Shell Global Solutions

ARE YOU SEEING THE FULL

SPECTRUM OF POSSIBILITIES?
The many ways you can revamp a vacuum distillation
unit (VDU) to unlock your downstream assets

WHITE PAPER
CONTENTS

1. The spectrum of VDU revamps that can unlock your downstream assets

2. The economics of a VDU revamp

3. Five key value-adding design differentiators

4. Case studies

4.1 Increasing VDU capacity to provide more hydrocracker feed

4.2 Enhancing VGO quality to improve downstream reliability

4.3 Recovering more waxy distillates from the short residue to generate more margin

4.4 Improving VDU run length to maximise uptime

5. Benchmarking data proves the value of leading-edge technology

6. Why choose Shell

7. Key takeaways
 Shell Global Solutions

DO YOU

feel constrained by your VDU capacity?

experience issues maintaining the desired vacuum level in your VDU?
see metals slip from your VDU unit?
have concerns about your VDU column and furnaces run lengths?
want to lift more vacuum gas oil (VGO) from the crude distillation unit (CDU) to
fill downstream units?
suffer coking issues in the furnace or wash bed?

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Shell Global Solutions

1. THE SPECTRUM OF REVAMPS THAT CAN UNLOCK

YOUR DOWNSTREAM ASSETS
The performance of a VDU and the levels of contaminants in the VGO can have a major bearing on
a refinerys margins, as they can affect the capacity, reliability and cycle length of the hydrocracker,
fluidised catalytic cracking or other downstream conversion units.

Fortunately, refiners can cost-effectively improve the performance of their VDU by revamping the unit
using Shells deep-flash, high-vacuum technology. Indeed, many refiners worldwide have unlocked
margin improvements in this way: since 1985, Shell Global Solutions has delivered almost 50 new
designs or revamps.

These projects are always driven by the customers specific circumstances and objectives, and it is
important to understand that they are highly customised initiatives. So, in this white paper, we profile
four recent VDU revamps, each of which was driven by a distinct key objective.

These case studies show how customers have:

increased the capacity of their VDU to provide more hydrocracker feed (Section 4.1);
enhanced VGO quality to improve downstream reliability (Section 4.2);
recovered more from the short residue to generate more margin (Section 4.3); and
improved VDU run length to maximise uptime (Section 4.4).

2. THE ECONOMICS OF A VDU REVAMP

Experience shows that a VDU revamp can unlock substantial value. For example, compared with a
typical conventional unit, an 8.9-Mt/y or 150,000-bbl/d unit that uses Shell deep-flash technology can
improve a refinerys margin by some $7.8 million per year.

This is because it can:

generate 13% more distillates;
cut energy costs by 25%; and
improve mechanical availability by 1.5%.1

The capital cost is usually relatively low, the payback time is short, typically a year or less, and the
hardware changes are often possible within an existing refinery turnaround window.

4 1
Shell 2008 international benchmarking studies
 Shell Global Solutions

3. FIVE KEY VALUE-ADDING DESIGN DIFFERENTIATORS

Shell deep-flash technology has been developed through extensive research on mass
transfer and separation equipment, and been supported by operating experience
from numerous Shell and Shell-advised units over many years. Indeed, Shell Global
Solutions has licensed Shell deep-flash technology in 26 revamped and 24 grassroots
units since 1985.
As shown in Figure 1, this technology includes five key design features that can be tailored to meet
a refiners specific revamp requirements. It is important to note, however, that, because each refiners
circumstances and business objectives are unique, revamp projects are highly tailored, so, some projects
may not incorporate all these design features.

5 Empty spray sections

4 Draw off trays

3 Wash oil section

2 Schoepentoeter*
1
Furnace

FIGURE 1: Five key value-adding design differentiators of Shells deep-flash technology.

The first of these value-adding design differentiators is Shell proprietary furnace coil design.
Conventional technologies can be prone to coking, but Shell Global Solutions has developed technology
involving suppressed vaporisation that controls the flow regime in a furnace. The liquid coats the
walls of the heated coils continuously throughout the furnace and the vapour passes through the core,
thereby completely avoiding a mist flow region where the droplets can hit the very hot walls and form
coke. Consequently, Shell-designed units typically achieve pacesetting cycle lengths (Figure 2).

