HDHPLUS®

Integrated Scheme with

Sequential Hydroprocessing
Elvis Castillo
05/10/2006
 HDHPLUS® Process

• HDHPLUS® is a Slurry technology for deep

hydro cracking of heavy
vacuum residues (PDVSA ownership)
• Very high VR conversion level - up to or
more than 85% of the vacuum residue
• Axens / IFP / Intevep / PDVSA alliance for
• Continuous improvements to HDHPLUS®
• Integration with Sequential Hydroprocessing
• Worldwide marketing of integrated scheme
 HDHPLUS® Integrated Scheme

• Integration of HDHPLUS® with Sequential

HydroProcessing of primary hydrocracked
products
• SHP = MHC or high severity hydrocracking
• Production of on-specification products

VR HDHPLUS® Euro V
SHP Product
H2 Quality
SR VGO
Catalyst Flakes
+ additives
 HDHPLUS® Main Features

• Can process heavy refractory VR feeds

regardless of sulfur, metals, asphaltene and
CCR contents
• Typical performance:
• VR Conversion 85 – 92%
• Asphaltene conversion: 80 - 85%
• Low gas yields: 8 - 9 wt%
• Distillate yields over 100 vol% with HDHPLUS®
• Distillate yields over 110 vol% with integrated
scheme
• Unconverted residue are solid flakes produced in
low quantities (< 10 wt% of VR feed).
 Integrated Scheme HDHPLUS® + SHP
Product Destinations

• LPG to sale
• Gasoline fraction  to Cat reformer
• Kerosene product  jet fuel pool
• Diesel product  diesel pool
• VGO product  FCC feed or lube base
• Residue product are solid flakes conveyed to
storage  solid fuel
 HDHPLUS® Typical Operating Conditions

• Total pressure, bar 180 – 200

• H2 partial pressure, bar 125 – 150
• Reaction temperature, °C 440 – 470
• Space velocity, hr-1 0.4 – 0.7
• H2 treat-gas ratio, Nm3/m3 600 - 700
 Integrated Scheme (HDHPLUS® + SHP)
Slurry Separation Sequential Fractionation
Hydroconversion Section Hydroprocessing Section

SR VGO
Recy H2

FG
R1 R2 & LPG
HPS HDT HyK

Naphtha

Jet fuel
Vac Diesel

Additive Fresh H2 Catalyst VGO

slurry + Recy H2 Emulsion Flakes
VR Feed
 HDHPLUS® Development Stages

1983-1988 Joint development of HDH by Intevep with

Veba.
Pilot plant 150 bpsd at Sholven
1988-1994 Semi-Commercial Operation 3500 bpsd at
Bottrop (Germany) in oil and residue mode
1998-2003 HDH improvement including the SHP Concept
(10 bpsd Pilot Plant) to generate HDHPLUS®
2004-2006 Integration with Axens for Puerto La Cruz and
El Palito deep conversion projects.
2006 Agreement Axens / IFP / PDVSA / Intevep for
improvement and marketing of integrated
scheme
 HDHPLUS® Design Features

• Equipment design
• Bottrop experience incorporated in design
• Reactor Modeling from 0.3 m up to 2.5 m
diameter cold mock-ups experiments
• Standard equipment and metallurgy for the
entire HP section
• Cold Wall Reactors
 HDHPLUS® Operability

• Operating procedures derived from

Bottrop experience
• Start-up, shut-down, emergency handling,
• Very stable operation controlled through the
gas velocity.
• Sedimentation and plugging control solved in
Bottrop and incorporated in design
• Strong reaction system that handles upsets
quickly without affecting the system stability
and the run length.
 HDHPLUS® Case Study (1/4)
Feed Properties

• Heavy crude Vacuum Residue

• Specific Gravity 1.065
• Viscosity @150°C,cSt 2781
• Sulfur, wt% 4.47
• Nitrogen, wt% 1.013
• C7 Asphaltenes, wt% 16.0
• Conradson Carbon, wt% 25.1
• Nickel + Vanadium, ppm 894
 Yields of HDHPLUS® Case Study (2/4)
Compared with Coker Yields

HDHPLUS® Coker
• Yield vs. VR Feed, vol%
• Naphtha 21.3 14.4
• Middle Distillates 51.2 38.0
• VGO 29.5 17.0
• Total liquid 102.0 69.4

• Yield vs. VR Feed, wt%

• H2S+NH3 4.0 1.4
• C1-C4 8.9 7.6
• Flakes (Coke) 7.5 32.9
• H2 consumption 2.3 0.0
 HDHPLUS® Case Study (3/4)
Integrated Scheme HDHPLUS® + SHP Yields

• SHP Feed = HDHPLUS® effluent + SR VGO

• SHP in high severity hydrocracking mode

• Yields vs. SHP feed:

• Naphtha 32.2 vol%
• Middle Distillates 63.5 vol%
• VGO 17.1 vol%
• Total liquid 112.8 vol%
• H2 consumption 2.9 wt%
 HDHPLUS® Case Study (4/4)
HDHPLUS® + SHP Product Properties (Euro V)

Heavy Naphtha Diesel

•Sp. Gr. 0.755 •Sp. Gr. 0.845
•Sulfur < 5 ppm •Sulfur < 10 ppm
•Nitrogen < 2 ppm •Cetane 55
 To cat reformer •Pour point < -25 °C
 To diesel pool

Kerosene Unconverted Oil

•Sp. Gr. 0.815 •Sp. Gr. 0.862
•Sulfur < 5 ppm •Sulfur < 50 ppm
•Smoke pt 23 mm •Nitrogen < 10 ppm
•Naphthalene < 1% vol •Hydrogen 13.5 wt%
 To Jet Fuel pool  FCC feed or base lube
 PDVSA Puerto La Cruz Project
Integrated Scheme HDHPLUS® + SHP
• HDHPLUS® Unit
• 50 000 bpd of Merey VR
• VR Conversion: 85 - 92%
• Sequential Hydroprocessing Unit
• On-line high pressure HyK of a blend
• 51 000 bpd of HDHPLUS effluent
• + 47 000 bpd of SR VGO
• Conversion: 85 %
• Maximization of ULSD (S< 10 ppm, cetane> 51) + jet fuel
• Basic engineering in execution
• Start-up in 2011
• Investment 1.7 G$
 PDVSA El Palito project
Integrated Scheme HDHPLUS® + SHP
• HDHPLUS® Unit:
• 46 000 bpsd of Merey-Mesa VR
• VR Conversion: 85 - 90%
• Sequential Hydroprocessing:
• On-line Mild Hydrocracking of a blend of:
• 44 000 bpsd of HDHPLUS
• + 44 000 bpsd of SR VGO
• Conversion 55%
• Production ULSD (S< 10 ppm, cetane> 45)
• Production of low Sulphur FCC feed
• Conceptual Engineering achieved
• Start-up in 2011
• Investment 1.8 G$
 Conclusion

• HDHPLUS® is a slurry technology for deep

hydrocracking of heavy Vacuum Residues
• HDHPLUS® / SHP integrated scheme
technology enables:
• High conversion > 85% of heavy VR feeds
• Production of Euro V quality products
• Full research and development stages can
assure a successful commercial operation.
• Two commercial projects in progress in
Venezuela