Abb RRTC Paper

ABB Lummus Global
Opportunities for optimization of refineries using
Thermal Conversion technologies
by
F. Hollander, A. Keukens, M. van Es

ABB Lummus Global, The Hague, The Netherlands
&
B. Douwes
Shell Global Solutions, Amsterdam, The Netherlands
0. Summary
Thermal Conversion technologies remain dominant technologies in residue

upgrading in most parts of the world. Their simple basic process layout has
been refined in recent years to remain a reliable and economic technology
with distinct advantages over more complex and high investment conversion
technologies. Also for the near future Thermal Conversion processes are
expected to play a key role in refinery operations relying on further
improvements in technology, operation and unit management. Russia and
the CIS Republics depend heavily on fuel oil and heavy distillates. Not
surprisingly, demand for state-of-the-art Thermal Conversion technologies is
growing, both in revamp situations and new applications. Shell, with ABB
Lummus Global as authorized licensor, has developed innovative Thermal
Conversion technologies that play a leading role in today’s residue upgrading
market, but also in the conversion of heavy and vacuum gasoils. That
leading role of Shell and ABB has resulted in more than 80 operating units
worldwide. Based on the latest projects, most of them in Russia and the CIS
Republics, different case studies - including revamping of existing crude or
visbreaking units, addition of the Shell Vacuum Flasher and grass-roots Shell
Soaker Visbreaking, Shell Th ermal Gasoil Process and Shell Deep Thermal
Conversion units - are presented showing the “opportunities for optimization
of refineries using Thermal Conversion technologies”.
Russian Refining Technology Conference 2001 Page 1 of 24

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1. Introduction
The Shell Soaker Visbreaker process has a long and successful history. The
relationship between Shell and ABB Lummus Global in the field of
visbreaking was first established in the early sixties, with the construction of
a number of conventional coil visbreakers. By the early 1970’s, the Shell
Soaker Visbreaker concept was sufficiently developed to be commercially
applied. The process was licensed for the first time in 1977. At this time,
Shell appointed ABB as the authorized licensor for the process and to
become more deeply involved in servicing this technology. The Shell Soaker
Visbreaker Technology has subsequently become one of the more widely
applied refining processes. The number of licensed units totals 90 with a total
installed capacity of about 400,000 tons per day, approximating to more than
70 percent of the world’s visbreaking capacity in the last decade.
Visbreaking has shown to be a robust technology in the dynamic refining

market. Although other competitive processes have been developed, Shell
Soaker Visbreaking remains of major importance in the upgrading of heavy
residues. The installation of new visbreaking plants nowadays continues at
the same pace as in the 1980’s. This success is based on the fundamental
strengths of the process. It remains a low cost, high conversion, long run
length process that is very flexible with regard to feedstock and operational
changes while producing valuable light products and stable fuel oil.
Over the years continued implementation of improvements in the Shell

Soaker Visbreaker process, have resulted in designs geared to high
reliability and performance. Shell’s continuous effort in the development of
new applications has resulted in new thermal conversion technologies such
as vacuum flashing technology, deep thermal cracking and thermal gasoil
conversion. These new technologies are emerging, well-proven and will
widen the choice of refiners to optimize their refinery with Thermal
Conversion solutions.
This paper describes in brief four different Shell Thermal Conversion

technologies licensed by ABB as authorized licensor based on the latest
projects in Russia and the CIS Republics, the Czech Republic, Germany,
India and Saudi Arabia. Different case studies - including revamping of
existing crude, vacuum or visbreaking units, addition of the Shell Vacuum
Flasher and grass-roots Shell Soaker Visbreaking, Shell Thermal Gasoil
Process and Shell Deep Thermal Conversion units - are presented.
Other technologies from the Shell Thermal Conversion portfolio, are Shell
High Pressure Distillate Conversion and technologies that are developed to
(co-)process slops and asphalts. These technologies are aimed to meet the
future gasoil endpoint and environmental specifications.

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2. Technologies
2.1 Shell Soaker Visbreaking Technology (SSVB)
The Shell Soaker Visbreaking (SSVB) Technology has been developed by

Shell in the late seventies. The technology has since evolved further and has
been successfully licensed and applied in over 80 units worldwide. Shell
Soaker Visbreakers account for over 70% of the total Visbreaking capacity
built or being built in the last 10 years. This makes it the most successful and
widely applied residue upgrading technology in the world.
The main objective of the Shell Soaker Visbreaker is to reduce the viscosity
of Atmospheric or Vacuum Residue, which significantly reduces the need of
cutterstock for blending to commercial fuel oil. Besides the viscosity
reduction, valuable products like LPG, Naphtha and Gasoil are produced.
Other possible feedstocks that can be used are asphalt and slops.
By shifting the majority of the cracking process from the heater coils (as in
all-coil designs) to the Soaker drum, prolonged residence time is achieved,
allowing a lower cracking temperature. In combination with Shell’s patented
Soaker internals this assures better selectivity, longer runlength, lower
energy demand and lower capital investment.
The main characteristics of the technology are:

§ Typical feedstock is Vacuum Residue
§ Large feed stock flexibility
§ Compact unit comprising a residue conversion and a fractionation
section
§ Application of a soaking vessel with proprietary internals
§ The amount and the viscosity of the residue (and hence of the fuel oil)
are reduced, typically fuel oil production reductions of 25 wt.% can be
achieved
The benefits of the Shell Soaker Visbreaking technology compared to the

conventional furnace (coil) cracking technology can be summarized as
follows:
§ Longer run length and higher on stream time
§ Improved selectivity towards Gasoil
§ Reduced fuel and power consumption
§ Lower capital expenditure
§ Improved operability due to use of pressure (Soaker) and temperature
(heater) as control variables
Figure 2.1 below presents the Shell Soaker Visbreaker process. Preheated
residue feedstock is charged to the Visbreaker heater (1) and from there to
the Soaker (2). The conversion takes place in both the heater and the
Soaker. The operating temperature and pressure are controlled such as to
reach the desired conversion level and/or unit capacity. The cracked feed is

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then charged to an atmospheric fractionator (3) to produce the desired

products like gas, LPG, naphtha, kero, gasoil and cracked residue.
gas
3 naphtha
x
steam
steam
gasoil
2
Charge 1 visbroken residue
Figure 2.1 Simplified Flow Scheme of Shell Soaker Visbreaker Unit
Revamping of existing crude and (coil) Visbreaker units is possible, ABB has
revamped succesfully several existing coil visbreakers and crude units into
Shell Soaker Visbreaker. The Russian market shows great potential with a
growing number of crude and visbreaking units nearing the end of their
economic life span. With an investment of between 30% and 60% of a new
grass roots unit, revamping towards a Shell Soaker Visbreaker is a fast and
low cost solution to reduce the amount of cutterstock required for the
production of fuel oil.
2.1.1 Case 1: Grass-roots Shell Soaker Visbreaker Unit
Client: Kirishinefteorgsintez
Project: Basic Design and Engineering / Detailed Engineering
Time: 1994 / 2001
Background:
The project involved the implementation of a new Shell Soaker Visbreaker

Unit, consisting of the following elements:
• Feed heating and reaction

• Fractionation and residue stripping
• Gasoil stripping
• Naphtha stabilization
• Off-gas amine absorbe

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Currently, the project is in the detailed engineering phase. Expected start-up

is in 2003.
Feedstock:
The Shell Soaker Visbreaker Unit will process a blend of vacuum residues
from West Siberian and Ukhta origin. The unit capacity is 5789 MT/SD.
Yields and Properties:
The following product yields can be obtained. Main product properties are
also shown:
Feedstocks
Vacuum Residue 241.2 t/h
Viscosity 1941 cSt @ 100°C
Products
-
Offgas (C4 ) Yield 1.8 wt%
H2S content < 0.005 wt% (Note 1)
+
C5 content 8.2 wt%
Stabilized Naphtha (C5 – 173°C) Yield 4.4 wt%
2
RVP < 0.7 kg/cm a
+
Visbreaker Residue (173°C ) Yield 93.8 wt%
Flashpoint > 65 °C
Table 2.1 Yields and Properties of Shell Soaker Visbreaker products
Note 1: After Amine treatment.
Blending details:
The final fuel oil product will fulfil the Mazut M100 specifications of which
viscosity is the governing parameter. In this example, blending with typical
Light Cycle Oil (LCO) from a Fluid Catalytic Cracker is shown.
In the Table 2.2, the required amount of LCO is given for the situation with
and without a Shell Soaker Visbreaker Unit.
Saving 60 t/h on LCO and producing more than 70 t/h less Fuel Oil clearly
underlines the benefits of a Shell Soaker Visbreaker Unit.

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LCO Requirements Fuel Oil

Production
Vacuum Residue (w/o SSVB) 90 t/h (27.2 % of total) 331 t/h
Visbreaker Residue (with SSVB) 31 t/h (13.5 % of total) 257 t/h
Table 2.2 Cutterstock requirements and fuel oil production comparison
2.1.2 Case 2: Revamp to Shell Soaker Visbreaker Unit
Client: LUKOIL Permnefteorgsyntez

Project: Basic Design and Engineering Package
Time: 2001
Background:
The project involves the revamp of an existing thermal cracker into a Shell
Soaker Visbreaker Unit. The main objective of this project is to re-use as
much of the existing equipment as possible. The unit includes the following
sections:

Feedstock:
While the current feedstock consists of residual material of varying nature

and various refinery slops, the revamped unit will process a mixture of
vacuum residue originating from West Siberian and Local Perm crudes. The
design unit capacity is 2800 MT/SD.
Process Scheme:
The current process scheme with respect to the separation and fractionation
of the heater effluent is given in the Figure 2.2 below. The Rectifier operates
at elevated pressure compared to the Stripper, which operates at near
atmospheric conditions. Steam is used for stripping of the residue.

