaction
aromatics content targets for ULSD product specifications. This pathway due to the clean nature of the ULSD product.
allows a portion of the reactor to be operated in a temperature Catalyst acidity is carefully controlled to avoid full
range that is favourable for ASAT, maximising ASAT and the hydrocracking, which would result in excessive distillate
product property improvements associated with it throughout the yield shift to naphtha.
catalyst cycle.
Shell Global Solutions and Criterion Catalysts &
Two-Stage - Deep Aromatic Saturation (DAS) Technologies offer a wide range of solutions including
The requirement for the first stage operation of the two-stage ASAT naphtha hydrotreaters to process straight run naphtha and
technology, indicated as DAS for deep aromatic saturation, is to coker naphtha, distillate hydrotreaters, and sulphur recovery
prepare ULSD feedstock for the second stage noble metal catalyst units - all of which form part of Shell Global Solutions’
system. Since the noble metal catalyst can be poisoned by H2S overall Sulphur Technology Platform.
and NH3, these by-products are removed in an inter-stage stripper,
Utilising SRO for cetane enhancement will result in some
and the stripped liquid is recombined with clean treat gas to
shift of distillate to naphtha. The multi-functional catalysts
complete the aromatic saturation reactions.
used in the SRO system permit some naphthenic molecules
An advantage of two-stage ASAT units is that they can be to “exit” the reversible aromatic saturation loop via
designed for low to moderate pressure operation. The major conversion, increasing the overall conversion. SRO catalyst
disadvantages are that they are more complex than single stage systems can also deliver the required density, aromatics
operations and are hydrogen intensive. and cetane at ~10 per cent lower overall H2 consumption
than ASAT.
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HYDROCARBON
PROCESSING®
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Improving Operations:
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HYDROCARBON
PROCESSING®
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