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(1) Oil sand bitumen hydrotreating / hydrocracking to produce synthetic crude oil. UOP always strives to provide users with the most economical technology for solving problems. Canadian Northern Sunshine Company wants to use oil sands asphalt to produce synthetic crude oil with high cetane ULSD, choose solvent deasphalting as a modification technology of oil sands asphalt. In order to obtain high quality synthetic crude oil, it is necessary to hydrogenate the deasphalted oil, vacuum gas oil and atmospheric gas oil obtained from the oil sand bitumen, thus requiring multiple sets of hydrogenation units to meet the requirements. UOP has designed a combination of DAO hydrotreatment, atmospheric gas oil hydrotreating and VGO / DAO hydrocracking, saving investment and operating costs. The amount of equipment, compression, pumping and process heating utilities are greatly reduced. DAO is modified by DAORCDUnionfining technology. Hot high pressure separators operating at high temperatures are integrated with atmospheric gas oil hydrotreaters. Most of the naphtha and about half of the distillate produced in the DAO RCD Unionfining reactor is still in the vapor phase under the operating conditions of the hot separator. Of the hot separator effluent, there is also a sufficient amount of hydrogen available for the hydrotreating of atmospheric gas oil. As a result, the vapor-phase distillate from the top of the hot separator can be fed directly to the atmospheric gas oil hydrotreating reactor, hydroprocessed with atmospheric gas oil, and the reactor volume and operating conditions are designed to produce ULSD specifications. Only - some of the more hydrogen used to meet the needs of the reactor bed cooling. The hydrotreated DAO obtained at the bottom of the first hot separator is sent to the hydrocracking reactor inlet. The addition of a high pressure, low pressure head pump to the bottom of the hot separator greatly reduces the power required to send the hydrotreated DAO to the hydrocracking reactor inlet, reducing design pressure and therefore reducing equipment and investment. The VGO from the vacuum tower is passed to the inlet of the hydrocracking section and the VGO / DAO blend is converted to the desired quantity of product within the VGO distillation range for blending to produce a synthetic crude. The first reactor for hydrocracking was packed with the highly active pretreatment catalyst KF-848 supplied by the UOP / Albemarle Consortium overlying the Unicracking catalyst for hydrocracking. This allows control of the first reactor's organic nitrogen removal rate to optimize plant performance and operating cycle. The effluent from both the hydrotreating and hydrocracking reactors shares a splitter and a fractionation system. (2) Overweight Crude Hydrotreating / Hydrocracking to Produce Synthetic Crude Oil. UOP designed a hydrogenation unit for users in South America who process Orinoco heavy crude in Venezuela. The project includes the processing of overweight crude oil with a 9 API weight with delayed coking and hydrogenation units. Naphtha, light gas oil and heavy gas oil obtained from atmospheric and vacuum distillation and coking units are hydrogenated in several UOP hydrogenation units designed for use with hydrogenated naphtha, distillates and The gas oil is blended with the untreated vacuum residue to yield a synthetic crude oil having a specific gravity of 25 API. Pilot test results designed well, and now the device has been running, and meet the design requirements. (3) Unicracking hydrocracking unit with separate hydrotreating. UOP has designed separate hydrotreating hydrocracking processes for several heavy crude oils and more heavily coker gas oils. Crude oil from these plants comes from high nitrogen crude oil such as Marlene crude oil with a specific gravity of 18.4 API and nitrogen content of 4000ppm and crude oil of the West Coast of the United States with a specific gravity of 15.3API and a nitrogen content of 5400ppm. Users in South America want to produce the largest amount of distillate oil and are designed to use a separate hydrocracking hydrocracking process with HC-115 catalyst for hydrocracking; users in the West Coast of the United States produce the largest amount of naphtha and are designed to be hydrotreated separately Hydrocracking processes, hydrocracking HC-24 catalyst selection. These designs were successfully validated in mid-size installations and all achieved the purpose of processing coker heavy gas oil. (4) hydrocracking of deasphalted oil (DAO). There are currently one or two sets of hydrocracking units in the world that process some deasphalted oil to produce lube base oil at low conversions and two sets of hydrocracking units to process deasphalted oil at high conversions to produce transportation fuels. Saudi Aramco Riyadh refinery hydrocracking unit processing vacuum gas oil (VGO) / deasphalted oil (DAO) mixed oil (deasphalted oil accounted for 15% -20%), the use of two processes, the maximum flexibility in the production of Naphtha or middle distillate. HYDROCRACKING UNITS AT Whangarei Refinery, New Zealand VGO / DAO blends containing 20-25% deasphalted oil are processed to produce maximum quantities of kerosene and diesel. The catalyst system contains four catalysts, DHC-39, DHC-32, HC-115 and DHC-8. It has been confirmed that DHC-8 catalyst can effectively convert the tail of deasphalted oil. Since its operation in 1997, the plant has been able to achieve the highest yield of middle distillates and maximum throughput, resulting in longer catalyst life and significantly improved operating efficiency compared to past operating conditions. Due to the improved performance of hydrocracking units, New Zealand Refineries has been able to meet 96% of New Zealand's domestic diesel demand, 89% of jet fuel and kerosene demand and 73% of gasoline demand. A set of hydrocracking units in Europe is designed to process VGO / DAO blends to produce the largest amount of mid distillate. Crude oil contains 25% DAO, DAO nitrogen 3800ppm, Con's residual carbon 6.5%, nickel + vanadium 30ppm, the design will be 95% of the feedstock into distillate. The device uses two steps, the catalyst system containing KF-848, DHC-32, DHC-39 and DHC-8 four catalysts. The results of the operation of the medium-sized plant have confirmed that the design values ​​are better than expected.
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