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Commercial Technology to Convert Group I Facilities to Group II/III Lube Production

Commercial Technology to Convert Group I Facilities to Group II/III Lube Production. History of Lubricants and Basestocks. Lubricants have been used since ancient times Petroleum-based lubricants business began in the mid-1800’s Initial processing was limited to separation by boiling point.

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Commercial Technology to Convert Group I Facilities to Group II/III Lube Production

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  1. Commercial Technology to Convert Group I Facilities to Group II/III Lube Production

  2. History of Lubricants and Basestocks • Lubricants have been used since ancient times • Petroleum-based lubricants business began in the mid-1800’s • Initial processing was limited to separation by boiling point

  3. 250 200 150 100 50 0 1993 1995 1996 1997 1998 1999 2000 2001 2002 2003 2004 2005 2006 2007 Lube Activity Focused on Group II & Group III Production • Group II and Group III Base Oils are the high growth areas • Demand for improved fuel economy and lower emissions mean lower viscosity/volatility engine oils • Demand for increased equipment reliability • Extended service intervals/fill for life for engines requires both performance and stability • Group II/III plants have Opex advantages versus Group I plants Hydroisomerization Capacity (kbpd) ExxonMobil Technologies Others Lube Product,( kbpd)

  4. Performance Requirements Pushes Quality • Improved fuel economy • Lower Emissions • Longer Life • Better low temperature performance • High temperature performance • Viscometrics • Thermal stability • Soot handling (diesels) • Lower Viscosity • Lower Volatility • Higher Saturates • Lower Pour, Lower CCS • Higher VI • Higher Saturates • Higher Saturates

  5. Volatility a Driver for Increased VI Group I / Group II 95 VI 19 Group II+ 17 API SM Max Mid Tier Group III 15 13 Top Tier Group III Noack Volatility, Mass% 11 9 GM Proposed Global Spec. Group IV / PAO’s 7 5 3 3.5 4 4.5 5 5.5 6 6.5 7 7.5 8 8.5 Viscosity @ 100°C, cSt API SM 5W30

  6. Common Routes for Base Oil Production Solvent Extraction Solvent Dewaxing Hydrofinishing Group I RHCTM Group II Catalytic Dewax Hydrofinishing RHCTM Group II /III Distillate/DAO Fuels Hydrocracker Vacuum Distillation Solvent Dewax Gasoline & Diesel Group II HC Bottoms Catalytic Dewax Vacuum Distillation Group II /III Lube Hydrocracker Catalytic Dewax Hydrofinishing Group II / III

  7. Process Choice: Blocked or Broadcut? • Blocked: Lube Grades Processed Individually • Pro: • Smaller catalytic equipment • Production to optimum specification for each product • Clear target response to feed change • Con: • Intermediate tankage required between units • More complex operation • Broadcut: Unfractionated Fuels H/C Bottoms or VGO to Lube H/C • Pro: • Single operation, no stock switch—simpler control • Minimal/no intermediate tankage • Con: • Larger catalytic vessels • One grade dictates operating severity—possible overtreating of others

  8. Integrated Group I Facilities Adjust Viscosity Hydroprocessing (RHT or RHC™) Group II Group III Solvent Dewaxing Vacuum Gas Oil Hydrofinishing(MAXSAT™) Catalytic Dewaxing (MSDW™ ) Group I Facilities Group II Group III Vacuum Distillation Atmospheric Resid Vacuum Resid DAO Deasphalting Improve Cold Flow Properties Convert wax to High VI Lube Improve Color and Stability, Saturate Polynuclear Aromatics Improve VI, Reduce Sulfur & Nitrogen, Saturate or Extract Aromatics, Reduce CCR, Remove Metals Remove Asphaltic Material and Adjust Viscosity Extract Converting Vacuum Gas Oil and DAO to High Quality Lube Base Stocks is a multi-step Process

