| DISCLAIMER |
II |
| |
| ABSTRACT |
III |
| |
| TABLE OF CONTENTS |
IV |
| |
| LIST OF GRAPHICAL MATERIALS |
VI |
| |
TABLES |
VI |
| FIGURES |
VIII |
| SCHEMATICS |
IX |
| |
| EXECUTIVE SUMMARY |
1 |
| |
| BACKGROUND |
2 |
| |
EECP CONCEPT |
2 |
| |
| SUBTASK PRODUCT EVALUATIONS PERFORMED
FOR TASK 2.5 OUTSIDE DOW FUNDING |
5 |
| |
| |
SUBTASK 2.5.1 PREPARATION OF LAPORTE
AFDU PRODUCTS |
7 |
| |
Experimental |
7 |
| Results and Discussion |
7 |
| |
| FISCHER-TROPSCH PRODUCT UPGRADING (TASK
2.5) |
10 |
| |
| |
SUBTASK 2.5.2 LAB BATCH FRACTIONATION |
13 |
| |
Experimental |
13 |
| Results and Discussion |
13 |
| SUBTASK 2.5.3 HYDROCRACKING PILOT |
18 |
| |
Experimental |
18 |
| Equipment |
20 |
| Feed Composition |
20 |
| Results and Discussion |
22 |
| SUBTASK 2.5.4 WAX FINISHING PILOT |
30 |
| |
Speciality Low and Medium Melting Point Waxes |
30 |
| Speciality High Melting Point Waxes |
30 |
| Experimental |
34 |
| Equipment |
35 |
| Results and Discussion |
39 |
| SUBTASK 2.5.5 ASTM TESTING FOR NAPTHA,
DIESEL, WAX PROPERTIES |
43 |
| |
Oxygen Concentration Determination |
43 |
| SUBTASK 2.5.6 DIESEL BLENDING TESTS |
49 |
| |
Experimental |
49 |
| Neat F-T Diesel Blending to Transportation Fuel |
49 |
| Hydrocracker F-T Diesel Direct Blending to
Transportation Fuel |
52 |
| Results and Discussions |
52 |
| SUBTASK 2.5.7.1 A&B&C NAPTHA
FRACTIONATION |
63 |
| |
Experimental |
63 |
| SUBTASK 2.5.7.2 NEAT NAPATHA
HYDROTREATING |
78 |
| |
Experimental |
78 |
| Feed Composition |
78 |
| Equipment |
78 |
| Results and Discussion |
78 |
| SUBTASK 2.5.7.3 ETHYLENE CRACKING |
85 |
| |
Experimental |
85 |
| Feedstock Component |
87 |
| Reaction Mechanism |
87 |
| Kinetics |
88 |
| Cracking Severity |
88 |
| Residence Time |
88 |
| Effect of Operating Variables on Yields |
89 |
| Feedstock Hydrogen Content |
89 |
| Decoking |
90 |
| Results and Discussion |
91 |
| Feed Inspection Tests on FT Napthas and KBR
Petroleum Based Naptha |
94 |
| SUBTASK 2.5.7.4 FUEL CELL REFORMER |
101 |
| |
Replacement for Subtask 2.5.7.5 Catalytic Reforming
Pilot |
101 |
| Experimental |
103 |
| Results and Discussion |
106 |
| SUBTASK 2.5.7.5 CATALYTIC REFORMING
PILOT |
111 |
| |
Experimental |
111 |
| Results and Discussion |
111 |
| SUBTASK 2.5.7.6 NEAT DIESEL
HYDROTREATING |
112 |
| |
Experimental |
112 |
| Feed Composition |
112 |
| Equipment |
112 |
| Results and Discussion |
112 |
| SUBTASK 2.5.8 WAX FRACTIONATION |
120 |
| |
Experimental |
120 |
| Results and Discussion |
120 |
| |
| CONCLUSIONS |
121 |
| |
| BIBLIOGRAPHY |
121 |
| |
| LIST OF ACRONYMS AND ABBREVIATIONS |
124 |
| |
| APPENDICES |
| |
Appendix A Subtask 2.5.2 Report on Lab
Batch Frationation |
| |
Appendix B Subtask 2.5.3 Report on
Hydrocracking Pilot |
| |
Appendix C Subtask 2.5.4 Report on Wax
Finishing Pilot |
| |
Appendix D Subtask 2.5.5 Report on
Oxygen Test Development |
| |
Appendix E Subtask 2.5.6 Report on
Diesel Blending Tests |
| |
Appendix F Subtask 2.5.7.1 Report on
Naptha Fractionation |
| |
Appendix G Subtask 2.5.7.2 Report on
Neat Naptha Hydrotreating |
| |
Appendix H Subtask 2.5.7.3 Report on
Ethylene Cracking |
| |
Appendix I Subtask 2.5.7.4 Report on
Fuel Cell Reforming |
| |
Appendix J Subtask 2.5.7.6 Report on
Neat Diesel Hydrotreating |
| |
| LIST OF TABLES |
| Table 2.5.2-1 |
