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Small modular catalytic units for production of high-octane unblended gasolines through the process of Zeoforming

Small modular catalytic units for production of high-octane unblended gasolines through the process of Zeoforming. The process of Zeoforming, an effective method for production of high-octane unblended gasolines ( Based on the results of industrial operation of a Zeoforming-40 installation ).

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Small modular catalytic units for production of high-octane unblended gasolines through the process of Zeoforming

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  1. Small modular catalytic units for production of high-octane unblended gasolines through the process of Zeoforming The process of Zeoforming, an effective method for production of high-octane unblended gasolines(Based on the results of industrial operation of a Zeoforming-40 installation) Zeoforming is a technology for catalytic conversion of low-octane gasoline fractions (straight-run gasoline fractions of oils and gas condensates) into high-octane unblended gasolines proved at pilot to industrial levels. Zeoforming has been adjusted: Pilot level: At the Urengoy Gas Condensate Processing Plant, Nizhnevartovsk Gas Processing Plant, Luginetskoe Oil Field (Tomsk Region), Volgograd Refinery, Orenburg Gas Processing Plant.

  2. Demonstrational level: A 5,000-ton/year Zeoforming installation for unblended gasoline production from stable gas gasoline has been in operation at Nizhnevartovsk Gas Processing Plant since September 1992. Industrial level: An industrial Zeoforming installation of 40,000 ton/year capacity with respect to straight-run gasoline fraction (“Zeoforming-40”) began to operate in Poland in February, 1997. Lurgi Company (Germany) was the general contractor and designer. The commercial products of the installation are unblended Eurosuper-95 gasoline and liquefied gas. All the guarantee parameters presented by "Zeosit" are fully met: the octane number of the gasoline is 95 RON and total yield of both commercial products not less than 92-95%. During the start-and-adjustment works, new additional possibilities of the process and the catalyst were tested which may allow a still higher efficiency in future installations (i.e., an increased yield of the commercial products, octane number of the gasoline, and catalyst lifetime) without making the investments or running costs higher.

  3. Process parameters: Temperature, оC 320-450 Pressure, MPa 0.5-1.5 WHSV of the feedstock, ton/ton of cat. per hour 1-4 Advantages: In contrast to Reforming, the process of Zeoforming does not require: ►a hydrofining stage to remove sulphur and nitrogen-containing compoundsfrom the raw material ► either hydrogen or any related compressor equipment ► expensive catalysts based on noble metals , which decreases the capital and running costs. The catalysts are based on an environment-friendly system. The installations can operate autonomously.

  4. Being autonomous, these mini-plants are useful in remote regions or regions difficult of access where oil, gas condensate, or other hydrocarbon raw material are produced. They are expedient in meeting the demand in motor fuels of the local population as well as geologists and oilmen. Depending on the type of the raw material and the chosen production mode, RON-80orRON-91 - 93 gasolines can be produced at one and the same installation. The gasoline yields are: when RON-80 gasoline is produced – 80-92%, when RON-91 - 93gasoline is produced –65-85%.

  5. Expenditure rates of the main and auxiliary materials * - depends on the chosen process flow-sheet ** - depends on the chosen process flow-sheet and the capacities of the chosen electrical receivers

  6. Fractioning installation Hydrofining installation Hydro-isomerisation installation C5-C69% Gasoline fraction 35% Feedstock Diesel fuel 35% Gasoline fraction 26% iso-paraffins 8.5% Fuel oil 30% Hydrogen-containing gas Hydrogen-containing gas Blending unit High-octane component 22% Unit of gas desulphurisation Reforming installation H2 Diagram of conversion of oil fractions or gas condensate into motor fuels through different processes: Diagram 1. Conventional scheme (Reforming and isomerisation)

  7. Diagram 2. Zeoforming technology (Verkh-Tarskoe oil is taken as an example) High-octane gasoline 25-28% Fractioning installation Zeoforming installation Fuel gas 1% Gasoline fraction 35% Feed-stock Diesel fuel 35% Liquefied gas 6-9% Fuel oil 30% Fuel oil30%

  8. Starting the installation Dynamics of costs and profits depending on the capacity of a Zeoforming installation (the data concern the production of gasolines of 92 to 95 RON)

  9. Comparative analysis of the net present value (NPV)for the installations of high-octane gasoline production via ZeoformingandReforming

  10. 12 10 Reforming gasolines 2 8 Benzene content, %wt. 6 4 Zeoforming gasolines 2 1 0 70 75 80 85 90 MON of the gasoline Range of the benzene content in Zeoforming gasolines (1) and Reforming gasolines (2) depending on the octane number of the gasoline

  11. Range of the aromatic content in Zeoforming gasolines (1) and Reforming gasolines (2) depending on the octane number of the gasoline 80 70 Reforming gasolines 60 2 50 1 Aromatic content, %wt. 40 Zeoforming gasolines 30 20 10 65 70 75 80 85 90 MON of the gasoline

  12. Zeoforming vs. Reforming: key parameters

  13. Zeoforming vs. Reforming: key parameters Continuation

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