*Schoepentoeter is a Shell trademark 5

Shell Global Solutions

16

14

12
Decoking cycle, y

10

0
380 390 400 410 420 430 440

716 736 756 776 796 816

Coil outlet temperature, C/F

Heat shields are not used on the hottest tube parts. Downstream units have equally short cycle lengths,
which removes the incentive to extend HVU run lengths.

FIGURE 2: Many Shell-designed units run for four or more years before decoking is required.

Shell direct-contact spray condensation sections also contribute to improved distillate recovery.
Conventional VDUs often have packed pumparound condensation sections, but this packing can
increase pressure drop and reduce yields. The Shell approach is to achieve vapour condensation by
direct contact with liquid in an empty space. This removes the need for packing and reduces column
height. Crucially, it also maximises distillate recovery, as the pressure drop is lower than for packed
condensation sections, thus enabling lower flash-zone pressures.
Entrainment of vacuum residue (VR) from the flash zone often limits the VGO yield of conventional
VDUs owing to quality concerns. To address this, the proprietary Shell Schoepentoeter Plus vane-type
feed inlet device is designed to achieve a high de-entrainment efficiency at a lower pressure drop than
conventional feed inlet devices. It also offers good vapour distribution. This highly efficient feed inlet
device can help operators to process more difficult crudes and meet tighter product specifications.
Coking of the wash oil section, which washes down the remnants of entrained VR, is a common
reason for premature VDU shutdowns. Shell-designed wash oil sections and wash rate management
aim to avoid coking and, thus, extend cycle lengths, increase distillate yields and meet tighter product
specifications. Maintaining a low pressure drop across the wash oil section is key to this: conventional
designs may see a gradual increase in pressure drop over the wash oil packing due to coking, which
can cause deterioration in distillate yield and quality.
Based on its operating experience, Shell Global Solutions has developed guidelines for the design and
operation of wash oil beds that can enable continuous operation for over four years without coking of
the wash oil packing. As shown in Figure 3, Shell-designed and advised units can typically operate for
over four years without coking of the wash oil bed packing.

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 Shell Global Solutions

14

12

10
Wash bed lifetime, y

8 Best-in-class line

0
380 390 400 410 420

716 726 736 746 756 766 776 786

Flash zone temperature, C/F

FIGURE 3: Shell-designed and advised units can typically operate for more than four years without coking of the
wash oil bed packing.

Shell low-pressure-drop insulated draw-off trays help to maximise VGO yield by:
having minimum liquid holdup on the tray to avoid coking;
insulating the bottom trays to minimise condensation of hot vapour, i.e., wild reflux, against the
relatively cold tray surface by having an empty space between double walls; and
leaving large open areas for vapour passage and thus providing a very low pressure drop, good
vapour distribution and a lower flash-zone pressure.

In addition, the draw-off trays shallow design helps to reduce the column height, thereby saving capital
costs, and makes them easy to install because they do not require seal welding.

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Shell Global Solutions

4. CASE STUDIES
4.1 Increasing VDU capacity to provide more hydrocracker feed

Situation
A South Korean refiner planned to create a new 20,000-bbl/d lubricant base oil plant that would take
unconverted oil from the hydrocracker. To meet the targeted yield of lubricant base oil, it was necessary
to revamp the hydrocracker to increase its throughput by about 10%. In addition, it was vital to
produce additional feedstock for the hydrocracker by going further back into the processing stream and
revamping the VDU.

The objectives of the VDU revamp were to increase the VGO yield from 30,000 to 35,000bbl/d and
ensure suitable quality VGO for hydrocracker feedstock. The changes made to the refinery configuration
during this project are shown in Figure 4.

Solution
As part of the pre-revamp feasibility study, several options were studied in detail to achieve the target
VGO yield. Shell Global Solutions then conducted costbenefit analyses on these options. The refiner
selected the option that involved the largest revamp, as this was the lowest-capital-cost option. However,
it was also the most technically challenging, as it involved extensive modifications of the existing units
resulting in complex implementation.

