REFINING

UOP Uniflex™ MC™

Residue Hydrocracking Process
Robust, cost-effective solution for residue conversion
Introduction
The Uniflex MC process converts vacuum residue and other heavy
feedstocks into higher-valued distillable products. This high conversion
slurry hydrocracking technology combines elements of several commercial
technologies: CANMET TM Hydrocracking process, UOP UnicrackingTM
process, UOP UnionfiningTM process, and employs highactivity
molybdenum based MicroCatTM catalyst. The catalyst is produced on site F E AT U R E S & B E N E F I T S
from readily available commodity chemicals. Uniflex MC is easily integrated
into existing refinery configurations, providing refiners the ability to High Reliability Design
increase bottom-of -the -barrel conversion, reduce residual fuel oil • Based on a proven reactor system based on
production and increase production of light fuels. The product streams are a commercial unit that demonstrated over 15
also suitable as high value petrochemical complex feedstock.: years operation.
• Supported by 30 years of extensive research,
Technology Delivery pilot plant operations, and development.
Uniflex MC is delivered as two separate technology packages; the Uniflex
• UOP’s expertise in high-pressure
Process and the MC Catalyst System. Both are delivered through UOP's
hydroprocessing which is reflected in the design,
"Schedule A" Basic Engineering design package. The MC Catalyst System
technical services, and project optimization
can also be supplied as part of an engineered, modular supply from UOP’s
capabilities associated with Uniflex Technology.
Modular Equipment Group to reduce on-site construction and facilitate
Ease of Operation
enhanced process automation and advanced control.
Generates the Highest Product Value
Process Chemistry Uniflex has the highest total yield of valued
The Uniflex Process unit is a thermal cracking / hydrogenation process. products with 95-98% conversion of a wide range
Residue molecules are thermally cracked by application of heat at high of low-value residue feedstocks. Selectivity to
pressure and with sufficient residence time. The cracked molecules react distillate products is the hallmark of Uniflex, with
with hydrogen in the presence of catalyst to produce stable, lighter production of LPG, Naphtha, and Diesel as fuels
products predominantly in the transportation fuel range. As a side reaction, or petrochemical feedstock.
free radicals produced as a result of thermal cracking can react to form
High Product Quality as Products or Feedstocks
even larger free radicals which form a “mesophase” of condensed materials.
The catalyst inhibits this reaction by terminating the free radicals. A second The integrated Uniflex/DHT process produces
function of the catalyst is to prevent any mesophase formed from reformer grade Naphtha, Euro V Diesel and sweet,
coalescing and forming larger molecules. The relationship between olefin-free LPG. The LPG and Light Naphtha are
operating temperature, reactor size and catalyst addition rate can be excellent Steam Cracker feeds with high normal
optimized to a refiner's particular processing and economic situation. paraffin content. LVGO can be processed in an
FCC or Hydrocracking unit, with or without,
Process Description pretreatment in the Uniflex unit.
The configuration of the Uniflex process is very similar to that of a Integration with Other Units
conventional hydrocracking process, consisting of a reaction section, Due to the number of products produced by any
a separation section to recover liquid and gaseous reaction products, and slurry hydrocracking technology, integration with
a fractionation section to separate its product into the various boiling- range the existing or new complex is critical to extract
fractions required by a refiner. full value from the technology. UOP is uniquely
Feedstock, combined with catalyst, and hydrogen-rich recycle gas are positioned to optimize a total project with a broad
heated and then introduced to the bottom of the first upflow reactor at understanding of refining and petrochemical
operating temperature. configurations.
The reactor’s unique design promotes intensive back-mixing of catalyst Product Yields
and reactants without reactor internals. The resulting near-isothermal The yield structures produced when processing
conditions allow the reactor to operate stably at the higher severity Vacuum Residue from a typical sour crude in a
required to achieve maximum residue conversion, while minimizing Uniflex process unit are illustrated in the figure
undesirable secondary cracking reactions that produce lower-valued shown below. The advantages of the yields versus
gaseous byproducts. other technologies include:
The first reactor’s liquid effluent is routed to the bottom of the second • Ability to be highly selective to Naphtha and Diesel
reactor. The second reactor effluent and vapor from the first reactor flow
to the unit’s separation section where liquid and vapor fractions are • Flexibility to shift to heavier products if desired
recovered. Vapors are scrubbed, combined with makeup hydrogen and • Total liquid yields up to 115 vol%
recycled back to the reaction section. Liquid from the separator section
These advantages provide refiners the ability
flows to the unit’s fractionation section for product recovery. A portion of
to more-closely tailor their operations to satisfy
the unconverted residue (pitch) is recycled to the second reactor. The rest
projected declining residual fuel oil markets and
of the unconverted residue can be used as a low-cost substitution fuel for
increasing fuel and petrochemical feedstock
conventional heavy liquid residue or coker feed, or used as a solid fuel for
demands.
end users such as fluidized boilers and gasifiers. Optionally the pitch can
be sent to a Solids Recovery section to produce additional liquid products Uniflex Process Typical Yields
and a solids stream, which can be sent for metals recovery. Uniflex Product
Reactor Fractionator
Uniflex MC Process Configuration
Fuel Gas, LPG (9-12 Wt%)
Recycle H2
Gasoline (15-18 Wt%)
Makeup C4-
H2 Flash Gas Diesel (49-54 Wt%)

Uniflex Vacuum Gas Oil (13-22-Wt%)

Reactors Naphtha
Vacuum
Diesel Residue Pitch (2-5 Wt%)
(100 Wt%)
Diesel
Fractionator
LVGO MicroCat Catalyst
Vac
The high-activity catalyst (MicroCat) used in the
Feed Uniflex process is generated on-site in the MC
MC Catalyst Section. The refiner will produce the
Catalyst Solids
Section Recovery MicroCat from commodity raw materials readily
HVGO available in bulk quantities on the open market.
This section contains simple process operations
to produce consistent, high quality catalyst.
Additional Processing Options
On site quality assurance testing is part of the
• Integrated Distillate Hydrotreating: With the addition of six pieces technology package.
of equipment fuels products can be treated to produce sweet LPG,
reformer grade Naphtha and Euro V quality Diesel. This is at a cost of Additional Opportunities
about 50% of a new stand-alone DHT unit. Refiners can also benefit from the synergies which
• Enhanced LPG Recovery: Where LPG has a higher value than fuel gas, arise when the Uniflex MC process is used in
recovery of this product can be increased to 99% at an effective capital association with other Refining and Petrochemical
cost and low utility consumption. processes. The Uniflex MC process unit can be used
to upgrade/ convert marginal-quality refinery
• Side-Car VGO Hydrotreating: VGO quality can be cost effectively
streams such as FCC slurry oils and heavy coker gas
improved with the addition of a small HT reactor on the product stream.
oils. For refiners with existing delayed coking units
who are considering increasing refinery throughput,
the addition of a Uniflex process can debottleneck
the delayed coking unit and provide a significant
increase in the refinery’s overall liquid product yield.

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The information in this document
should not be construed as a
UOP LLC, A Honeywell Company representation for which UOP assumes
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or recommendation to practice a
Des Plaines, IL 60017-5017, U.S.A. patented invention without a license.
www.uop.com UOP4523-78 May 2018