Exxon Mobil New Refinery Trends
Exxon Mobil New Refinery Trends
Exxon Mobil New Refinery Trends
Processes/Breakthroughs in Refinery
Technology
Hydroisomerization
• MIDW™ for fuels
• MSDW™ for lubes
MTG (Methanol-To-Gasoline)
BenzOUT™ (benzene reduction technology via aromatic alkylation)
H2 purification via Rapid Cycle Pressure Swing Adsorption (RCPSA)
Technology Designed to Meet Global Needs
Hydroisomerization
• MIDW™ for fuels
• MSDW™ for lubes
MTG (Methanol-To-Gasoline)
BenzOUT™ (benzene reduction technology via aromatic alkylation)
H2 purification via Rapid Cycle Pressure Swing Adsorption (RCPSA)
What is MIDW?
Mobil Isomerization DeWaxing
Improves diesel cold flow properties:
Pour point
Cloud point
CFPP (cold filtration test)
Selectively converts long chain paraffins to isoparaffins
Enables fuels to flow at low temperatures
Other benefits:
End-point (T95) reduction
Improved cetane and density
Applicable to kerosene and HDC bottoms
Upgrading Diesel via Shape-selective Catalysis
Heavy distillate boiling range streams have increased concentration of n-
paraffins
N-paraffins have high cetane value, but poor cold-flow properties
PARAFFINIC DIESEL
MOLECULE ISOPARAFFINIC DIESEL
MOLECULE
GO
SHAPE-
SELECTIVE
CATALYST
n-Tetradecane 5.0
7-Methyltridecane -37.2
Amount
n-Octadecan 28.2
Methylheptadecane 5.7
n-Nonadecane 32.1
7-Hexyltridecane -28.3
Linear Sequence
3rd Generation
100
70
o
60
50
0 20 40 60 80 100
CLOUD POINT
Cloud REDUCTION (Fo) (oF)
Point Reduction
Increased Selectivity via Catalyst R&D
MIDW catalyst is compatible with
conventional HDT catalysts
“Drop-in” potential as stand-alone or
stacked-bed
Wide operating window
Capable of operating in both sweet and sour
applications
Highly distillate selective (low naphtha/gas yields)
compared to original dewaxing catalyst technology
New ULSD units provide potential
MDDW
MIDW
100
opportunities 90
80
Multi-bed reactors 70
50
40
30
D
20
is
til
la
10
te
N
ap
0
ht
ah
MIDW
LP
G
MDDW
Where is MIDW?
MIDW units currently in operation (8)
- ExxonMobil (2)
- USA (2) (one converted to MSDW)
- Canada (3)
- Germany (1)
- Asia (1)
- Russia (one under construction)
MIDW Commercial Operating Experience
2
1.8
1.6
Feed Sulfur (wt%)
0.4
0.2
0
0 100 200 300 400 500 600
1.8
1.6
SWEET UNITS (TYPICAL)
Feed Sulfur (wt%)
0.4
0.2
0
0 100 200 300 400 500 600
MIDW
Bed
Optional R2
Bypass
Cascade HDT/MIDW commercial data
Renewable Diesel
Isomerized
Renewable Diesel
What about lubes base oil grouping (API)?
Group I Group II Group III Group IV
80 < VI < 120 80 < VI < 120 VI > 120 PAOs
% Sat < 90% % Sat < 90% % Sat > 90%
% S > 0.03 % S < 0.03 % S < 0.03 Chemical Rx
Solvent Refining Catalytic Hydroprocessing Single
Component
Very Wide
Chemical Group V
Spectrum
OTHERS
(E.g. Synthetic Esters)
Chemical Rx
High growth rate for group II and group III base oils
Demand for improved fuel economy and lower emissions translates to lower
viscosity/volatility engine oils
Demand for increased equipment reliability
Extended service intervals/fill for life for engines requires both performance
and stability
Grassroots group II/III plants have Cap-Ex and Op-Ex advantages versus
Group I plants when integrated with existing fuels hydrocrackers.