The key changes were:

revamping the furnaces to increase their duty by adding tubes in the convection section and
switching completely to gas firing instead of dual-fuel firing;
replacing the existing vapour horn type feed inlet device with a Shell Schoepentoeter Plus
inlet device to reduce the entrainment of VR to VGO and to ensure better vapour distribution; and
upscaling the transfer line and the column feed inlet nozzle to limit the velocity of the two-
phase flow in the transfer line below the sonic velocity limit and thus ensure the mechanical stability of
the transfer line and efficient de-entrainment performance of the inlet device.

Working closely with site staff, Shell Global Solutions also took all possible steps to minimise the vacuum
column pressure drop to help maximise distillate yield. The pumparound and wash bed packing were
replaced with the latest-generation, low-pressure-drop structured packing and the existing chimney trays
were replaced with proprietary Shell low-pressure-drop draw-off trays.

The team also installed new spray distributors and made minor plant modifications outside the column to
support the main revamp, including upgrading the heat exchangers and pumps.

During the period from concept development to commissioning, Shell Global Solutions remained
closely engaged with the client for successful on-time completion of this complex project. A subsequent
performance test run confirmed that all the revamp targets had been met. The improvement is quality
parameters is shown in Table 1.

VGO QUALITY PARAMETER BEFORE REVAMP AFTER REVAMP

D1160 T95%, C 540 562
Nickel + vanadium, wppm 0.3 0.5
Conradson carbon residue, wt% 0.4 0.5

TABLE 1: How the revamp changed the VGO product qualities.

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 Shell Global Solutions

Value delivered
The projects economics were highly attractive. The cost of the modifications and the additional
downtime required for implementation was about $26 million, and the additional VGO that the revamp
unlocked increased margins by about $46 million per year. The simple payback period, therefore, was
less than one year.

Before
CDU-1
HCU
35 kbbl/d
AR
54.5 kbbl/d VGO
VDU 30 kbbl/d Base oil
75.5 kbbl/d 20 kbbl/d
CHGO
21 kbbl/d 5 kbbl/d

VR
AR DCU

CDU-2

AR T-AR
RDS RFCC

After
CDU-1
HCU
40 kbbl/d
AR
56 kbbl/d VGO
VDU 35 kbbl/d Base oil
76 kbbl/d Hydrowax 20 kbbl/d
CHGO
20 kbbl/d 5 kbbl/d

VR
AR DCU

CDU-2

AR T-AR
RDS RFCC Revamp
New

FIGURE 4: The refinery block scheme before (left) and after (right) the VDU revamp. Before the revamp, the refinery had
an open-art VDU and a non-Shell-licensed hydrocracker. The project introduced a Shell-licensed deep-flash VDU and
hydrocracker, and a new lubricant base oil unit.

THE PROJECT AT A GLANCE

Project: South Korean refinery, VDU revamp
Objective: Increase VGO capacity, ensure suitable VGO quality
Key changes: Furnace revamp; Shell Schoepentoeter Plus inlet device; transfer line
upscaling; column feed inlet nozzle upscaling
Benefit: $46 million margin increase, less than one year payback period

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Shell Global Solutions

4.2 Enhancing VGO quality to improve downstream reliability

Situation
An Indian refiner wanted to unlock more barrels of VGO from its 18,000-t/d CDU. For this project,
however, it was found that changes to the furnace were unnecessary and most of the packing could
stay. There was already sufficient capacity in the column, furnace and transfer line, and modifications
were only required to the wash oil section internals and the feed inlet device. Consequently, this was a
minimum capital expenditure revamp.

The refiners previous attempts to increase the VGO yield had resulted in high metals contamination.
Investigations identified several potential causes, including:
the feed entry device was not doing enough to de-entrain the VR from the VGO;
the velocity in the transfer line was high; and
the VR entrainment in the slop cut and the wash oil rates both exceeded Shell guidelines.

Solution
Shell Global Solutions proposed three main actions to improve the situation:
1. Recycle the vacuum slops to the VDU furnace for reprocessing and recovering additional VGO.
2. Install a Shell Schoepentoeter Plus feed inlet device to improve the VR de-entrainment performance.
3. Install the Shell proprietary wash bed configuration to minimise the wash oil rate to maximise the VGO
recovery with acceptable quality for downstream units.

Value delivered
The modifications were implemented during a turnaround window. The data from a test run then enabled
the VGO increase to be calculated. After derating, which was necessary to adjust for a change in feed
quality and because the plant operates in bituminous mode for eight months of the year, the average
annual VGO benefit was calculated to be 1.5wt% on crude throughput (263t/d of additional VGO on
a crude throughput of 18,000t/d). Given the enhanced value of VGO compared with that of VR, this
had a major impact on the refiners margins.

