Transcript Document

Small modular catalytic units for production of high-octane
unblended gasolines through the process of Zeoforming
The process of Zeoforming, an effective method
for production of high-octane unblended gasolines
(Based on the results of industrial operation of a Zeoforming-40 installation)
Zeoforming is a technology for catalytic conversion of low-octane gasoline fractions
(straight-run gasoline fractions of oils and gas condensates) into high-octane
unblended gasolines proved at pilot to industrial levels.
Zeoforming has been adjusted:
Pilot level:
At the Urengoy Gas Condensate Processing Plant, Nizhnevartovsk Gas
Processing Plant, Luginetskoe Oil Field (Tomsk Region), Volgograd Refinery,
Orenburg Gas Processing Plant.
JSC Siberian Technological Company “Zeosit” - SEC “Zeosit” Pr. Lavrentieva, 6, Novosibirsk 630090, Russia Tel. /Fax: (383) 330-05-96, 335-62-51
E-mail: [email protected] URL: http://www.zeosit.nsc.ru
Demonstrational level:
A 5,000-ton/year Zeoforming installation for unblended gasoline
production from stable gas gasoline has been in operation at
Nizhnevartovsk Gas Processing Plant since September 1992.
Industrial level:
An industrial Zeoforming installation of 40,000 ton/year capacity with respect
to straight-run gasoline fraction (“Zeoforming-40”) began to operate in
Poland in February, 1997. Lurgi Company (Germany) was the general
contractor and designer. The commercial products of the installation are
unblended Eurosuper-95 gasoline and liquefied gas. All the guarantee
parameters presented by "Zeosit" are fully met: the octane number of the
gasoline is 95 RON and total yield of both commercial products not less than
92-95%. During the start-and-adjustment works, new additional possibilities
of the process and the catalyst were tested which may allow a still higher
efficiency in future installations (i.e., an increased yield of the commercial
products, octane number of the gasoline, and catalyst lifetime) without
making the investments or running costs higher.
JSC Siberian Technological Company “Zeosit” - SEC “Zeosit” Pr. Lavrentieva, 6, Novosibirsk 630090, Russia Tel. /Fax: (383) 330-05-96, 335-62-51
E-mail: [email protected] URL: http://www.zeosit.nsc.ru
Process parameters:
Temperature, оC
Pressure, MPa
WHSV of the feedstock, ton/ton of cat. per hour
320-450
0.5-1.5
1-4
Advantages:
In contrast to Reforming, the process of Zeoforming does not require:
► a hydrofining stage to remove sulphur and nitrogen-containing compounds
from the raw material
► either hydrogen or any related compressor equipment
► expensive catalysts based on noble metals ,
which decreases the capital and running costs.
The catalysts are based on an environment-friendly system.
The installations can operate autonomously.
JSC Siberian Technological Company “Zeosit” - SEC “Zeosit” Pr. Lavrentieva, 6, Novosibirsk 630090, Russia Tel. /Fax: (383) 330-05-96, 335-62-51
E-mail: [email protected] URL: http://www.zeosit.nsc.ru
Being autonomous, these mini-plants are useful in remote regions
or regions difficult of access where oil, gas condensate, or other
hydrocarbon raw material are produced. They are expedient in
meeting the demand in motor fuels of the local population as well
as geologists and oilmen.
Depending on the type of the raw material and the chosen production
mode, RON-80 or RON-91 - 93 gasolines can be produced at one and
the same installation.
The gasoline yields are:
when RON-80 gasoline is produced – 80-92%,
when RON-91 - 93 gasoline is produced – 65-85%.
JSC Siberian Technological Company “Zeosit” - SEC “Zeosit” Pr. Lavrentieva, 6, Novosibirsk 630090, Russia Tel. /Fax: (383) 330-05-96, 335-62-51
E-mail: [email protected] URL: http://www.zeosit.nsc.ru
Expenditure rates of the main and auxiliary materials
Materials,
Measure units
Approximate
expenditure rate per
1 ton of the feedstock
Catalyst, kg/ton
0.06-0.10
Nitrogen, nm3/ton
~3
Air, nm3/ton
~ 18
4 Cooling down the technological flows
Recycled cooling water
(t=25°C), ton/ton
0-12*
5 Providing for the rectification process
Water vapour, ton/ton
0-0.15*
Fuel gas, nm3/ton
15-25*
Electric power, KWt·hour/ton
15-25**
№
Units, Apparatus, Production Stages
1 Reactors
2 Regeneration and purging
3 Catalyst regeneration
6 Furnace section
7 Pumps, compressors, fans ABO
* - depends on the chosen process flow-sheet
** - depends on the chosen process flow-sheet and the capacities of the chosen electrical receivers
JSC Siberian Technological Company “Zeosit” - SEC “Zeosit” Pr. Lavrentieva, 6, Novosibirsk 630090, Russia Tel. /Fax: (383) 330-05-96, 335-62-51
E-mail: [email protected] URL: http://www.zeosit.nsc.ru
Diagram of conversion of oil fractions or gas condensate into
motor fuels through different processes:
Diagram 1. Conventional scheme (Reforming and isomerisation)
Fractioning
installation
Hydrofining
installation
Hydro-isomerisation
installation
Gasoline
fraction 35%
Feedstock
Diesel fuel 35%
Fuel oil 30%
Hydrogen-containing gas