Others
ExxonMobil
Technologies
Integrated Route to Base Oils
Group I Integrated into Group II & Group III Lube Plant
Group
GroupII Hydroprocessing
Hydroprocessing Catalytic
Catalytic Hydrofinishing
Hydrofinishing Group II
Solvent
SolventPlant
Plant (HDT/RHC)
(HDT/RHC) Dewaxing
Dewaxing(MSDW)
(MSDW) (MAXSAT)
(MAXSAT) Group III
Existing
Existing
Solvent
Group II
SolventDewaxing
Dewaxing
• 8 RHC/RHT units in
80
operation or in design
70 Group III Group III • Group I solvent operation
60 improves VI with a yield
VI Increase
Aromatic Saturation
Kinetic
Relative Aromatics
8 control
6 Equilibrium
Control
4 Kinetic
2 Control
Equilibrium
0
Control
0 20 40 60 80
Relative Temperature
Lube hydrocracker with MSDW™
Lube
Distillate MSDW Base Stock
Hydrocracker
60-80% yield 85-97% yield
VI uplift
20 - 100 4 - 10
H2 Consumption
800 - 2000 100 - 400
(scf/bbl)
MSDW-2 MLDW
Reactive chemistry (Isomerization) (Cracking)
Pour Point, °C -15 -15
KV @ 100°C, cSt 5.03 5.57
Viscosity Index 113 102
Lube Yield, wt% 94.2 75.9
MSDW Catalyst
LHDC/MSDW demonstrated as a versatile process for producing group II/III
base stocks from a range of crude sources
RHC/MSDW can be considered an economic alternative to LHDC/MSDW
when group I facilities exist
MSDW catalysts provide highest dewaxing yields with high VI, and broad
feedstock flexibility
Development of MAXSAT HDF catalyst adds significant value to entire lube
complex
Operating or in Design/Construction
Lube Hydrocrackers 6
RHC/RHT 8
MSDW 24
MAXSAT (HDF) 18
MSDW-2 pilot study on hydrocracked DAO
MSDW catalyst is tolerant to poisons and maintains activity
Dewaxing Temperature (°C) + 80
160 ppm N, 700 ppm
S, 0.57% CCR
+ 60
22 ppm N, 150 ppm S
24 ppm N, 280 ppm S 0.14% CCR
0.06% CCR
+ 40
+ 20 2 ppm N
18 ppm S 2 ppm N
8 ppm S
Base
0 50 100 150 200 250
Time on stream (days)
HDC HVGO HDC DAO HDC DAO HDC DAO HDC DAO
feed 1 -reference feed 2 feed 3 feed 4 feed 5
ExxonMobil Methanol to Gasoline Technology Overview
Paraffins
Naphthenes Gasoline
Aromatics
ExxonMobil MTG Process Flow Diagram
Treated
Gasoline
Heavy
Gasoline Finished
Gasoline
Stabilized
H2O Gasoline
Raw HGT
Gasoline Stabilizer Reactor
DeEthanizer Splitter Stabilizer
27
New Zealand Plant Operating Experience
Daily gasoline yield and octane indicated a very consistent process performance
1 vol %
legislation pending 1 vol % 1 - 5 vol %
range
0.62 vol%
1.5 - 4 vol %
range
Reformate ~ 30 3-11 ~ 75
Hydrocrackate ~3 1-5 ~3
Others ~ 31 0-3 ~6
Octane
Gasoline Gasoline Hydrogen Light
Volume Pool Balance Olefins
Reduced
Reformer Feed Tailoring -
Production
Benzene Light Olefins
Concentrate Pretreatment
Light end
Full Reformate
Splitter BenzOUT
Reactor
Splitter
Incentives include:
reducing benzene to meet regulations
upgrading light olefins to high octane gasoline
increasing gasoline volume and reducing RVP
commercially demonstrated
avoid H2 consumption
provide the flexibility to increase H2 production by allowing refineries to feed
the C6’s to the reformer
Conversion can be achieved according to specific needs
100
Benzene Conversion (%)
Olefin/Aromatic Ratio
BenzOUT (example of product volume increase)
benzene light olefin
pre‐treatment
concentrate
light end
full reformate
Splitter
40 KB/D
splitter
42.3 KB/D
Page 8
BenzOUT product properties
Typical Gasoline End Point
Temperature (oF)
Product
Feed
% Evaporated
Final product properties are a function of feed composition and
benzene conversion
approximate (R+M)/2 increase of 2 - 5
approximate RVP reduction of 0.5 PSI
Process demonstrated in a North America refinery
Light Olefin
Reformate
BenzOUT
Catalyst
Mogas Blending
100
Olefin/Aromatic ratio
Benzene Conversion (%)
0
0 10 20 30 40 50 60
Days on Stream
Hydrogen (%)
90
• Reliable through first three-months 85
operation 80
– unattended operation w/ no unplanned
shutdowns 75
– seamless integration with refinery treat gas 70
system
65
– tested for full hydraulic load at various speeds
– varied product flows and enriched hydrogen 60
10/25/07 11/4/07 1/13/08
concentration
– demonstrated individual module flexibility via
planned S/D & S/U
RCPSA enables low-cost H2