Technology And Cost Of Technology And Cost Of Overview Overview - PDF document

Technology And Cost Of Technology And Cost Of Overview Overview Sulfur Reduction In Sulfur Reduction In • Why Low Sulfur Fuels Transportation Fuels Transportation Fuels • How To Reduce Sulfur in Both Gasoline and Diesel • International Experience Regarding The Central America Regional Workshop Central America Regional Workshop Benefits and Costs of Reducing Sulfur Fuel Quality Fuel Quality Michael P. Walsh Michael P. Walsh Tons of Directly Emitted PM From Tons of Directly Emitted PM From Increase in In-Use Vehicle Emissions Increase in In-Use Vehicle Emissions Diesel Fuels Sulfur Diesel Fuels Sulfur in Bangkok Due To Sulfur in Fuel in Bangkok Due To Sulfur in Fuel (Gasoline) (Gasoline) Tons Per Million Gallons Percent Increase 2.5 Compared to 150 PPM Sulfur 2 67% 60% 500 ppm 800 ppm 50% 1.5 70% 40% 1 33% 30% 74% 30% 0.5 20% 26% 10% 0 0 500 1000 1500 2000 2500 3000 3500 4000 4500 5000 0% CO/10 HC NOx Sulfur in Fuel (PPM) Derived From US EPA Data Impact on Vehicles Meeting EURO 3 Standards 1

Increase in In-Use Vehicle Emissions Increase in In-Use Vehicle Emissions Other Benefits from Sulfur Control Other Benefits from Sulfur Control in Bangkok Due To Sulfur in Fuel in Bangkok Due To Sulfur in Fuel (Diesel) (Diesel) • Sulfur reduction reduces SO2 emissions. 94% 100% 350 ppm 500 ppm – Less sulfate formation in the atmosphere (about 1/3 90% of SO2 reacts to sulfate) 80% – Reduced acid rain. 70% • Sulfur reduction reduces engine wear. 60% 45% 50% – Reduction from 2500 ppm to 500 ppm reduces engine 33% 40% wear 10 - 20%; about 33% if starting out at 5000 ppm. 30% 16% – Greater engine wear with infrequent oil change. 20% 5% 0% 10% • Allows More Advanced Vehicle Technologies 0% HC NOx PM • Retrofit Opportunities Impact on Vehicles Meeting EURO 3 Standards What a refinery does: What a refinery does: Typical Refinery Products Typical Refinery Products • Converts crude oil to usable products • Liquefied Petroleum Gas (LPG) • Naphtha (for petrochemical feed) • Adjusts yields to match product demand • Motor Gasoline • Distillates (Jet, Diesel, Heating Oil) • Lubricants, Waxes • Adjusts qualities to meet product • Fuel Oil specifications. • Asphalt 2

Types of Refinery Processes Crude Oil Characteristics – –Sulfur Sulfur Types of Refinery Processes Crude Oil Characteristics Sweet vs Sour Crude Sweet vs Sour Crude • Physical Separation Processes Product Sweet Crude Sour Crude – Distillation/Fractionation (PPM Sulfur) (PPM Sulfur) – Extraction Naphtha 100 400 Jet/Kerosene 500 4000 • Chemical Processes – Cracking/Conversion Distillate 2000 10000 – Combination/Reformulation Fuel Oil 6500 30000 – Hydrotreating Refinery Configuration Refinery Configuration Topping Refinery Topping Refinery Overview Overview • Topping – Simple crude separation, no FG LPG LPG ability to change yield and quality 2 1 • Hydroskimming – Simple crude separation, SR Naphta 400 F Naphta no ability to adjust yield. Can increase 30 P 31 R C O octane, lower sulfur Crude Kerosene 500 F D 100 MBPD D 12 U Distillate • Conversion – Yield adjustment capability C U 30 T S Diesel 700 F and quality improvement Fuel Oil 18 37 • Deep Conversion – Large yield/quality Atm. Residue 700+ F flexibility, fuel oil minimization. 37 3