THE PROJECT AT A GLANCE

Project: Indian refinery, CDU revamp
Objective: Increase VGO capacity
Key changes: Recycle vacuum slops to the VDU furnace; Shell Schoepentoeter Plus inlet
device; Shell proprietary wash bed configuration
Benefit: 1.5-wt% (on crude throughput) increase in annual VGO yield

4.3 Recovering more waxy distillates from the short residue to generate
more margin

Situation
A refiner in Asia Pacific intended to increase its hydrocracking capacity, which would require additional
waxy distillate production. Its vacuum distillation column was operating at relatively mild flash zone
conditions that resulted in a significant quantity of valuable 550C minus content (hydrocracker feedstock
material) being lost to the short residue.

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 Shell Global Solutions

Solution
In 2009, Shell Global Solutions studied several debottlenecking options for recovering additional waxy
distillates. These included either revamping or replacing the existing furnace and column and installing a
new furnace and column in either parallel or series. After a thorough evaluation, the refiner selected the
option of processing the short residue from the existing unit under deep-flash conditions in a new furnace
and high-vacuum column, which would be in series with the existing vacuum column. This option scored
better than the others in terms of capital expenditure, shutdown time and operational flexibility.

In 2010, Shell Global Solutions delivered the basic design package for the new unit: a vacuum furnace,
a high-vacuum column and the associated equipment. The unit was designed to recover 54wt% of
short residue feed as additional waxy distillate while maintaining the product quality specifications and
minimising cracking of the feedstock. The design challenge was to meet the distillate recovery and quality
targets because the short residue feed was heavier and contained a higher concentration of contaminants
compared with typical feeds to VDUs.

Several innovative features were introduced, especially around the steam stripping section design, and the
Shell Schoepentoeter Plus was introduced as feed inlet device. The new furnace was designed to ensure a
minimum decoking interval of three years. The furnace and the column function are designed to function well
under a wide variation in feed quality.

As shown in Figure 5, the short residue from the existing VDU contains a significant amount of 550C minus
content, which is recovered in the new high-vacuum unit (HVU).

Despite the units technical complexity, the final package was delivered within a tight time frame of 12 weeks.

Overhead

Overhead
LVGO

VGO

VGO
T95: 604C

Long residue
T50: 480C

Short residue
T30: 535C
T50: 570C

UP
GR
AD
Existing VDU E
Short residue
T5: 574C
T: C represents ASTM D1160 vol % temperature: C

New HVU

FIGURE 5: The new HVU recovers the valuable 550C minus VGO material that was previously lost.

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Shell Global Solutions

Value delivered
In 2014, the unit was successfully commissioned. Its capacity, turndown operability and waxy distillate
and short residue qualities and properties were found to be achievable and sustainable.

THE PROJECT AT A GLANCE

Project: Asia-Pacific refinery, VDU revamp
Objective: Increase waxy distillate production
Key changes: Changes to the steam stripping section; Shell Schoepentoeter Plus inlet device
Benefit: The recovery of valuable 550C minus VGO material from short residue

4.4 Improving VDU run length to maximise uptime

Situation
A refiner in South East Asia intended to revamp its VDU to achieve a minimum run length of three years
to match the hydrocracker shutdown cycle. Owing to frequent fouling of the vacuum column wash
section, the run length of the unit could not be extended beyond two to two and a half years.

Solution
In the first phase, Shell Global Solutions carried out a study to identify the revamp requirements to
achieve the desired run length and helped the refiner make a preliminary estimate of the cost associated
with the revamp.

Subsequently, Shell Global Solutions delivered a basic design package for the modifications of the
vacuum column and associated equipment. In addition to the target of increased run length, other
revamp targets were set during the basic design, including unit throughput, VGO and waxy distillate
yield and quality, and achievable depth of flash at the end of a three-year run length. The key
modifications suggested for the column were to convert the existing two-stage wash section into a single-
stage wash section and to replace the existing feed inlet device with a Shell Schoepentoeter Plus device.

