DAURA LUBE 2013 CASE STUDY

HYDROTREATER UNIT REVAMP

PRODUCTION OF HIGH QUALITY Refining Development

BASE OILS BY USING CATALYTIC G. M. ADHAM, A. G. ABED and N. N. JASIM

DEWAXING TECHNOLOGY MRC / DAURA REFINERY

Studying the new technologies features and its advantages in

comparison with conventional technology
Market demand for lubricants is expected to maintain steady growth in the future. Together with this
increasing demand, there will continuous pressure on the refining companies to improve quality and reduce
costof their lubricants to increase their ability of competition in the markets. This is accomplished through
using of hydro-processing technology instead of conventional solvent technology.

The conventional solvent

technology of lubricants
manufacturing Figure 1, FIG.1 CONVENTIONAL SOLVENT TECHNOLOGY OF LUBRICANTS
consisting of treating neutrals
distillate and bright stock
from vacuum distillation unit LIGHT NEUTRAL

and de-asphalting unit ATM RESIDUE

respectivelyin solvent VAC.
UNIT MEDIUM NEUTRAL
SOLVENT SOLVENT DEWAXED BASE OILS
extraction unit to improve EXTRACTION UNIT DEWAXING UNIT
HYDRO-FINISHING
viscosity index then in solvent
HEAVY NEUTRAL
de-waxing unit to lowering
the pour points of lubricants,
finally treated with hydrogen RESIDUE
to improve color, thermal BRIGHT
stability and decreasing the DE-ASPH.
STOCK
harmful component content UNIT
(sulfur, nitrogen and oxygen
component).

The removal of wax from base oils through solvent de-waxing [SDW] is expensive from investment, operating
and maintenance view points, for that reason EXXONMOBIL research and development corporation developed a
new catalytic process, which has been proven in commercial operation, de-waxes high pour point lube raffinate
to low pour high quality lube base stocks named (MOBIL LUBE DEWAXING - MLDW).This process overcomes
several of the key limitation experienced with the [SDW] unit represented by reduced operating cost, greater
ease of operation, improve lube yields, permit the manufacturing of very low pourand cloud point oils,
eliminate the need for separate product finishing operationand reduce environmental pollutants.

The process uses a new proprietary catalyst system that can operate at mild operating conditions similar to
those in lube hydro-finishing unit. It involves pour point lowering through the selective cracking of normal and
slightly branched paraffin's [wax component] to higher hydrocarbons which are readilyremoved by standard

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distillation or stripping techniques. Typically, the operating conditions for MLDW range between 250 –
3000psig total pressure, 300 – 3500C reaction temperature and 500 – 5000SCFB of recycled gas.

The first commercial scale testing of MLDW was carried out in MOBIL GRAVENCHAN, FRANCE refinery in
1978 using an existing oil hydro-finishing unit. A complete range of product including circulating and industrial
hydraulic oils, diesel and passenger car engine oils, gear oils and transformer oil was formulated with the
various MLDW base stocks. The quality of these products, as measured by standard laboratory bench and
engine testes was compared with that of the same products blended with standard solvent de-waxed oils. In all
cases no differences in quality were observed. MLDW processes have been selected for application in many of
MOBIL as well as other refining companies around the world during the following years.

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PROCESS DISCRIPTION
The MLDW process is a fixed bed
reactor system operates under a
moderate hydrogenpressureand use a
proprietary catalysis one to effect
pour point reduction and the other
to impart oxidation stability to the
MLDW product. The de-waxing
catalyst is based on a new class of
synthetic shape selective zeolites with
channel openings of about 6A in
diameter. The size of this channel
plays an important rule in the
catalytic properties of the zeolite.
The general equipment requirements
for the MLDW unit are the same as
for many existing lube oil hydro-
finishing units Figure 2, the primary
difference is the need for adding de-
waxing reactor(s) and light
hydrocarbons separation system.

Since the high melting paraffin waxes

are n-paraffin and the melting point FIG.3 RELATIVE CRACKING RATES FOR PARAFFINS OVER MLDW CATALYST

decreases as the degree of the

branching of the paraffinic molecules
increasing, pour point reduction Pentane
C-C-C-C-C C-C-C-C
should ideally achieved by removing |
C
the paraffin'sselectively according to 0.23 0.01

their melting point. The catalyst has

C
just the desired selectivity to Hexane |
C-C-C-C-C-C C-C-C-C-C C-C-C-C-C C-C-C-C C-C-C-C
accomplish this. Figure 3 shown the | | | | |
C C C C C
relative cracking rates of various 0.71 0.38 0.22 0.09 0.09

paraffin structures over this catalyst.

