RP214 Toc

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CONTENTS
GLOSSARY xxiii
1 INTRODUCTION 1-1
2 SUMMARY 2-1
TECHNICAL ASPECTS 2-1
ECONOMIC ASPECTS 2-2
3 INDUSTRY STATUS 3-1
TRENDS IN TRANSPORTATION FUEL DEMAND 3-3
TRENDS IN ENVIRONMENTAL REGULATION 3-3
Gasoline 3-7
Kerosene 3-8
Diesel Fuel 3-9
Heating Oil and Residual Fuel Oil 3-9
INSTALLED CAPACITIES 3-11
Worldwide Summary 3-12
United States and Canada 3-14
Europe 3-16
Asia-Pacific 3-16
Latin America and the Caribbean 3-17
The Middle East and Africa 3-17
NEW HYDROTREATING CAPACITY 3-17
4 HYDROTREATING TECHNICAL REVIEW 4-1
PROCESS CHEMISTRY 4-1
Desulfurization 4-1
Denitrogenation 4-1
Deoxygenation 4-2
Hydrogenation 4-2
Demetalation 4-3
Carbon Residue Reduction 4-4
Hydrocracking 4-4
Reaction Thermodynamics 4-4
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CONTENTS (Continued)
4 HYDROTREATING TECHNICAL REVIEW (Concluded)
PROCESS VARIABLES 4-5
Reaction Temperature 4-5
Reaction Pressure 4-5
Space Velocity 4-6
Catalyst Types 4-6
HYDROTREATING CATALYSTS 4-6
Active Metals 4-6
Catalyst Supports 4-7
Promoters 4-9
Catalyst Suppliers 4-9
Catalyst Loading/Unloading 4-13
Catalyst Deactivation 4-15
Catalyst Regeneration and Rejuvenation 4-16
HYDROTREATING REACTORS 4-16
Fixed Bed Reactors 4-17
Moving Bed Reactors 4-17
Ebullated Bed Reactors 4-19
Slurry Bed Reactors 4-19
PRODUCT AND HYDROGEN RECOVERY 4-21
Gas Separation 4-21
Recycle Gas Treatment 4-21
Fractionation 4-23
Makeup Hydrogen Supply 4-24
5 ROLE OF HYDROTREATING IN THE REFINERY 5-1
REFINERY OVERVIEW 5-1
Hydroskimming Refineries 5-1
Conversion Refineries 5-3
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5 ROLE OF HYDROTREATING IN THE REFINERY (Concluded)
REFINERY HYDROTREATING APPLICATIONS 5-6
Naphtha Hydrotreating 5-8
Catalytic Reformer Feed Treatment 5-9
Isomerization Feed Treatment 5-9
Cracked Naphtha Desulfurization 5-10
Benzene Hydrogenation 5-11
Pyrolysis Naphtha Hydrogenation 5-12
Middle Distillate Hydrotreating 5-13
Kerosene Hydrotreating 5-13
Diesel Hydrotreating 5-14
Heating Oil Desulfurization 5-15
Hydrocracking Feed Treatment 5-16
Heavy Gas Oil Hydrotreating 5-16
FCC Feed Treatment 5-17
Lube Oil Hydrotreating 5-17
Indirect Resid Desulfurization 5-18
Resid Hydrotreating 5-18
Residual Fuel Oil Desulfurization 5-19
Coker Feed Treatment 5-20
RFCC Feed Treatment 5-21
6 HYDROTREATING GAS OIL FOR FCC FEED 6-1
FCC PRETREATMENT BENEFITS 6-1
FCC Performance 6-1
FCC Feed Economics 6-2
FCC Product Quality 6-4
PROCESS REVIEW 6-5
Catalyst Patents 6-5
Process Patents 6-5
Commercial Processes 6-8
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6 HYDROTREATING GAS OIL FOR FCC FEED (Concluded)
PROCESS DESCRIPTION 6-9
Hydrotreating Reaction (Section 100) 6-10
Gas Recovery (Section 200) 6-10
Product Recovery (Section 300) 6-11
PROCESS DISCUSSION 6-20
Feedstock 6-20
Product Quality and Yield 6-20
Process Parameters 6-20
Reactor Conditions 6-21
Hydrotreating Catalyst 6-21
Hydrogen Supply 6-21
Equipment Sizing 6-21
Reactor 6-21
Furnace Heaters 6-22
Compressors 6-22
Hydrogen Recovery 6-22
Ammonia and Hydrogen Sulfide Removal 6-23
Product Fractionation 6-23
Catalyst Replacement 6-23
Materials of Construction 6-23
Waste Treatment 6-24
Safety 6-25
COST ESTIMATES 6-25
Investment Costs 6-25
Production Costs 6-26
Economic Analysis 6-35
7 HYDROTREATING RESIDUAL OIL FOR RESID
FLUIDIZED CATALYTIC CRACKING FEED 7-1
RESID PROPERTIES 7-1
RESID HYDROTREATING 7-2
RFCC PRETREATMENT BENEFITS 7-3
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7 HYDROTREATING RESIDUAL OIL FOR RESIDUAL
FLUIDIZED CATALYTIC CRACKING FEED (Continued)
PROCESS REVIEW 7-6
Process Patents 7-7
Reactor Patents 7-7
Hydrotreating (Section 100) 7-8
Feedstock 7-19
Hydrogen Quench 7-21
Reactor 7-21
Furnace Heater 7-21
Compressors 7-21