Value delivered
The design package was delivered in September 2014. Shell Global Solutions supported the refiner
throughout the implementation stages, especially during the installation and start-up activities in June
2016. The performance test run of the revamped unit was carried out in August 2016. From the
performance test run data analysis, it was concluded and accepted by the refiner that all the revamp
targets had been achieved. The targets for the three-year run length and the depth of flash at the end of
the three-year cycle will be assessed at the end of run.

THE PROJECT AT A GLANCE

Project: South East Asia refinery, VDU revamp
Objective: Increase VDU run length (frequent fouling of the vacuum column wash section
had been a key constraint)
Key changes: Convert the wash section from two stage to single stage; Shell
Schoepentoeter Plus inlet device
Benefit: Unit run length extended to three years or more

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 Shell Global Solutions

5. BENCHMARKING DATA PROVES THE VALUE

OF LEADING-EDGE TECHNOLOGY
According to Shell 2008 international benchmarking studies, by using Shell technology, customers are
benefiting from:
higher VGO recovery. Whereas conventionally designed units have flash zone pressures of about
30mmHg about half the Shell designed and operated deep-flash vacuum units have flash zone
pressures of 20mm Hg or less, as shown in Figure 6. Lower flash zone pressures mean higher VGO
recovery.
enhanced reliability. Shells design and operating practices for furnaces and wash oil sections
have effectively resolved coking in these areas, which are two main causes of unscheduled HVU
shutdowns. As shown in Figure 7, of the Shell designed and advised vacuum units, all but one site is
above the industry average and most are within the first quartile. Mechanical availability is 2% higher
than the industry average.
long cycle length. As shown in Figure 8, many of the Shell designed and advised vacuum units
have cycles of four or more years (at some sites the cycle length is dictated by the downstream
conversion units).
improved yield. Whereas conventionally designed units typically have cut points in the range
535565C, many of the Shell designed and advised deep-flash vacuum units have cut points over
575C, and some over 600C, as shown in Figure 9.
50
45
40
Flash zone pressure, mmHga

35
30
25
20
15
10
5
0
Shell designed and advised vacuum units1

FIGURE 6: About half of the Shell designed and operated vacuum units have flash zone pressures of 20mm Hg or less.

100
99
98
Mechanical availability, %

97
96 Industry average
95
94
93
92
91
90
Shell designed and advised vacuum units1

FIGURE 7: All but one of the Shell designed and operated vacuum units are above the industry average
for mechanical reliability.

1
Shell 2008 international benchmarking studies 13
Shell Global Solutions

7.0
Turnaround cycle length, y

6.0
5.0
4.0
3.0
2.0
1.0
0.0
Shell designed and advised vacuum units1

FIGURE 8: Many of the Shell designed and advised vacuum units have cycles of four or more years (at some sites the cycle
length is dictated by the downstream conversion units).

650
HVGO 95% true boiling point cut point, C

1,182

HVGO 95% true boiling point cut point, F

625
1,132
600

1,082
575

1,032
550

525 982

500 932

Shell designed and advised vacuum units 1

FIGURE 9: Many of the Shell designed and advised vacuum units have cut points over 575C, which provides greater yields.

6. WHY CHOOSE SHELL?

VDU revamps can often be very challenging, so, if they are not engineered
properly, it may be impossible to meet the desired revamp objectives. Experience
and leading-edge technology are key to a successful, value-adding project.
Shell is an owneroperator
As well as being an oil and gas technology licensor, Shell also operates its own plants, so the
operational feedback we receive from these assets helps to provide special insights into the challenges
that our customers are facing. We also ensure that we incorporate the lessons learned from these plants
into our design practices.

Track record
Since 1985, we have licensed Shell deep-flash high-vacuum technology in 26 revamped units, see the
table opposite.