Mass Balance Closure Around Subtask 2.5.2 Lab Batch
Fractionation |
15 |
| Table 2.5.2-2 |
Neat F-T Naptha Product Properties from Subtask 2.5.2 Lab Batch
Fractionation |
16 |
| Table 2.5.2-3 |
Neat F-T Diesel Product Properties from Subtask 2.5.2 Lab Batch
Fractionation |
17 |
| Table 2.5.2-4 |
Neat F-T Wax Product Properties from Subtask 2.5.2 Lab Batch
Fractionation |
18 |
| Table 2.5.3-1 |
Hydrocracker Feed Blends |
24 |
| Table 2.5.3-2 |
Feed properties for Hydrocracking Pilot Plant |
25 |
| Table 2.5.3-3 |
Yields Relative to Feed and Product Properties |
26 |
| Table 2.5.3-4 |
Hydrocracked Diesel Blends for Treating |
28 |
| Table 2.5.3-5 |
Hydrocracked Product Properties |
29 |
| Table 2.5.4-1 |
Desired Low- and Medium-Melting Point Wax Products Properties |
33 |
| Table 2.5.4-2 |
Desired High-Melting Point Wax Product Properties |
34 |
| Table 2.5.4-3 |
Feedstock Inspection Testing |
37 |
| Table 2.5.4-4 |
Design Basis Confirmation Operating Conditions - Wax Blend Feed |
41 |
| Table 2.5.4-5 |
Basis for Design-Product Testing for Feed Composed of FT Heavy
Product Liquid |
42 |
| Table 2.5.5-1 |
Naptha Characterization Testing Schedule for Subtask 2.5.5 |
46 |
| Table 2.5.5-2 |
Diesel Characterization Testing Schedule for Subtask 2.5.5 |
47 |
| Table 2.5.5-3 |
Wax Characterization Testing Schedule for Subtask 2.5.5 |
48 |
| Table 2.5.7.1-1 |
F-T Light Product from ISOtainer |
66 |
| Table 2.5.7.1-2 |
Batch and Continuous Distillation Product Results |
67 |
| Table 2.5.7.1-3 |
Subtask 2.5.7.1a Continuous Distillation Heavy Diesel Test
Results |
69 |
| Table 2.5.7.1-4 |
Subtask 2.5.7.1b F-T Light Product from Drum One Test Results |
70 |
| Table 2.5.7.1-5 |
Subtask 2.5.7.1c F-T Light Product from Drum Two Test Results |
71 |
| Table 2.5.7.1-6 |
Subtask 2.5.7.1.b Batch Distillation Product Results |
72 |
| Table 2.5.7.1-7 |
Subtask 2.5.7.1.c Batch Distillation Product Test Results |
73 |
| Table 2.5.7.1-8 |
Inspection Tests on Neat F-T Naptha Products |
75 |
| Table 2.5.7.1-9 |
Inspection Tests on Neat F-T Diesel Products |
76 |
| Table 2.5.7.1-10 |
Subtask 2.5.7.1a Continuous Distillation Soft Wax Test Results |
77 |
| Table 2.5.7.2-1 |
Naptha Feed Properties for Hydrotreating Pilot Plant |
82 |
| Table 2.5.7.2-2 |
Yields (Calculated by D2887) for Hydrotreating Naptha |
84 |
| Table 2.5.7.2-3 |
Hydrotreated Naptha Properties |
85 |
| Table 2.5.7.3-1 |
Feed Inspection Tests on FT Napthas and KBR Petroleum Based
Naptha |
95 |
| Table 2.5.7.6-1 |
Diesel Feed Properties for Hydrotreating Pilot Plant |
116 |
| Table 2.5.7.6-2 |
Yields for Hydrotreating Diesel |
118 |
| Table 2.5.7.6-3 |
Diesel Hydrotreating Product Blend and Distillates |
119 |
| Table 2.5.7.6-4 |
Diesel Hydrotreating Product Properties |
120 |
| |
| LIST OF FIGURES |
| Figure 2.5.3-1 |
Hydrocracking Pilot Plant Block Flow Diagram |
22 |
| Figure 2.5.4-1 |
P88 Wax Finishing Pilot Plant |
39 |
| Figure 2.5.6-1 |
Cetane Number Response to Direct Blending F-T Diesel into a
Future Tier II CARB Like Diesel Pool |
54 |
| Figure 2.5.6-2 |
Pour Point Response to Direct Blending F-T Diesels into a Future
Tier II CARB Like Diesel Pool |
55 |
| Figure 2.5.6-3 |
Cloud Point Response to Direct Blending F-T Diesels into a
Future Tier II CARB Like Diesel Pool |
57 |
| Figure 2.5.6-4 |