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CURRENT OPERATION
NAPHTHA
RECTIFIER
LIGHT GASOIL
HEATER EFFLUENT
SEPARATOR
REACTOR
NAPHTHA
HEAVY GASOIL
STRIPPER
RESIDUE
Figure 2.2: Current situation
In an attempt to redeuce investment cost, by re-using as much of the existing

equipment (specifically the columns) as possible, the following flow scheme
was developed and proposed to the client:
PROPOSED OPERATION
NAPHTHA / OFFGAS
RECTIFIER
SEPARATOR
GASOIL STRIPPER
SOAKER
STRIPPER
HEATER EFFLUENT
GASOIL
RESIDUE
INDICATES REUSED EQUIPMENT
Figure 2.3 Proposed new scheme
As can be seen from Figure 2.3, the Separator, Stripper and Rectifier will be
re-used. As advanced construction materials are required for such high

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temperature equipment, re-using these columns is of primary importance for

reducing the required investment. A new stripper is foreseen for quality
control of the Visbreaker Gasoil.
The complete fractionation section is operating near atmospheric pressure in

the new situation. This highly improves the quality of separation between
Residue, Gasoil and Naphtha. The Naphtha is further processed in a
Naphtha Stabilizer (the existing column and associated equipment will be
re-used for that purpose) producing Stabilized Naphtha, LPG and Fuel Gas.
The Fuel Gas is treated to remove H2S in a central amine absorber unit.
With the proposed scheme, the following product yields can be obtained.
Main product properties are also shown:
Feedstocks
Vacuum Residue 118 t/h
Coker Naphtha (note 1) 20 t/h
Products
Offgas (C2-) Yield 1.4 wt%
+
C5 content < 5 wt%
LPG (C3/ C4) Yield 1.0 wt%
+
C5 content < 3 wt%
Stabilized Naphtha (C5 – 165 °C) Yield 17.3 wt%
-
C4 content < 1 wt%
Gasoil (165 – 350 °C) Yield 10.0 wt%
Flashpoint > 65°C
Visbreaker Residue (350 °C+) Yield 70.3 wt%
Table 2.3 Yields and properties of Case 2
Note 1: Unstabilized Naphtha from the Delayed Coker Unit is stabilized

together with the Visbreaker Naphtha in the common Naphtha
Stabilization section.
Blending details:
The final fuel oil product will fulfil the Mazut M100 specifications of which
viscosity is the governing parameter. In this example, blending with typical

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Light Cycle Oil (LCO) from a Fluid Catalytic Cracker with and without a Shell
Soaker Visbr eaker Unit is shown.
In Table 2.4, the required amount of LCO and the total fuel oil production is
presented.
Fuel Oil
LCO Requirements
Production
Vacuum Residue (w/o SSVB) 30 t/h (20% of total) 148 t/h
Visbreaker Residue (with SSVB) 6.4 t/h (5.5% of total) 117 t/h Note 1
Table 2.4 Cutterstock requirements and fuel oil production comparison,

Case 2
Note 1: Includes gasoil produced by unit.
From Table 2.4, the benefits of a Shell Soaker Visbreaker Unit can be seen.
2.2 Shell Vacuum Flasher (VF) Technology
To maximize the recovery of distillates from the Thermal Conversion

effluents Shell has developed proprietary Flashing Technology for
integration/combination with Thermal Conversion Units. Shell has developed
a proprietary transfer line that maximizes the recovery of distillates and
avoids entrainment of residue. The other draw back of open art flashing
technology in thermal conversion service is the short run length of the
vacuum columns due to severe coking and fouling. Due to the application of
proprietary column internals the fouling and coking has been reduced
substantially resulting in vacuum flasher run lengths up to several years.
The main characteristics of the technology are listed below.