  9. Group III Group II Integrated Route to Base Oils Group I Integrated into Group II & Group III Lube Plant Hydrofinishing(MAXSAT) Group I Solvent Plant Hydroprocessing (RHT/RHC) Catalytic Dewaxing (MSDW) Group II Group III Existing Solvent Dewaxing Group II Group III • 8 RHC or RHT units in operation or in design • Group I solvent operation improves VI with a yield loss to aromatic extracts • Removal of 3-4 ring aromatic compoundsand complex sulfur and nitrogen compoundsallows reduction in hydroprocessing severity, hydrogen consumption and associated yield loss Group III Group II VI Increase Aromatic Extract Base Conversion to 360-O C Fuels

  10. RaffinateHydroconversion (RHC) or Hydrotreating (RHT) Add Flexibility • Lower investment than grass roots • Maintains use of solvent-based lube facilities and Debottlenecks solvent extraction • Produces high quality Group II & II+ base stocks; also Group III capable • Higher VI, higher saturates, lower volatility, lower sulfur • Improved color and stability • Easily processes full range of viscosity grades • Preserves wax production with solvent dewaxing, or… • May use Catalytic Dewaxing (MSDW) to eliminate solvent dewaxing

  11. Maximize Use of Existing Group I Equipment Fuels 50-70% Yield with 15-35 VI Uplift DW: 70-85% Base Oil Yield RHC™ or RHT Light Neutral Lube Vacuum Distillation Solvent Dewaxing Solvent Extraction Medium Neutral Heavy Neutral 80-98% yield with 3-30 VI Uplift and H2 use of 300-600 scf/B High-quality wax with upstream Hydroprocessing Aromatic Extract

  12. Case Studies – Overview • Solvent Extraction Unit (SEU) and Solvent Dewaxing Unit (SDW) Exist to Process a Full Range of Lubes (Can Include Bright Stock) • Flexibility Required to Produce Group II / II+ Lubes • Options: • CASE 1: SEU, RHC and SDW – keep Neutral grades of wax production with improved slack wax quality • CASE 2: SEU, RHT and catalytic dewaxing (MSDW) – maximum production, but no wax product • All Products Produced to 110VI with Addition of RHC or RHT • Solvent Dewaxing and Catalytic Dewaxing (MSDW) Considered

  13. Case Studies – Overview (2) • Three Products – 100N/325N/600N • Base Production of 100VI/95VI/95VI • SEU Solvent Ratio Decreased to Increase Overall Production SEU Raffinate produced at 85 VI (DWO basis) • Two Crudes Considered: • Arab Light – high quality crude source example • Urals – low quality crude source example

  14. Case Studies – Results • Total Production Maintained with Both Solvent Dewaxing and Catalytic Dewaxing (MSDW) – 110VI Products – by Balancing Process Steps • Large Increase in Extraction Capacity with Reduction in Severity; Substantial Product Rate Increase Possible • VDU Side Streams Viscosity Increased to Meet Constant Product Viscosity • Hydroprocessing viscosity impact differs from solvent processing • Wax Production Increase is Possible When SDW Can Support • Effects are Crude Independent – Relative Changes Consistent for AL and Urals

  15. Study Case 1 – Summary of Effects

  16. Study Case 2 – Summary of Effects

  17. RHC is Commercially Proven . . . • First Unit Streamed in 1999 – Ten Years of Consistent Performance • Commercial Sequence of SEU/RHC/SDW (Ketone) • Very Low Catalyst Ageing • EHCTM Group II+ Products Show Excellent Performance in Formulations • Multiple Units Designed and Operating/In-construction • Excellent Flexibility for Complete Slate of Viscosity Grades including Bright Stock • Group III Capable