C5-C6
9%
Gasoline
fraction
26%
Hydrogencontaining gas
Unit of gas
desulphurisation
H2
High-octane
component 22%
iso-paraffins
8.5%
Blending
unit
Reforming
installation
JSC Siberian Technological Company “Zeosit” - SEC “Zeosit” Pr. Lavrentieva, 6, Novosibirsk 630090, Russia Tel. /Fax: (383) 330-05-96, 335-62-51
E-mail: [email protected] URL: http://www.zeosit.nsc.ru
Diagram 2. Zeoforming technology
(Verkh-Tarskoe oil is taken as an example)
High-octane gasoline
Fractioning
installation
Zeoforming
installation
Gasoline
fraction 35%
Feed-stock
Diesel fuel 35%
25-28%
Fuel gas
1%
Liquefied gas
6-9%
Fuel oil
30%
JSC Siberian Technological Company “Zeosit” - SEC “Zeosit” Pr. Lavrentieva, 6, Novosibirsk 630090, Russia Tel. /Fax: (383) 330-05-96, 335-62-51
E-mail: [email protected] URL: http://www.zeosit.nsc.ru
Dynamics of costs and profits
depending on the capacity of a Zeoforming installation
(the data concern the production of gasolines of 92 to 95 RON)
Costs, rel. units
Profits, rel. units
80 thou. ton/year
40 thou. ton/year
Точечная 3
Starting the installation
0
5
10
15
20
25
30
35
40
45
50
55
number of months
60
JSC Siberian Technological Company “Zeosit” - SEC “Zeosit” Pr. Lavrentieva, 6, Novosibirsk 630090, Russia Tel. /Fax: (383) 330-05-96, 335-62-51
E-mail: [email protected] URL: http://www.zeosit.nsc.ru
Comparative analysis of the net present value (NPV)
for the installations of high-octane gasoline production
via Zeoforming and Reforming
NPV, million USD
10
Zeoforming
8
Reforming
6
4
2
0
-2 0
-4
20
40
60
80
100
Capacity of installation with respect to the gasoline produced,
thou. ton/year
JSC Siberian Technological Company “Zeosit” - SEC “Zeosit” Pr. Lavrentieva, 6, Novosibirsk 630090, Russia Tel. /Fax: (383) 330-05-96, 335-62-51
E-mail: [email protected] URL: http://www.zeosit.nsc.ru
Range of the benzene content
in Zeoforming gasolines (1) and Reforming gasolines (2)
depending on the octane number of the gasoline
Benzene content, %wt.
12
10
Reforming
gasolines
2
8
6
4
Zeoforming gasolines
2
1
0
70
75
80
85
90
MON of the gasoline
JSC Siberian Technological Company “Zeosit” - SEC “Zeosit” Pr. Lavrentieva, 6, Novosibirsk 630090, Russia Tel. /Fax: (383) 330-05-96, 335-62-51
E-mail: [email protected] URL: http://www.zeosit.nsc.ru
Range of the aromatic content
in Zeoforming gasolines (1) and Reforming gasolines (2)
depending on the octane number of the gasoline
Aromatic content, %wt.
80
70
Reforming
gasolines
60
2
50
1
40
Zeoforming
gasolines
30
20
10
65
70
75
80
85
90
MON of the gasoline
JSC Siberian Technological Company “Zeosit” - SEC “Zeosit” Pr. Lavrentieva, 6, Novosibirsk 630090, Russia Tel. /Fax: (383) 330-05-96, 335-62-51
E-mail: [email protected] URL: http://www.zeosit.nsc.ru
Zeoforming vs. Reforming:
key parameters
Additionally required
for Reforming
Parameter
Zeoforming
Reforming
The reaction temperature, оC
320-450
480-520
Pressure, atm.
5-15
3-35
Hydrogen equipment
Is not required
Is required
Hydrogen equipment
Raw material hydrofining
Is not required
Is required
Desulphurisation Unit
Raw material
Hydrocarbon fractions C5 –
Hydrocarbon fractions C6
240оC; olefin-containing gases;
–180оC (naphthenes)
oxygen-containing compounds
Catalyst
Contains no noble metals;
ecologically safe
Contains Pt, Pd; may
contain other heavy
metals
Final product
High-octane gasoline ready for
use, with benzene content 1-3%
vol. The second desired product
is liquefied gas The second
desired product is liquefied gas,
a fuel both for domestic
purposes and for automobiles
High-octane aromatic
component of gasoline
which needs blending,
with benzene content
5-15% vol.
Blending Unit
JSC Siberian Technological Company “Zeosit” - SEC “Zeosit” Pr. Lavrentieva, 6, Novosibirsk 630090, Russia Tel. /Fax: (383) 330-05-96, 335-62-51
E-mail: [email protected] URL: http://www.zeosit.nsc.ru
Zeoforming vs. Reforming:
key parameters
Parameter
Gasoline yield :
Zeoforming
RON-80
Motor gasoline :
RON-92 «Euro-super-95»
- for fraction 35-160оС
80-90%
65-75%
60-67%
- for fraction 70-180оС
85-92%
70-85%
65-75%
Reforming
Additionally
required for
Reforming
Depend on blending
conditions
Blending Unit
Desulphurisation Unit
Permissible sulphur
content in the raw material
is not limited
less than 0.0004 % wt.
Sulphur content in the
gasoline produced
depends on the sulphur content in the raw
material but does not exceed 0.05% wt.
no more than
0.0004% wt.
Catalyst lifetime
Continuation
proved to be at least 20 000 hours at the
industrial installation Zeoforming-40 in
Poland
Costs of the catalyst:
Zeoforming –
$ 18 000-20 000 /ton;
Reforming –
$ 67 000-90 000 /ton
For capacities 80-600 thousand tons/ year,
Is profitable for
Economic characteristics
the investments are repaid in less than
capacities above 6001.5 – 2.5 years
800 thousand tons/year
JSC Siberian Technological Company “Zeosit” - SEC “Zeosit” Pr. Lavrentieva, 6, Novosibirsk 630090, Russia Tel. /Fax: (383) 330-05-96, 335-62-51
E-mail: [email protected] URL: http://www.zeosit.nsc.ru