C C
Molecules having a longer chain Heptanes | |
C-C-C-C-C-C-C C-C-C-C-C-C C-C-C-C-C-C C-C-C-C-C C-C-C-C-C C-C-C-C-C C-C-C-C-C C-C-C-C-C
length but having about the same | | | | | | | | |
C C C C C C C C C
critical dimensions crack faster; |
C
however as the degree of branching 1.0 0.52 0.38 0.09 0.17 0.05 0.06 0.08

increases, the cracking rate is

decreased substantially.

The excellent catalytic selectivity for de-waxing lead to higher de-waxed lube yield than that obtained by solvent
de-waxing. However, particularly with the light naturals, MLDW products have a lower viscosity index and a
higher viscosity when compared with the SDW product even though either lube properties, including
performance qualities are not adversely effected.

The feed to the MLDW can be any properly stripped raffinate from the practiced solvent extraction processes,
furfural, phenol, normal methyl pyrrolidone. Raw naphthenic distillate, soft waxes (foot soil, petrolatum

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filtrate), and de-asphalted residuum (non-extracted) can also be de-waxed into low pour point oils via MLDW.
The waxy charge is mixed with a hydrogen rich gas, preheated to reaction temperature and charged to the
MLDW reactor system. The de-waxed product is flashed to separate hydrogen – rich circulating gas.Excess
product gas is removed from the system and the remaining hydrocarbons which boil below the lube range are
removed by standard distillation or stripping.

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COMMERCIAL PLANT PRODUCT YIELDS AND PROPERTIES

The range of possible MLDW operating conditions TABLE 1 – Range of MLDW Operating Conditions
are shown in table 1. These have been demonstrated Reactor system Fixed bed
in the laboratory pilot plan for de-waxing a complete Type of feed Waxy raffinate, Raw
slate of commercially prepared lube base stock Naphthenic distillate
raffinates. The bulk of the work was done with MID Soft waxes
Deasphalted
EAST crude oil; however, other crude sources have Residuum
been investigated. Product yields and physical Expectable reactor pressure 250-3000 psig
properties obtained in the laboratory from MLDW of Hydrogen circulation 500-5000 SCF/B
three solvent – refined raffinate are shown in table 2. Hydrogen consumption 100-200 SCF/B
Catalyst selectivity is such that essentially no
methane and ethane are formed. Very little desulfurization to hydrogen sulfate takes place. The yield of light
hydrocarbons boiling below the lube faction are a function of the amount of wax that must be removed to
meet product pour point.

TABLE 2 – MLDW of Three Solvent Refined Paraffinic Raffinates (MID EAST CRUDE – ARIBIAN LIGHT)
150 SUS
Lube Viscosity Grade 60 SUS 500 SUS
Bright Stock
MLDW CHARGE PROPERTIES
Gravity, °API 36.8 29.2 25.3
Pour Point, °F 55 > 115 > 115
RCR, % wt --- --- 0.55
ASTM Distillation, °F D-86 D-1160 D-1160
10% vol 616 870 946
50% vol 650 908 ---
90% vol 682 950 ---
95% vol 690 960 ---
MLDW YIELDS, %wt
C2 & lighter 0.3 0.2 0.4
C3 2.4 1.6 1.2
C4 5.0 3.7 2.6
C5 4.7 3.3 2.2
Lt. Naphtha 11.1 6.8 4.0
Hvy. Naphtha 5.0 1.0 0.1
Lube Product 71.8 83.7 89.8
Total 100.3 100.3 100.3
H2 Consumption, SCF/B 130 135 105
LUBE PROPERTIES
Gravity, °API 33.7 27.8 24.5
Pour Point, °F -60 25 20
Flash Point (COC), °F 340 500 590
Viscosity, cs @ 40°C --- --- 454.2
Viscosity, SUS @ 100°F 61 513 2435
Viscosity Index --- 94 95

The first commercial scale testing of MLDW was carried out in MOBIL Gravenchon, FRANCE refinery in 1978
using an existing hydrogen treating unit. Unit alterations were made during a scheduled turn around and
involved mainly piping items to direct charge stock to the unit and product from the unit. Also, items were
added to permit processes measurements not normally obtained on the unit. The processes configuration was
similar to that shown in Figure 2 above except that steam stripper – vacuum dryer was used to remove that
light hydrocarbons from the lube instead of a distillation column.

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Commercially prepared waxy furfural raffinate from MID EAST-ARABIAN LIGHT crude was de-waxed during
the four week test. Six different quality raffinate were processed ranging from 150SUS @ 1000F neutral to
150SUS @ 2100F bright stock. Also, a 300SUS @ 1000F solvent de-waxed oil was processed to produce extremely
low pour point heavy oil at available operating conditions. Product pour points ranged from 20F to -50F.