§ Proprietary transfer line and column internals
§ No residue entrainment
§ Long run length
§ High Flashed Distillate Yield
§ No feed heater
§ Effective cutpoints up to 550°C can be achieved
§ Production of Light Flashed Distillate to Gasoil specification
§ Can be applied to all Thermal Conversion Technologies except Delayed
Coking
§ Can be added to existing thermal conversion units
The main benefits of Shell Thermal Conversion Flashing Technology

compared to open art flashing technology can be summarized as follows:
§ Longer run length and higher on stream time

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§ Higher distillate yields

§ Additional Gasoil recovery
Figure 2.4 below presents the Shell Soaker Visbreaker process including the
Shell Vacuum Flasher. Similar to the SSVB, preheated residue feedstock is
charged to the Visbreaker heater (1) and from there to the Soaker (2). The
cracked feed is then charged to an atmospheric fractionator (3). The cracked
residue is fed into the Shell Vacuum Flasher (4) which separates the light
vacuum gasoil (LVGO) and heavy vacuum gasoil (HVGO) from the vacuum
flashed cracked residue (VFCR).
gas
3 naphtha
steam gasoil
LVGO
steam
2
4
HVGO
Charge 1
vacuum flashed
cracked residue
Figure 2.4 Shell Soaker Visbreaker with Shell Vacuum Flasher
A calculation has been done for a typical Visbreaker unit with a capacity of
4000 MT/SD, processing Middle East Vacuum residue with a viscosity of
3900 cSt at 100°C. Figure 2.5 presents the difference in blending of a
Visbreaker unit and a Visbreaker unit with Vacuum Flasher.
The Shell Vacuum Flasher is an option for refineries were Heavy or Vacuum
Gasoil can be processed in a Hydrocracker or an FCC unit or Shell Thermal
Distillate Conversion unit. Visbroken Vacuum Gasoil, by its parrafinic nature,
is a good feedstock for FCC’s.

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GAS GAS
76
76
NAPHTHA
FEED VB 164
VB NAPHTHA 164
4000 GASOIL 460
FEED
4000 GASOIL 460
GAS
1404
HGO + OIL
VB RES. 3200 3200
4924
VB RES. VGO 620
FUEL VF
GAS OIL
OIL 1164 2680 VB TAR FUEL
4544 OIL
Figure 2.5 Blending example
The Shell Vacuum Flasher can be built in a modular way and added next to
the visbreaker plot. Figure 2.6 shows a 3D-model of a visbreaker unit
originally built by Shell and to which a Shell Vacuum Flasher was added later
on. The Shell Vacuum Flasher section has been highlighted.
Figure 2.6 Modular design of Shell Vacuum Flasher Add -on

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2.2.1 Case 3: Shell Soaker Visbreaker Unit with Vacuum Flasher
Client: Indian client

Project: Basic Design and Engineering Package
Time: 2000
Background:
The project involved the basic design of a new Shell Soaker Visbreaker Unit
including Shell Vacuum Flasher Technology, consisting of the following
elements:

• Overhead product compression (recontacting) section
• Vacuum Flasher
Currently, the project is in the EPC phase. Expected start-up is in 2002.
Feedstock:
The Shell Soaker Visbreaker and Vacuum Flasher Unit will process a
feedstock comprising of 85% Vacuum Residue and 15% PDA pitch
originating from a 50:50 Arab mix crude. The unit capacity is 3600 MT/SD.
Table 2.6 shows the product yields and main properties that will be obtained
in this unit.
Light and Heavy Vacuum Gasoils are used as feed to the Hydrocracker. The
Vacuum Flashed Cracked Residue is blended to meet refinery fuel oil
specifications.

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Feedstocks
Viscosity 7,251 cSt @ 100°C
Products
-
H2S content 11.1 wt%
Stabilized Naphtha (C5–165°C) Yield 4.1 wt%
2
RVP < 0.7 kg/cm a
Visbreaker Gasoil (165–350°C) Yield 11.2 wt%
Flashpoint 60 °C
Light Vacuum Gasoil (350–420°C) Yield 1.8 wt%
C7-insolubles < 0.2 wt%
Heavy Vacuum Gasoil (420–520°C) Yield 10.0 wt%
+
Vacuum Flashed Cracked Residue (520°C )
Yield 70.9 wt%
2.2.2 Case 4: Shell Vacuum Flasher added to existing SSVB
Client: Shell Harburg

Project: by Shell
Time: 1979
Background:
The project involved the addition of a Shell Vacuum Flasher to an existing

Shell Soaker Visbreaker Unit including, consisting of the following elements:
• Vacuum Flasher
The revamped plant was started-up in 1981.
Feedstock:
The Shell Soaker Visbreaker and Vacuum Flasher Unit process a mix of
Deutsche Roh Oel and Tia Juana Pesado vacuum residue. The unit capacity
is 2500 MT/SD.