HFRR Lubricity Response to Direct Blending F-T Diesels into a
Future Tier II CARB Like Diesel Pool |
58 |
| Figure 2.5.6-5 |
SLBOCLE Lubricity Response to Direct Blending F-T Diesels into a
Future Tier II CARB Like Diesel Pool |
60 |
| Figure 2.5.6-6 |
Viscosity @ 313°K (40°C) Response to Direct Blending F-T Diesels
into a Future Tier II CARB Like Diesel Pool |
61 |
| Figure 2.5.6-7 |
Accelerated Stability Response to Direct Blending F-T Diesels
into a Future Tier II CARB Like Diesel Pool |
63 |
| Figure 2.5.7.2-1 |
Naptha Hydrotreating Pilot Plant Block Flow Diagram |
83 |
| Figure 2.5.7.3-1 |
Relationship Between Hydrogen Content of Feedstock and
Single-Pass Ethylene Yield |
94 |
| Figure 2.5.7.3-2 |
Hydrogen Contents of F-T Napthas and KBR Reference Petroleum
Naptha |
96 |
| Figure 2.5.7.3-3 |
Feed Inspection Tests on Hydrotreated F-T Naptha versus KBR
Petroleum Naptha Refrence |
97 |
| Figure 2.5.7.3-4 |
Prediction of Commercial Ethylene Yields for Hydrotreated F-T
Naptha and KBR Petroleum Naptha |
99 |
| Figure 2.5.7.3-5 |
Prediction of Commercial Proplylene Yields for Hydrotreated F-T
Naptha and KBR Petroleum Naptha |
100 |
| Figure 2.5.7.4-1 |
Feed Inspection Tests on F-T Napthas versus Processed Petroleum
Feeds |
108 |
| Figure 2.5.7.4-2 |
Carbon Balances for F-T Napthas and Petroleum Feeds |
109 |
| Figure 2.5.7.4-3 |
Reformate Compositions of F-T Napthas versus Processed petroleum
Based Feeds |
111 |
| Figure 2.5.7.6-1 |
Diesel Hydrotreating Pilot Plant Block Flow Diagram |
117 |
| |
| LIST OF SCHEMATICS |
| Schematic 1 |
EECP Concept |
3 |
| Schematic 2.5-1 |
Flow of Work Diagram for Task 2.5 and Task 2.6 Product
Evaluations |
6 |
| Schematic 2.5.1-1 |
Work Flow Diagram for Subtask 2.5.1.1 Preparation of LaPorte
AFDU Products |
8 |
| Schematic 2.5-2 |
Work Flow Diagram for Subtask Product Evaluations Performed for
Phase II RD&T Task 2.5 |
13 |
| Schematic 2.5.3-1 |
Work Flow Diagram for Subtask 2.5.3 Product Evaluation Performed
for Phase II RD&T Task 2.5 |
20 |
| Schematic 2.5.4-1 |
Work Flow Diagram for Subtask 2.5.4 Product Evaluation Performed
for Phase II RD&T Task 2.5 |
32 |
| Schematic 2.5.5-1 |
Work Flow Diagram for Subtask 2.5.5 Product Evaluation Performed
for Phase II RD&T Task 2.5 |
45 |
| Schematic 2.5.6-1 |
Work Flow Diagram for Subtask 2.5.6 Product Evaluation Performed
for Phase II RD&T Task 2.5 |
51 |
| Schematic 2.5.6-2 |
Flow of Work for Subtask 2.5.6 Diesel Blending Tests |
52 |
| Schematic 2.5.7.1 |
a, b, and c-1 Work Flow Diagram for Subtask 2.5.7.1 a & b 7 c
Product Evaluation Performed for Phase II RD&T Task 2.5 |
65 |
| Schematic 2.5.7.2-1 |
Work Flow Diagram for Subtask 2.5.7.2 Neat Naptha Hydrotreating |
81 |
| Schematic 2.5.7.3-1 |
Work Flow Diagram for Subtask 2.5.7.3 Product Evaluation
Performed for Phase II RD&T Task 2.5 |
87 |
| Schematic 2.5.7.4-1 |
Work Flow Diagram for Subtask 2.5.7.4 Product Evaluation
Performed for Phase II RD&T Task 2.5 |
103 |
| Schematic 2.5.7.4-2 |
Flow of Work for Subtask 2.5.7.4 Fuel Cell Reformer Evaluation
of Hydrotreater (HT) F-T Naptha Feed |
105 |
| Schematic 2.5.7.4-2 |
Flow of Work for Subtask 2.5.7.4 Fuel Cell Reformer Evaluation
of Hydrocracker (HC) F-T Naptha Feed |
106 |
| Schematic 2.5.7.6-1 |
Flow of Work for Subtask 2.5.7.6 Fuel Product Evaluation
Performed for Phase II RD&T Task 2.5 |
115 |