Naphtha reformer off –gas was supplied to the unit with 68 – 75% vol. hydrogen purity. Periodic step changes
in hydrogen purity occurred when the reformer operation was changed. Simultaneous changes in MLDW
pressure were made to maintain a constant hydrogen partial pressure throughout the test. The unit was piped
to either cascade a once through flow of hydrogen rich gas to another hydro-treating unit or alternately to
recycle gas from the low temperature separator back to the furnace. Both options were used in the test.

A steam stripper and vacuum drier adequately remove the light hydrocarbons produced in the MLDW.
However, the process configuration did not permit collect on of the gasoline and gas oil fractions for quality
testing since they were recovered in combination with other refinery streams. Specification flash point lube
products were readily produced and large quantities of the oils were collected for quality evaluation.

Catalyst performance was excellent and as expected based on pilot plant work. Also, product yields table 3 and
quality was as anticipated from the earlier laboratory studies. De-waxed lube yields were higher than those
obtained inthe refinery solvent de-waxing units and its quality was equivalent to that obtained with SDW.

TABLE 3 – Commercial MLDW Yields and Lube Properties (MID EAST CRUDE – ARIBIAN LIGHT)
150 SUS
Lube Viscosity Grade 60 SUS 500 SUS
Bright Stock
MLDW CHARGE PROPERTIES
Gravity, °API 32.2 29.5 25.2
Pour Point, °F 95 15 > 130
RCR, % wt --- --- 0.68
ASTM Distillation, °F D-1160 D-1160 D-1160-1
10% vol 764 772 913
50% vol 792 818 1012
90% vol 825 902 ---
95% vol 835 921 ---
MLDW YIELDS, %wt
C2 & lighter 0.6 0.3 0.6
C3 2.7 5.8 1.3
C4 5.4 4.7 4.5
C5 4.0 2.3 2.6
Lt. Naphtha 7.0 3.4 3.5
Hvy. Naphtha 1.5 3.5 0.5
Lube Product 79.1 80.0 87.1
Total 100.3 100.2 100.1
H2 Consumption, SCF/B 150 100 50
LUBE PROPERTIES
Gravity, °API 29.3 27.5 24.7
Pour Point, °F 5 -50 15
Flash Point (COC), °F 430 435 600
Viscosity, cs @ 40°C 32.25 57.4 473.6
Viscosity, SUS @ 100°F 167 296 2543
Viscosity Index 94 --- 94

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PRODUCT YIELDS AND PROPERTIES

A slate of base stock ranging in viscosity from 60SUS @ 100 0F to 150SUS @ 2100F (transformer oil to bright
stock) and of the three quality levels produced as MOBIL oil refineries - turbine, premium and regular – were
tested in various MOBIL product lines. In all cases quality evaluations were run side – by – side on product
blended with the same additives packages and both MLDW and SDW base oils. Products were tested in the
laboratory bench and engine testes which have been determined to be must critical of the quality of a
particular product. In all cases, the qualities were found essentially equivalent.

Physical properties of base stocks de-waxed by Table 4 –Effect of MLDW on Base Stock Viscosity Index
both processes were equivalent with the exception Lube Viscosity VI
of VI and viscosity the VI of light naturals table 4 (SUS @ 100°F) (SDW-MLDW) a
were about 6 to 8 number; lower than those for 100-200 6-8
equivalent SDW stocks this difference in VI 300-500 4-6
decrease with increasing base stock viscosity and 600-800 3-5
2500 0
was ZERO with bright stocks (2400 – 2500SUS
a- In all cases SDW and MLDW stocks were essentially equivalent
@ 1000F). a 20 - 50SUS @ 1000F viscosity increase in quality
from the same raffinate was obtained with MLDW
of naturals compared to SDW. As with VI, the difference diminished as the stock de-waxed become more
viscous. In some instances, the increased viscosityof the MLDW product can be advantages. If necessary, the
boiling range of the distillate could be altered to compensate for the viscosity rise.

The product lines tested included engine oils, industrial turbine and circulating oils, gear oils, refrigerator of a
product line were tested to widen the number of base stocks used. tables 5 – 8 summarize the various product
lines evaluated and the results of many bench and engine testes run to establish quality.

In all cases, the results of testes which ranged from CATERPILLAR and FORD vs engine testes of diesel and
passenger car engine oils to laboratory oxidation and demulsibility tests of industrial and hydraulic oils showed
essentially equivalent quality. The refrigerator and transformer oils were evaluated against standards set by
their current naphthenic derived counterpart. The refrigerator oil was equivalent or better than the
naphthenic reference oil for Ammonia and Freon applications. The transformer oil evaluated extensively by USA
and EUROPEAN electrical builders and organizations. The oil surpassed also specifications except for some very
restrictive EUREPEAN oxidations testes.