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The following product yields can be obtained. Main product properties are
also shown:
Feedstocks
Products
Offgas (C4-) Yield 2.8 wt%
2
RVP < 0.7 kg/cm a
Flashpoint 60 °C
Vacuum Gasoil (365–530°C) Yield 13.0 wt%
+
Yield 65.2 wt%
The Vacuum Flashed Cracked Residue is blended to meet European fuel oil
specifications.
2.3 Shell Thermal Gasoil Process (STGP)
As highlighted in Section 2.2, by implementation of a vacuum flasher in the

Shell Soaker Visbreaker Process, considerable amounts of valuable vacuum
distillate can be recovered from the Visbroken residue. The recovered
vacuum distillate can be further processed in a conversion unit, like for
instance a Hydrocracker (HCU) or a Fluid Catalytic Cracker (FCC).
In refineries with no vacuum distillation unit, or in refineries withfully loaded

HCU or FCC, an interesting solution is to convert the recovered vacuum
distillate in an integrated recycle thermal cracker heater system. The
combination of a Shell Soaker Visbreaker for residue conversion and a
separate thermal conversion heater system for distillate conversion is called
the Shell Thermal Gasoil Process (STGP). This technology was originally
developed in the sixties as an alternative for conversion of atmospheric
residue by FCC and HCU, and has since then been continuously improved
and developed further. Shell currently operates nine (8) such units.

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Description
Although there can be very significant differences with respect to choice of

feedstock and the recovery of different products, most units applying the
Shell Thermal Gasoil Process follow the same concept, which is shown in
Figure 2.7.
gas
naphtha
4 steam gasoil
3
steam 6
5
Charge 1
vacuum flashed
cracked residue
Figure 2.7 Simplified Flow Scheme of Shell Thermal Gasoil Process
The preferred feedstock for the Shell Thermal Gasoil Process is atmospheric
residue, although vacuum residue can be used as well. The preheated
feedstock is charged to the visbreaker heater (1) and from there to the
soaker (2). The conversion takes place in both the heater and the soaker.
The operating temperature and pressure are controlled such as to reach the
desired conversion level and/or unit capacity. The cracked feed is then
charged hot to a cyclone (3) to separate the majority of the residue from the
valuable distillate products. The cyclone overheads are routed to the
atmospheric fractionator (4) to produce the products like gas, naphtha,
gasoil, heavy distillate and a residue. Cyclone bottoms and fractionator
bottoms are routed to a vacuum flasher (5) together. In this vacuum flasher,
vacuum distillate is recovered from the residue. The temperature and
pressure in the flashzone determine the cutpoint between the distillate and
residue. The recovered heavy and vacuum distillates from the fractionator
and the vacuum flasher are converted in the distillate cracking heater (6) at
elevated pressure. Conversion levels, defined here as 165 - 350°C TBP
material on feed, can be as high as 30 - 40 wt%. To fully convert the
distillate, the unconverted material is recycled via the atmospheric
fractionator and vacuum flasher. Consequently, the distillate furnace feed
consists partly of fresh feed and partly of recycled material.

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Benefits
The benefits of the Shell Thermal Gasoil Process compared to other

conversion technologies (Fluid Catalytic Cracking and Hydrocracking) can be
summarized as follows:
§ Due to the highly integrated compact two stage thermal conversion unit
design, comprising of a residue and a recycle distillate conversion
section, a combined fractionation and vacuum flashing section,
substantial lower capital expenditure is required.
§ In a STGP large feedstock flexibility is possible, ranging from
atmospheric residue to vacuum residue, due to the nature of the
process. In contrast to FCC and HCU technologies, which are limited in
their feedstock flexibility.
§ Complete conversion of the waxy distillate fraction, although a slightly
lower conversion is achieved on the overall conversion compared to FCC
and HCU technologies; the only products are gas, naphtha, gasoil and
vacuum residue, typically 55-60 wt% of the atmospheric residue is
upgraded to gasoil minus products.
§ No up-front vacuum distillation unit is required, as the majority of the
vacuum gasoil in the atmospheric residue can be recovered in the
vacuum flasher.
2.3.1 Case 5: Shell Thermal Gasoil Process
Client: Saudi Client

Project: by Shell
Time: 1994/2000
Background:
The project involved the installation of a new Shell Thermal Gasoil unit
integrated with a gasturbine for power production. The unit consists of the
following elements:
• Integrated heat recovery and feed heating and reaction

• Cyclone
• Vacuum Flasher
• Gasturbine
Successful Start-up of the unit took place in 2000.