Hydroskimming Refinery Hydroskimming Refinery Reformer Reformer Gas • SR Naphtha is hydrotreated and split. LPG LT Naph Isomerate ISOM • Heavy part (Heavy Naphtha) is 5 5 3 Naph H T catalytically processed and reformed to a 30 HY Naph REF Reformate P Gasoline C 25 22 R 28 highly aromatic stream called Reformate. Crude O D 100 MBPD Kerosene D U 12 U Advantages: - High octane product Distillate C 30 T S Diesel TR Diesel H D S - Hydrogen also a product 18 18 Fuel Oil 37 Disadvantages: Aromatics are toxic and are Atm. Residue limited in clean fuel specs. 37 C5C6 Isomerization C5C6 Isomerization Diesel Hydrodesulfurization (HDS) Diesel Hydrodesulfurization (HDS) • Straight chain paraffins are catalytically • Standard Diesel HDS: converted to their chain counterparts. – Sulfur is catalytically removed in the presence of hydrogen • Advantages: - 10 to 12 numbers octane gain - Elimination of toxic benzene • Deep HDS – Higher activity catalyst and catalyst volume • Disadvantage: Product has higher RVP – More hydrogen consumed – High severity, high pressure operation – Loss of diesel yield 4

Conversion Refinery Conversion Refinery Fluid Catalytic Cracking (FCC) Fluid Catalytic Cracking (FCC) Catalytic Cracking (FCC) Catalytic Cracking (FCC) • Vacuum and coker gasoil feeds Gas LPG • Makes gasoline out of vacuum gasoil (a stream 4 Naph Gasoline Naph heavier than diesel). 30 Complex 44 C • Using intense heat (about 1,000 deg F), low Crude D P Kerosene R 100 MBPD U 12 pressure and a powdered catalyst, the cat O Distillate D 32 H D S Diesel TR Diesel U cracker converts heavy fractions into smaller 18 C LPG T ALKY gasoline molecules S V VGO F FCC Naph D C 25 • Product streams typically have high sulfur U C FCC LCO Fuel Oil Slurry content 17 Diesel HDS and Aromatic Diesel HDS and Aromatic Alkylation Alkylation Saturation Saturation • Combines FCC gas (propylenes/butylenes) with • Necessary for FCC LCO treatment isobutane to produce a high octane stream • 1 st stage - requires Diesel HDS called alkylate. • 2 nd stage – aromatic saturation with noble • Catalyst is sulfuric or hydrofluoric acid catalysts • Alkylate is an excellent diluent for other gasoline – Process consumes hydrogen blending components. – Gains of 17 to 23 cetane numbers are possible 5

Hydrocracking Hydrocracking Deep Conversion Refinery Deep Conversion Refinery Catalytic Cracking, Coking & Hydrocracking Catalytic Cracking, Coking & Hydrocracking • Similar and preferably lighter feeds than Gas cat cracking LPG 5 Naphta Naph Gasoline • More flexible. Can optionally maximize 30 Complex 47 C Kerosene gasoline, jet or diesel D 12 Crude U Distillate P 100 MBPD Diesel TR Diesel 42 HDS R • Uses a different catalyst, much greater 18 O LPG D ALKY pressure than FCC and a lot of U V FCC Naphta C F VGO T D C hydrogen 25 FCC LCO S U C Fuel Oil Slurry 2 Naph • Products have minimal sulfur C Naphta O H Distillate Kerosene K K Diesel E R Coke R Visbreaking Coking Visbreaking Coking • Also vacuum residue feed • Vacuum residue feed • Mild form of thermal cracking. Reduces • Thermal cracking process. No catalyst viscosity of residue involved. • Produces small quantity of diesel. • Use heat and moderate pressure to turn heavy residues to lighter products and coke (a hard coal-like substance used as an industrial fuel). 6

Blending Blending Gasoline Blending Component Qualities Gasoline Blending Component Qualities Light Isomerate Reformate FCC C4 Alkyalte MTBE • Blending is the physical mixture of a number Gasoline Naphtha of refinery streams to a finished product. Sulfur, 200 0 0 1200 5 2 PPM • Options include: Research 72 82 92 - 98 93 96 118 – Batch blending via manifolds into a tank Octane – In-line blending via injection of proportionate Benzene, 1.2 0.2 5.5 .5 0 0 components into a main stream vol% • Additives/Improvers such as octane Aromatics, 2 0.2 65 26 0 0 vol% enhancers, detergents etc. are added before or after blending RVP, psi 12 14 5 7.4 7 8 Clean Gasoline Quality Clean Gasoline Quality Clean Gasoline Quality Clean Gasoline Quality Changes Changes Changes Changes Moderate sulfur reduction Moderate sulfur reduction Severe sulfur reduction Severe sulfur reduction • Run crudes with lower sulfur content • Hydrotreat naphthas and FCC gasoline – Pricier. Not always possible – Higher capital expenditure. Some octane loss. • Distillation tailoring/undercutting – Loss of gasoline volume • Desulfurize FCC feed • Dilute sulfur with alcohol blending – Higher capital cost. – Pricy. Availability issues 7