14 1
Shell 2008 international benchmarking studies
 Shell Global Solutions

LOCATION START-UP CAPACITY, T/D FEEDSTOCK

Thailand 2016 10,000 Various blend
South Korea 2014 12,000 Middle East
India 2013 9,300 Arab light/heavy
Greece 2010 8,400 Middle East
Thailand 2006 6,300 Middle East
India 2004 47,000 Arab heavy/Maya
India 2003 47,000 Arab heavy/Maya
USA 2002 13,500 West America
Sweden 2002 10,600 Gullfaks/Troll
Italy 2002 5,800 Arab heavy
India 2002 22,000 Arab light/heavy
Germany 2000 3,500 North Sea
Italy 1999 9,538 North African
USA 1999 4,335 Various paraffinic
USA 1999 12,283 Gulf of Mexico/various
Indonesia 1998 2,600 Arab light
Indonesia 1998 3,900 Arab light
South Africa 1998 7,500 Middle East
Thailand 1997 5,400 Arab light
Germany 1996 4,500 Ekofisk
Thailand 1994 6,400 Oman
Argentina 1991 5,000 Mixed LR
Venezuela 1991 9,000 Lagotreco
Venezuela 1990 9,000 Lagotreco
France 1987 8,700 Arab light
Switzerland 1985 4,600 Arab heavy

Customised solutions
At Shell Global Solutions, we believe that the most appropriate solution for a specific customer
will always be a customised one. We have, therefore, developed our own approach to technical
collaboration we call it co-creation in which our consultants and technologists work closely with our
customers to identify and evaluate the best options and solutions to meet their business objectives.

Leading-edge technology
Benchmarking studies have shown that the technology solutions that we deploy through a VDU revamp,
which include the Shell Schoepentoeter Plus device, can help customers to increase VGO recovery,
reliability, cycle length and yield.

7. KEY TAKEAWAYS
Refiners can unlock their downstream assets by increasing VDU capacity and reliability, while also
controlling contaminant levels to within the conversion units acceptability limits, by revamping the unit
using Shell deep-flash technology.
The four case studies described in this white paper demonstrate that these are highly customised
projects and can be driven by a wide range of business objectives.
Such projects can generate substantial value. For example, compared with a typical conventional unit,
an 8.9-Mt/y or 150,000-bbl/d unit that uses Shell deep-flash technology can improve a refinerys
margin by $7.8 million per year.
The capital cost is usually relatively low, the payback time is short, typically a year or less, and the
hardware changes are often possible within an existing refinery turnaround window.
VDU revamps can often be very challenging, so, if they are not engineered properly, it may be
impossible to meet the desired revamp objectives. Since 1985, Shell Global Solutions has delivered
almost 50 new designs or revamps and the organisation leverages that track record, as well as its
owneroperator experience, to help deliver successful, value-adding projects.
15
 ABOUT THE AUTHOR
Kaushik Majumder, Distillation Team Lead, Shell Projects & Technology, is responsible
for process design and engineering support for capital projects in crude and vacuum
distillation. He has over 32 years of experience in the refining industry in design, operation,
troubleshooting and research and development. Kaushik has a bachelors degree in chemical
engineering from Jadavpur University, Kolkata, India, and masters and doctorate degrees from
the Indian Institute of Technology Delhi.

ABOUT US
Shell Global Solutions provides technical consultancy and licensed technologies for Shell
and third-party customers within the energy industry. Shell Global Solutions strives to deliver
innovative technical solutions and effective technology to support its customers in their day-to-
day operations and delivery of strategic plans. This support enables customers to improve the
capacity and performance of existing units; integrate new process units into existing refineries
and petrochemical complexes; incorporate advanced proprietary catalyst systems (Criterion)
and reactor internals; and design grassroots refineries.

Shell Global Solutions is affiliated with Shells catalyst companies, which innovate and
sell catalysts through a network that includes Criterion Catalysts & Technologies, Zeolyst
International, CRI Catalyst Company and CRI Leuna (formerly known as Kataleuna).

For further information, please visit our website at [Link]/globalsolutions.

Shell Global Solutions is a network of independent technology companies in the Shell Group. In this material, the expressions Shell and Shell
Global Solutions are sometimes used for convenience where reference is made to these companies in general, or where no useful purpose is
served by identifying a particular company.

The information contained in this material is intended to be general in nature and must not be relied on as specific advice in connection with any
decisions you may make. Shell Global Solutions is not liable for any action you may take as a result of you relying on such material or for any
loss or damage suffered by you as a result of you taking this action. Furthermore, these materials do not in any way constitute an offer to provide
specific services. Some services may not be available in certain countries or political subdivisions thereof.

Copyright 2017 Shell Global Solutions International BV. All rights reserved. No part of this publication may be reproduced or transmitted in any
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in writing from Shell Global Solutions International BV.