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Feedstock:
The Shell Thermal Gasoil Unit processes a mix of atmospheric and vacuum
residue from Arab Light Crude. The unit capacity is 5,250 MT/SD.
Table 2.7 shows the product yields and properties that are obtained.
Feedstocks
Products
-
2
RVP < 0.7 kg/cm a
Flashpoint 35 °C
+
Yield 65.2 wt%
About two thirds of the Visbreaker Gasoil is blended with the VFCR to make
European spec fuel oil. The remainder is sent to the refienry gasoil pool.
2.3.2 Opportunities for Russian refineries
The main objective of the Shell Thermal Gasoil Process is the reduction of
the viscosity of the residue feedstock while maximizing the production of
gasoil by thermally cracking the recovered heavy and vacuum distillates. For
hydroskimming refineries, i.e. refineries without upgrading potential of the
atmospheric residue or in refineries withfully loaded HCU or FCC, this option
has some very interesting features.
A phased approach can be applied to this unit. Initially only the residue
upgrading part, i.e. the Shell Soaker Visbreaker part, will be installed, with
some pre-investment for the next step. In the next step the vacuum flasher
and recycle distillate conversion heater are incorporated. Not only is the
initial investment lower, also a gradual reduction in fuel oil production and
associated gasoil production inc rease, will be achieved. This is certainly very
interesting for refineries producing for markets where there is still a vast
demand for fuel oil, like the Russian market.

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Additionally the installation of a Shell Thermal Gasoil Process will eliminate

the requirement of installation of a vacuum distillation unit and upgrading
facilities for the produced vacuum gasoil, like a fluid catalytic cracker or a
hydrocracker. Both of these units require huge investments (over 100 million
US$), while the investment required for a Shell Thermal Gasoil Process will
be substantially lower. This will facilitate an easier financial closure of a
project.
For refineries already converting atmospheric residue in a visbreaker,

implementation of the Shell Thermal Gasoil Technology is a low cost option
to reduce fuel oil production and increase production of valuable distillate
products. A revamp of a coil type visbreaker unit to a STGP Unit would
require installation of a soaker, cyclone, vacuum flasher and a recycle
distillate cracking heater. Also some modifications to the feed preheat and
the atmospheric fractionator and its overhead system, due to the changes in
yield, need to be implemented.
Based on aboves STGP, Shell has developed Shell's High Pressure

Distillate Conversion Process, to convert heavy tails of gasoils. With 80%
conversion of the 330°C - 370 °C (heavy) gasoil fraction into lighter materials
(< 330 °C), this technology enables refiners to meet tighter future gasoil
specifications.
2.3.3 Case 6: Comparison of SSVB and STGP
Client: Russian Client

Project: Feasibility study
Time: 2001
Background:
Hydroskimming refineries and refineries that process atmospheric, vacuum

or a combination of atmospheric and vacuum residues in thermal cracking
units or exisiting visbreakers can benefit clearly from the Shell Thermal
Gasoil Process.
The example below is a study for a Russian refiner, processing Ukhta crude,
considering to revamp an existing crude unit into a Shell Soaker Visbreaker.
Comparison of the SSVB and STGP technologies indicates the possibilities
when choosing for the latter.
While both technologies produces stable on-spec Mazut M100 without the
requirement of additional cutterstock, the Shell Thermal Gasoil Process
produces 350 MT/SD of high cetane gasoil that, after treatment, is an
outstanding component in the gasoil blending pool.

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Feedstock:
Comparison is made on the basis of Ukhta crude.
Shell Soaker Shell Thermal Gasoil

Feedstock
Visbreaker Process
Mix of Atmospheric and Vacuum Residue 2400 MTD 2400 MTD
Viscosity 188 cSt @ 100°C 188 cSt @ 100°C
Products
- 2.0 wt%
+ < 5 wt%
C5 content < 5 wt%
Stabilized Naphtha (C5 -165°C) yield 4.1 wt% 10.3 wt%
- < 1 wt%
C4 content < 1 wt%
Gasoil (165 – 350 °C) Yield 12.6 wt% 37.9 wt%
Flashpoint > 65°C > 65°C
+ 81.3 wt%
Visbreaker Residue (350°C ) Yield -
+ -
Visbreaker Residue (520°C ) Yield 47.4 wt%
After blending the Visbroken Residue with Visbroken Gasoil following

products remain:
Gasoil Production Fuel Oil

(net) Production (M100)
Shell Soaker Visbreaker 50 MTD 2205 MTD
Shell Thermal Gasoil Process 410 MTD 1638 MTD
Table 2.9 Gasoil and fuel oil production comparison, Case 6
2.4 Shell Deep Thermal Conversion Technology
The latest development by Shell in the area of Thermal Conversion is the

Shell Deep Thermal Conversion Technology. Due to the increase in non-fuel
oil outlets of thermally cracked residues new opportunities have arisen for

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thermal conversion. Shell has been able to improve the design and operation
of the unit such that high conversion levels can be achieved while
maintaining an acceptable unit run length.
This technology closes the gap between visbreaking and delayed coking
(Figure 2.8). It realizes most of the delayed coking upgrading while avoiding
the drawbacks of solids handling. The residual product of Shell Deep
Thermal Conversion remains liquid and stable and is referred to as ‘liquid
coke’. Liquid coke can no longer be blended into a stable fuel oil and is
processed directly in gasifiers (in power production or Partial Oxidation units)
or is used as refinery fuel.
Thermal Conversion yield patterns
70
60
50
40
Yield, wt%
30
20
10
0
C4-MINUS C5-350°C 350-520°C VFCR/COKE
Fraction
Visbreaking + VF Deep Thermal Conversion DTC Delayed Coking
Figure 2.8 Closing the gap between Visbreaking and Delayed Coking
The main characteristics of the technology are listed below:

§ Can be applied to both Shell Soaker Visbreaking as well as Shell
Thermal Gasoil units
§ Typically 45-60 wt% of Vacuum Residue is converted to distillate
products
§ Revamp of an existing unit is possible
§ Liquid residual product
§ Includes both design and operational know how
The main benefits of Shell Deep Thermal Conversion technology compared

to traditional Thermal Conversion technology can be summarized as follows:
§ Substantially higher conversion
§ Competitive run length and on-stream time

ABB Lummus Global
§ Higher distillate yields from Vacuum Flasher

§ Improved operability due to use of pressure and temperature as control
variables
On the other side the main benefits of Shell Deep Thermal Conversion
technology compared to delayed coking technology can be summarised as
follows:
§ Higher quality products (needing less hydrotreating)
§ Higher selectivity to gasoil
§ Substantially lower capital expenditure
§ No solids handling
Figure 2.9 below presents the Shell Deep Thermal Conversion process.
Preheated short residue is charged to the heater (1) and from there to the
soaker (2), where the deep conversion takes place. The conversion is
maximized by controlling the operating temperature and pressure. The
cracked feed is then charged to an atmospheric fractionator (3) to produce
the desired products like gas, LPG, naphtha and gasoil. The fractionator
bottoms are subsequently routed to a vacuum flasher (4), which recovers
additional gasoil and waxy distillate. The residual liquid coke is routed for
further processing depending on the outlet.
gas
3 naphtha
x
steam
gasoil
steam
2
x
waxy
4
x distillate
Charge 1
liquid coke
Figure 2.9 Shell Deep Thermal Conversion
The Shell Deep Thermal Conversion can also be combined with the Shell
Thermal Gasoil Process. Similar to STGP, an additional furnace will convert
the heavy distillates into gasoil.

ABB Lummus Global
2.4.1 Case 7: Deep Thermal Conversion
Client: CRC Litvinov, Czech Republic

Project: BDEP, EPC, Start -up
Time: 1997-1999
Background:
The project involved the basic design, EPC and start-up of a new Shell Deep
Thermal Conversion Unit including Shell Vacuum Flasher Technology, with
the possibility to operate in Visbreaking and Deep Thermal Conversion
mode. The unit consists of the following elements:

• Overhead product compression (recontacting) section
• Vacuum Flasher
Successful Start-up took place in 1999.
Feedstock:
The Shell Deep Thermal Conversion Unit processes a mixture of black

distillate and vacuum residues originating from a Ural crude. The unit
capacity is 2500 MT/SD.
Table 2.10 presents the product yields and main properties of this unit
running in SDTC mode.
When running in the SDTC mode, all vacuum distillates are sent to the FCC
unit; the VFCR is sent to the POX.
In SSVB mode conversion of the feed is significantly less severe, enabling

the unit to produce commercial fuel oil after blending with the vac uum
distillates and a small amount of cutterstock.
This unit demonstrates the maturity of the Shell Thermal Conversion

technologies, as it maximizes yields while maintaining a remarkable flexibility
toward the need of the client.

ABB Lummus Global
Feedstocks
Products
-
+
C5 content < 12.0 wt%
Unstabilized Naphtha (C5–165°C) Yield 7.6 wt%
2
RVP < 0.7 kg/cm a
Flashpoint 60 °C
VB Vacuum Gasoil (370 –420°C) Yield 1.3 wt%
CCR < 0.8 wt%
Heavy Vacuum Distillate (420–520°C) Yield 14.7 wt%
CCR < 0.8 wt%
+
Vacuum Flashed Cracked Residue (VFCR) (520°C )
Yield 56.8 wt%
2.4.2 Link to Russian market
Implementation of an IGCC is a high investment that can only be justified in

refineries that can consume all the power produced or in liberalized power
markets where refiners can export their excess production to the public grid.
Still, even without an IGCC, Shell Deep Thermal Conversion is an interesting
solution for refiners having an outlet for the residual product of this process.
Russian and other refineries alike, depending on the crude, especially when
not too heavy, can use the residue of SDTC economically as refinery fuel, for
the production of carbon black or in cement kilns.
Another outlet can be as fuel for neighbouring power plants. With a typical
heating value 40,000 kJ/kg, the only real constraint is maximum viscosity that
can be handled by the burners. Currently, burners are able to handle
viscosities up to 300 cSt.
3. Economy
Shell Thermal Conversion Technologies are, in general, low cost solutions

with very short payback times (normally in the order of one year). Of course,
this all depends on feedstock, configuration and prices for products. The