On-Stream Catalyst Replacement 7-22
Fixed Bed Catalyst Replacement 7-23
Safety 7-25
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7 HYDROTREATING RESIDUAL OIL FOR RESIDUAL
FLUIDIZED CATALYTIC CRACKING FEED (Concluded)
COST ESTIMATES 7-25
Process Comparison 7-38
8 HYDRODESULFURIZATION OF DIESEL FUEL 8-1
ENVIRONMENTAL REGULATIONS 8-1
DIESEL FUEL FEEDSTOCKS 8-2
DIESEL FUEL DESULFURIZATION 8-3
Feedstock Selection 8-3
Reactor Temperature 8-5
Reactor Capacity 8-5
PROCESS REVIEW 8-5
Process Patents 8-5
Feedstock 8-16
Reactor Quench 8-17
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8 HYDRODESULFURIZATION OF DIESEL FUEL (Concluded)
PROCESS DISCUSSION (Concluded)
Reactor 8-18
Compressors 8-18
Safety 8-20
COST ESTIMATES 8-20
9 SATURATION OF AROMATICS IN DIESEL FUEL 9-1
DIESEL AROMATICS TEST METHODS 9-1
ENVIRONMENTAL REGULATIONS 9-4
DIESEL FUEL FEEDSTOCKS 9-6
DIESEL FUEL AROMATICS SATURATION 9-7
Catalyst Hydrogenation Activity 9-9
Hydrogen Partial Pressure 9-12
PROCESS REVIEW 9-12
Process Patents 9-12
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CONTENTS (Concluded)
9 SATURATION OF AROMATICS IN DIESEL FUEL (Concluded)
Feedstock 9-25
Reactor Quench 9-26
Reactor 9-27
Compressors 9-27
Safety 9-30
COST ESTIMATES 9-30
APPENDIX A: PATENT SUMMARY TABLES A-1
APPENDIX B: DESIGN AND COST BASES B-1
APPENDIX C: CITED REFERENCES C-1
APPENDIX D: PATENT REFERENCES BY COMPANY D-1
APPENDIX E: PROCESS FLOW DIAGRAMS E-1
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ILLUSTRATIONS
3.1 Industry Status
Growth of Worldwide Hydrotreating Capacity 3-2
3.2 Industry Status
Refinery Product Consumption: United States 3-4
3.3 Industry Status
Refinery Product Consumption: Western Europe 3-5
3.4 Industry Status
Refinery Product Consumption: Japan 3-6
3.5 Worldwide Hydrotreating Capacity
by Region And FeedstockJanuary 1996 3-13
3.6 U.S. Petroleum Administration for Defense (PAD) Districts 3-15
4.1 Hydrotreating Technical Review
Selectivity of Active Hydrotreating Metals 4-8
Effect of Catalyst Shape on Reactor Pressure Drop 4-10
Effect of Pore Size on Catalyst Activity 4-11
On-Stream Catalyst Replacement for a Moving Bed Reactor 4-14
Fixed Bed Reactor Designs 4-18
Ebullated Bed Reactor Design 4-20
General Hydrotreating Unit Flow Diagram 4-22
5.1 Hydroskimming Refinery Block Flow Diagram 5-2
5.2 Conversion Refinery Block Flow Diagram 5-5
5.3 Refinery Hydrotreating Applications 5-7
6.1 Hydrotreating Gas Oil for FCC Feed
Effect of Hydrotreating Temperature on FCC Naphtha Yield 6-3
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ILLUSTRATIONS (Continued)
Effect of Feed Desulfurization on FCC Naphtha 6-6
Effect of Hydrotreating Temperature on FCC Naphtha Sulfur Content 6-7
Process Flow Diagram E-3
7.1 Hydrotreating Resid for RFCC Feed
Effect of Feed Gravity on RFCC Gasoline Yield 7-4
Effect of Total Fixed Capital on Profitability 7-35
Effect of Arabian Light-Arabian Heavy Price Spread on Profitability 7-40
8.1 Hydrodesulfurization of Diesel Fuel
Effect of Reactor Temperature on HDS and HDN Performance 8-4
Effect of Feed Capacity on Profitability 8-33
9.1 Saturation of Aromatics In Diesel Fuel
Correlation Between HPLC and FIA in
Measuring Total Aromatics Content 9-3
9.2 Saturation of Aromatics in Diesel Fuel
Correlation Between Total Aromatics Content and Cetane Number 9-5
Effect of Reactor Temperature on Aromatics Saturation 9-10
Effect of Hydrotreating Temperature and
Pressure on Total Aromatics Saturation 9-11
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ILLUSTRATIONS (Concluded)
Tradeoff Between Reactor Pressure and
Space Velocity on Aromatics Saturation 9-13
Effect of Feed Capacity on Profitability 9-42
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TABLES
2.1 Gas Oil Hydrotreating
FCC Feedstock Production
