g g

Hydrocracking A broad portfolio of advanced technology equipmentfor heavy duty refinery applications

GE Oil & GasGE Oil & Gas

Via Felice Matteucci, 250127 Florence - ItalyT +39 055 423211F +39 055 4232800Nuovo Pignone S.p.A.

www.ge.com/oilandgas

COMK/MARK 891/II - Designed by: Studio Tre FasiPrinted by: Sagraf - 1-2008©2008 Nuovo Pignone S.p.A. all rights reserved

GE imagination at work

Hydrocracking Process Information

In a global scenario of oil supplies shifting towards heavyand sour crudes that are more difficult to process, refinersmust meet increasingly tighter environmental regulations,difficult technical challenges and complex safetyrequirements. The supply of heavy crude oil (<20° API) has increased bymore than 15% since the year 2000 and projections indicatea continued significant increase in this trend of reduced lightcrude production.Transportation fuel regulations have significantly decreasedthe allowable level of pollutants over the past 10 years andeven lower targets are set for the near future. Levels ofsulfur and aromatics are key targets for more stringentregulation; the USA Tier II for gasoline allows 30ppm of sulfurand the EU will move from the current 50ppm to 10ppm by2009 for both diesel and gasoline. All domestic production as well as imports will have to becompliant with these regulations, meaning that more than60% of worldwide distillate and gasoline will be an ultra-lowsulfur product by the end of this decade.The need to increase the capacity of petroleum refineriescapable of handling very low API gravities including“unconventional crude” from bitumen sands (<10° API), whilemaintaining or even increasing the percentage of lighttransportation fuel produced, requires the upgrading ofrefinery processes with the introduction of new crackingfacilities. The refining of heavy oil is a complex process that requiresexperience and sophisticated technology.Hydrocracking (HCU) is a process that subjects feedstocks toa concentrated hydrogen atmosphere in the presence of acatalyst. The feed for the HCU comes from the toppingbottom and from upgrading processes such as coking,Fluid Catalytic Cracking (FCC), and deasphalting.The output normally goes to lighter hydrotreatingunits or directly to fuel blending. The HCU enhancesthe yield of light products and increases theflexibility of refinery out-turns by varying

the hydrogen concentration, catalyst and operatingconditions. Refiners can thus shift unit yields from gasolineto distillates to fulfill the market demand. Within the heavy-wall reactor, which is the core of theprocess, complex hydrocarbon transformations take place.Long chain paraffins are cut into shorter molecules, olefinsand aromatics are saturated with hydrogen, and sulfur andpollutants are removed with the formation of NH3, H2S andmetal residues.GE Oil & Gas boasts a long history in the downstreamsegment of the industry and provides one of the mostcomprehensive portfolios of equipment for hydrocracking.Our product line spans from heavy-wall reactors tofeedstock pumps, from hydrogen compressors to air coolersfor the primary process streams, and Hydraulic PowerRecovery Turbines (HPRTs) for power recovery and reducedemissions.

GE Oil & Gas footprint in Hydrocracking

Qualified by all major licensors of HCU process: • Chevron Lummus Global LLC• UOP LLC• Axens• ExxonMobil Research & Engineering Co.• Haldor Topsøe A/S• Shell Global Solutions International BV

Our experience speaks for itself ...• Installed capacity

• Hydrogen compression > 6.5mm Nm3/h• Feedstock pumping > 23.300m3/h• Amine washing > 6.000m3/h

• More than 40.600 tons of Cr/Molv steel forged and welded into reactors

GE Oil & Gas presence in Hydrocracking

deplhydrocracking1:deploffshore4 27-10-2008 15:17 Pagina 2

Re-cycle compressor

Make-up compressor

1st stage reactor

2nd stage reactor

HP separator

Hydraulic powerrecovery turbine

Air cooler

Fractionationtower

Air cooler

Centrifugalpump

Feedstock from:ADV, VDV, FCC

Hydrogen

Hydrogen20-40 bar

160-250 bar

100-180 bar300-400ºC

200-250 bar400-450ºC

120-180 bar

Feedstock

Feedstock

Cycle residue

Gas recovery

Light gasoline

NafhtaDistillate

Centrifugalpump

Hydraulic Power Recovery Turbine(HPRT)

In processes where, core hydrocrackingand amine regeneration is required, thefeedstock must be at high pressure toallow certain reactions to take place.Because downstream units areoperated at lower pressure, instead ofdissipating power through a valve,energy can be captured by inserting apower recovery turbine in the liquidflow. This energy may then be used forpumping other process feedstocksthereby saving electricity.GE produces reliable, highly efficientrotating equipment for hydraulicpower recovery. It has improved theinternal design to raise efficiency andhas a proven installed base in heavyduty refining applications. Energysavings and reducing CO2 emissionsare the key drivers for the use of thisequipment.The equipment used for the HydraulicPower Recovery Turbine is derived fromcentrifugal pump technology. Theinternal feedstock flow direction isreversed but the proven designfeatures taken from the traditionalpump product are the same with onlyminor modifications to the flow paths.The high pressure flow enters theturbine and activates the rotor,creating a helper effect for the electricmotor. The power thus transmittedresults in a saving of electric energy.