  18. First RHC Unit Streamed in 1999 Group II+ Production

  19. MSDW – Leading Selective Dewaxing Catalyst System • Integrates with RHC/RHT, and Lubes or Fuels Hydrocracking • Waxes Selectively Isomerized to High VI Lube • Highest Lube Product Yield and Low Fuels/Gas Production • Two Reactor Cascade System • Reactor 1: Zeolite Catalyst for dewaxing • Reactor 2: Noble Metal Hydrofinishing Catalyst • Low Hydrogen Consumption • Processes Full Range of Base Stocks • MSDW-2 Life Demonstrated >7 Years in Jurong and > 9 Years with Licensee • MSDW Licensed in 23 Units with 20 Units Starting up from 2002 to 2011 • New MSDW Catalyst – Commercialized in 6+ Units Since 2005 ExxonMobil Technologies Others

  20. MSDW: Leads by . . . • Feed Flexibility from Light Neutral to Bright Stock...Excellent Viscosity Retention • Product Flexibility for Group II and Group III • High Lube Product Yields with Minimum Fuels Byproducts • Excellent Low Temperature Properties of Products • Latest MSDW Shows Higher Activity than Prior Generations, Yet Maintains Exceptional Yield Selectivity, Robust Operation when Faced with Feed Contamination, and Superb Feed Rate Maintenance • No MSDW Load Ever Replaced for Reaching End-of-Cycle Condition, or Because of Feed Contamination Upset • Fully recovers activity after feed contamination upset – including hydro-processed coker gas oil • High tolerance for contaminants in feed: S, N, PNA’s

  21. ExxonMobil Selective Dewaxing HDW Catalyst Aging With More Advanced Catalysts 30 Cat: MSDW-2 Cat: MSDW-2 Cat: MSDW-2 Cat: MSDW-2 Year 2003 Year 2000 Year 2004 Year 2002 100N,150N,500N, BS 100N, 150N, 600N 150N, 500N 100N,150N Group II Group II Group II+ Group III Feed S < 150 wt ppm Feed S < 10 wt ppm Feed S < 10 wt ppm Feed S < 7 wt ppm 20 Feed N < 3 wt ppm Feed N < 1 wt ppm Feed N < 2 wt ppm Feed N < 1 wt ppm LHSV: 0.6 - 1.2 LHSV: 0.95 - 1.95 LHSV: 0.5 - 1.7 LHSV: 0.65 - 2.0 10 0 Delta Temperature, °C -10 Jurong Jurong Cat: MSDW Cat: MSDW Cat: MSDW-2 Cat: MSDW Year 2006 Year 2006 Year 2000 Year 2007 100N,150N 70N,150N 150N, 500N 150N, 500N -20 Group III Group III Group II Group II Feed S < 30 wt ppm Feed S < 30 wt ppm Feed S < 50 wt ppm Feed S < 50 wt ppm Feed N < 1 wt ppm Feed N < 1 wt ppm Feed N < 20 wt ppm Feed N < 20 wt ppm LHSV: 1.1 - 2.0 LHSV: 1.6 - 2.7 LHSV: 0.38 - 0.8 LHSV: 1.2 - 1.4 -30 0 200 400 600 800 1000 1200 1400 1600 1800 2000 2200 2400 2600 2800 3000 3200 3400 Days on Stream, [Day] MSDW: Proven Catalyst Stability

  22. MSDW Will Continue to Improve by . . . • Continuous Development Work to Further Improve Flexibility and Operation. New generations in Development Today to… • Expand already wide range of LHSV operation • Enhance already high tolerance to feed contaminants of S and N • Expand present exceptional operating stability and flexibility for very low pour point products (<-40°C)

  23. Catalytic Lube Application of EMRE’s Technologies ... Since 2000

  24. In Conclusion . . . • Adding RHC to Existing Solvent-Based Lube Facilities Raises Lube Quality from a Wide Range of Crude Sources • SEU/RHC/SDW will Produce Group II/II+ Lubes and is Capable for Group III Lubes (All Viscosity Grades) • Adding RHC to Existing Solvent-Based Plant Retains (And May Increase) Wax Production; Improves Wax Appearance Quality • MSDW for the Dewaxing Step May Further Increase Production, will Eliminate Wax Products • Join Our Satisfied Clients and Let EMRE's Lube Experience Work For You!

  25. THANK YOU !

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