Summary of Cost Estimates 2-4
2.2 Resid Hydrotreating
RFCC Feedstock Production
2.3 Diesel Hydrotreating
Low-Sulfur Diesel Production
2.4 Diesel Hydrotreating
Low-Aromatics Diesel Production
3.1 Worldwide Refinery Process Capacities, January 1996 3-1
3.2 Gasoline Specifications 3-8
3.3 Diesel Fuel Specifications 3-10
3.4 Fuel Oil Specifications 3-10
3.5 Worldwide Refinery Hydrotreating Capacity Summary, January 1996 3-12
3.6 Worldwide Hydrotreating Use, January 1996 3-14
3.7 United States and Canada Refinery Hydrotreating
Capacity Summary, January 1996 3-16
3.8 Refinery Hydrotreating Capacity
United States and Canada, January 1996 3-18
Western Europe, January 1996 3-22
Eastern Europe/Commonwealth of Independent States, January 1996 3-25
Asia-Pacific, January 1996 3-27
Latin America and the Caribbean, January 1996 3-30
The Middle East, January 1996 3-32
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TABLES (Continued)
Africa, January 1996 3-34
3.15 Planned and New Hydrotreating Construction, as of October 1995 3-36
4.1 Typical Hydrotreating Catalyst Supports 4-7
4.2 Hydrotreating Catalyst Vendors 4-12
4.3 Commercial Hydrotreating Catalyst Capacity 4-15
4.4 Hydrogen Consumption 4-24
4.5 Makeup Hydrogen Stream Compositions 4-25
5.1 Role of Hydrotreating in the Refinery
Patent SummaryGeneral A-4
Patent SummaryNaphtha A-21
5.3 Licensers for Naphtha Hydrotreating 5-9
5.4 Cracked Naphtha Properties 5-10
5.5 Effect of Olefin Saturation on Octane Loss 5-11
5.6 Benzene Hydrogenation Effect 5-12
5.7 Licensers for Middle Distillate Hydrotreating 5-13
5.8 Properties of Aviation Fuels 5-14
5.9 Properties of Diesel Fuels 5-15
5.10 Properties of Distillate Heating Oils 5-16
Patent SummaryLube Oil Hydrotreating A-27
5.12 Licensers for Heavy Gas Oil Hydrotreating 5-17
5.13 Licensers for Resid Hydrotreating 5-18
5.14 Properties of Residual Fuel Oils 5-19
5.15 Delayed Coker Yield and Quality Benefits 5-20
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TABLES (Continued)
FCC Product Yield and Quality Benefits 6-4
Patent Summary A-29
VGO Hydrotreating Cost Comparison 6-9
Design Bases and Assumptions 6-12
Feed Properties 6-13
Reactor Feed and Effluent Compositions 6-14
Stream Flows 6-15
Major Equipment 6-17
Utilities Summary 6-19
Waste Streams 6-24
Total Capital Investment 6-28
Capital Investment by Section 6-29
Production Costs by Volume 6-32
Hydroprocessing Cost Comparison 6-33
Direct Costs by Section 6-34
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TABLES (Continued)
FCC Feed Hydrotreating Profitability 6-36
Production Economics 6-37
7.1 Typical Resid Properties 7-2
7.2 Resid Conversion Process Comparison 7-3
RFCC Yield Benefits 7-5
Patent Summary A-32
Feed and Effluent Compositions for a Three-Reactor System 7-13
Stream Flows 7-14
Waste Streams 7-24
Production Costs by Hydrotreater Feed Volume 7-31
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TABLES (Continued)
RFCC Yield Benefits 7-34
RFCC Feed Hydrotreating Profitability 7-36
RFCC Feed Hydrotreating Profitability
Arabian Heavy (AH) Versus Arabian Light (AL) 7-39
8.1 Typical Diesel Feedstock Properties 8-2
Patent Summary A-51
Feed Properties 8-9
Feed and Effluent Compositions for Dual Reactor System 8-10
Stream Flows 8-11
Waste Streams 8-20
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TABLES (Continued)
Test Methods Relating To Diesel Aromatics Content 9-2
9.2 Typical Diesel Feedstock Properties 9-7
9.3 Typical Diesel Feedstock Aromatics Distribution 9-8
9.4 Hydrotreating Effect on Aromatics Distribution 9-8
Patent Summary A-55
Feed and Effluent Compositions for Dual Reactor System 9-19
Stream Flows 9-20
Waste Streams 9-29
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TABLES (Concluded)

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