ABB Lummus Global
table below presents a (rough) comparison of the TIC for four different
technologies. This comparison is based upon a 3,000 MT/SD unit processing
Atmospheric and/or Vacuum Residue from a typical Ural crude.
SSVB SSVB+VF STGP SDTC

Feed VR VR AR/VR VR
Typical TIC MM US$ 20.6 25.5 28.3 28.2
Table 2.11 Estimated TIC for Shell Thermal Conversion Technologies
The estimated TIC’s are based on new brown field unit including
engineering, equipment, instrumentation, piping, structures, buildings, etc.
The estimated TIC’s are CIS based and have an accuracy of 30%. Excluded
from the estimated TIC’s are other processing units for treatment, etc, utility
systems and license fees.
4. Conclusion
With the improvements and wider applicability of Shell's present Thermal

Conversion technologies good opportunities exist to process cheaper crude
oils and/or cheaper feedstocks (such as asphalt) and meeting future gasoil
specifications while maintaining the well-proven robustness. Shell's
continuous development in Thermal Conversion technologies provide higher
distillate yields, while increasing unit reliability and operability. The co-
operation of ABB and Shell guarantee the best possible provision of proven
experience and know-how in the Thermal Conversion area.
Depending on refinery layout, crude, product slate and environmental

legislation there is a Shell Thermal Conversion option for every refinery.

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ABB Lummus Global

Opportunities for optimization of refineries using

Thermal Conversion technologies

F. Hollander, A. Keukens, M. van Es

Thermal Conversion technologies remain dominant technologies in residue

Russian Refining Technology Conference 2001 Page 1 of 24

Visbreaking has shown to be a robust technology in the dynamic refining

Over the years continued implementation of improvements in the Shell

This paper describes in brief four different Shell Thermal Conversion

Russian Refining Technology Conference 2001 Page 2 of 24

2.1 Shell Soaker Visbreaking Technology (SSVB)

The Shell Soaker Visbreaking (SSVB) Technology has been developed by

The main characteristics of the technology are:

The benefits of the Shell Soaker Visbreaking technology compared to the

Russian Refining Technology Conference 2001 Page 3 of 24

then charged to an atmospheric fractionator (3) to produce the desired

Charge 1 visbroken residue

Figure 2.1 Simplified Flow Scheme of Shell Soaker Visbreaker Unit

2.1.1 Case 1: Grass-roots Shell Soaker Visbreaker Unit

The project involved the implementation of a new Shell Soaker Visbreaker

• Feed heating and reaction

Russian Refining Technology Conference 2001 Page 4 of 24

Currently, the project is in the detailed engineering phase. Expected start-up

Yields and Properties:

Note 1: After Amine treatment.

Russian Refining Technology Conference 2001 Page 5 of 24

LCO Requirements Fuel Oil

Visbreaker Residue (with SSVB) 31 t/h (13.5 % of total) 257 t/h

Table 2.2 Cutterstock requirements and fuel oil production comparison

2.1.2 Case 2: Revamp to Shell Soaker Visbreaker Unit

Client: LUKOIL Permnefteorgsyntez

• Feed heating and reaction

While the current feedstock consists of residual material of varying nature

Russian Refining Technology Conference 2001 Page 6 of 24

Figure 2.2: Current situation

In an attempt to redeuce investment cost, by re-using as much of the existing

INDICATES REUSED EQUIPMENT

Figure 2.3 Proposed new scheme

Russian Refining Technology Conference 2001 Page 7 of 24

temperature equipment, re-using these columns is of primary importance for

The complete fractionation section is operating near atmospheric pressure in

Yields and Properties:

Note 1: Unstabilized Naphtha from the Delayed Coker Unit is stabilized

Russian Refining Technology Conference 2001 Page 8 of 24

Table 2.4 Cutterstock requirements and fuel oil production comparison,

Note 1: Includes gasoil produced by unit.

2.2 Shell Vacuum Flasher (VF) Technology

To maximize the recovery of distillates from the Thermal Conversion

The main characteristics of the technology are listed below.

The main benefits of Shell Thermal Conversion Flashing Technology

Russian Refining Technology Conference 2001 Page 9 of 24

§ Higher distillate yields

Figure 2.4 Shell Soaker Visbreaker with Shell Vacuum Flasher

Russian Refining Technology Conference 2001 Page 10 of 24

Figure 2.6 Modular design of Shell Vacuum Flasher Add -on

Russian Refining Technology Conference 2001 Page 11 of 24

2.2.1 Case 3: Shell Soaker Visbreaker Unit with Vacuum Flasher

Client: Indian client

• Feed heating and reaction