Centrifugal Pumps

Our DDHF API 610 (ISO 13709) modelis a between bearings multistagecharge pump that features acylindrical outer barrel enclosing a

horizontally split inner volute case. Itis designed for continuous handlingof a wide range of feedstocks such asstraight run residue or cycle oils athigh pressure and temperature, andlow specific gravity.Important features include:• Highest level of performance,

reliability and availability; axiallybalanced over the entire operatingrange with a single or double suctionfirst impeller depending on theNPSH requirements

• Particularly indicated forapplications with high temperatures(up to 430°C) and high pressures (upto 350 bar) where strong resistanceto thermal shock is needed

• Broad experience and references(hundrends of units) in heavy dutyrefining applications: first andsecond stage flash pump; reactorcharge pump; LCF charge pump;heavy oil charge pump

• Hard facing and meticulous flowpath design which guarantees longpump life even with highly erosivefluids and the presence of sand.

• Customized impeller design toperfectly match the specificationrequirements

• Simplicity of maintenance, animportant consideration forapplications where minimum downtime is essential

Air Coolers

GE Oil & Gas manufactures Air CooledHeat Exchangers for all majorapplications of the oil and gas industryincluding the extremely demandingconditions found in refinery processessuch as hydrocracking reactor effluent.

Important features include:• Highly flexible designs capable of

accommodating the gamut ofprocess conditions includingtemperature, corrosion, fouling andpressure, which require specialattention to material type, thicknessand welding procedures

• Header configuration can be thePipe and Bend or Plug Box type. Thefully welded Pipe and Bend designis suitable for critical and hazardousapplications while the Plug Boxconfiguration is particularly welladapted for cooling and condensingof hydrocarbons and gases. Thesetwo designs give us the ability tocover all refinery process operatingconditions and to handle the highestpressures required by the industry

• Another important feature for theperformance of the cooler is thetube finning. We provide extrudedfins, indicated for high temperatureapplications and for permanentprotection against external corrosion.The high efficiency fins can beembedded or grooved even forhigher temperatures and pressures

• With sour gas or feedstock underhigh pressure, corrosion of theequipment is an importantconsideration and a special, thickermaterial is required. We have theability to machine and weld specialmaterials for advanced corrosionresistance such as low-alloy, nickel-alloy and titanium

• Thanks to our many years ofexperience with this product, wecan rely on our failure-proofmanufacturing capability includingweld and post-weld local heattreatment

Our ProductsOur Products Process Flow DiagramHeavy-Wall Reactors

Designed for applications where highpressure (up to 250 bar) and hightemperature (up to 450°C) are crucial,such as for 1st and 2nd stagehydrocracking reactors.Important features include:• Advanced technology for welding

thicknesses up to 400mm withoutweld overlay disbondling duringrapid cooling; all GE reactors arefabricated from forged rings

• Full qualifications and references formajor licensed processes (Chevron,Lummus Global LLC, UOP LLC, Axens,ExxonMobil Research & EngineeringCo., Haldor Topsøe A/S, Shell GlobalSolutions International BV)

• Unmatched handling and weldingprocedures which guaranteeequipment against fabrication andassembly flaws, as well as Post-Welding Heat Treatment (PWHT) forintermediate and final stress release

• 20 years of experience in thesuccessfull manufacturing ofreactors from 2 1/4 Cr1Mo1/4Vanadium, which has outstandingmechanical characteristics,excellent resistance to hydrogenattack and a significant reduction inweight

• Proven on-site capabilities withmore than 80 units recently installedin new refineries and as part ofexisting plant expansion, includingoil sands upgrading

• Proven capability in the fabricationof temporary facilities for theassembly of reactor sections atcustomer sites; this is required if

there are weight and dimensionconstraints at the customer site thatprevent fully assembled equipmentfrom being delivered

• Our new pulsing line with rails andspecialized workstations hasenhanced our manufacturingcapabilities and reduced lead time;our facility can handle the largestreactor diameters that the marketrequires

Reciprocating Compressors

Designed in accordance with API618standards for heavy-duty applications,GE Oil & Gas’ H series ReciprocatingCompressors are the prefect solutionfor Hydrogen Make-up service inhydrocracking plants. We boast thehighest level of performance, reliabilityand availabilty on more than 1,000units installed in hydroprocessing plantsup to 250 bar and from 100 kW up tothe highest power levels found in thisclass of machine. We have referencesfor 8 cylinder units and we havealready selected a 10 HG with acapability up to 95KNm3/h. Important features include:• Highest Market Rod load uprated

thanks to a new patentedcrosshead design in forged steelenhancing fatigue resistance on theconnecting rod

• Introduction of bimetallic Al-Sn mainand big end bearings with a higherload capacity and improved safetyfactor

• Hydraulic tightening applied on allthe main threaded connections with

a gain in accuracy, assemblyprecision and safety

• Optimized cylinder valve designproprietary to GE Oil & Gas whichimproves efficency and performanceof internal parts

• All materials are selected based onthe type of application, temperatureand pressure conditions and gascomposition. Different types ofsurface hardening and hardcoatings are used on the exposedand sliding surfaces

• Full range of tools for design andtesting; first-class capability andexperience in piping pulsation andvibration analysis

Centrifugal Compressors (Recycle)

Our BCL series centrifugal compressoris a proven and reliable technologywith an extensive installed base inmany different oil and gas sectorsincluding high head and high speedrefinery applications. Manufacturingcenters for this equipment are locatedin Florence (Italy), Le Creusot (France)and Oshkosh (USA).Important features include:• In-line, back-to-back or double flow

configurations • Specific materials are selected to

withstand the various forms ofcorrosion presented by sour gas orhydrogen based on our extensiveexperience in corrosive applications

• Shaft-end seals are of the dry gastype but other sealing solutions arealso available

deplhydrocracking1:deploffshore4 27-10-2008 15:17 Pagina 6