Table 5 – MLDW Product Quality Evaluation in Engine Oils

Product SDW MLDW Specification
Marine Diesel Engine Oil A B C A B C
Caterpillar 1-G
Total Weighted Demerits 70 47 100 Type
Total Groove Fill, % 18 18 25 Max
Caterpillar 1-H
Total Weighted Demerits 14 53
Total Groove Fill, % 7 8 30 Max
Modified CFR Diesel
Piston Rating (100 = clean) 94 92 90 Min
Multi grade Passenger Car Engine Oil A A
Sludge 8.6 9.5 8.5 min
Varnish 8.2 8.8 8.0 min
Piston Skirt Varnish 8.0 8.3 7.9 min
Cold Cranking Simulator cp @ °F 2400 2400 2400 max

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Table 6A – MLDW Product Quality Evaluation in Industrial Oils

Industrial Hydraulic Oils Light Heavy Light Heavy
TOST, Hrs to 2.0 NN ASTM D-943 2500 2100 2200 2300
Mobile sludge, weeks free Mobile 3 2 2 2
Demulsibility ASTM D-1401
Minutes t0 3 ml 28 10 6 15
Foam, Tend/Stab ASTM D-892 15/0 0/0 10/0 5/0
TUV Air Release DIN 51381
Minutes to 0.2% Air 3.5 3.8

Table 6B – MLDW Product Quality Evaluation in Industrial Oils

Heavy Circulation Oils C C
TOST, Hrs to 2.0 NN 1100 1000
RBOT, Minutes to 25 psi Drop 120 115
Demulsibility
Minutes to Break 25 15
ml Free Water 37.5 38

Table 6C – MLDW Product Quality Evaluation in Industrial Oils

Circulation Oils Test Method SDW MLDW
Light Heavy Light Heavy
(Oxidation Tests) A A B A A B
TOST, Hrs to 2.0 NN ASTM D-943 4600 3650 --- 4500 4000 ---
TOST Sludge, 1000 Hrs ASTM D-943 0.04 0.06 --- 0.05 0.03 ---
RBOT, Minutes to 25 psi Drop ASTM D-2272 340 300 120 350 330 135
Demulsibility
Minutes to Break ASTM D-1401 20 28 4 29 25 5
ml Free Water ASTM D-2711 --- --- 38 --- --- 38

Table 7 – MLDW Product Quality Evaluation in Gear Oils

Product Test Method SDW MLDW
Light Heavy Light Heavy
Industrial Gear Oils
Demulsibility
Minutes to Break ASTM D-1401 25 39 18 45
ml Free Water ASTM D-2711 84 83 84 85
Foam, Tend/Stab ASTM D-892 5/0 0/0 10/0 10/0
Mobil Oxidation Test MOBIL Equiv. Equiv. Equiv. Equiv.
%Viscosity Increase
US steel Oxidation Test US Steel
%Viscosity Increase 3.8 5.8 3.6 5.8
Automotive Gear Oils
Broolfield Viscosity ASTM D-2983
cp @ -150F 150000 110000
cp @ +100F 105000 153000
Mobil Oxidation Test MOBIL Equiv. Equiv. Equiv. Equiv.
%Viscosity Increase

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Table 8A – MLDW Product Quality Evaluation in Refrigerator Oils

Test Method Naphthenic Reference MLDW
Mobil Oxidation Test MOBIL
Evaporation loss, % 2 0.8
Viscosity Increase, % 13.4 5.7
Freon Miscibility MOBIL
R12 FLOC point, 0C -41 -72
Freon Compatibility DIN 51593
72 Hrs Border Line Pass
Froilabo Rig Compressor
R12 First Stage Pass Pass

Table 8B – MLDW Product Quality Evaluation Transformer Oils

Test Method NEMA Specification MLDW
Pour point, 0F ASTM 97 -40, max. -60
Dielectric Strength, KV
D-887 30, min 42
D-1816 @ 1mm GAP 28, min 30
Impulse Strength ASTM 3300
@ 1" GAP, KV 145, min 184
Power Factor, % ASTM 924
@ 250C 0.05, max 0.002
@ 1000C 0.3, max 0.044
Oxidation Stability ASTM 2440-1
(164 Hrs:Sludge/N.N.)
Uninhibited 0.1/0.42
+0.08% wt DBPC 0.3/0.6, max
+0.3% wt DBPC 0.2/0.4, max 0.026/0.33

These results demonstrate that product lines covering that entire range of viscosity levels and the entire
spectrum of application can be blended with stocks de-waxed by MOBIL'S MLDW processes and be of
equivalent quality to products blended with stocks prepared by standard de-waxing processes. Evaluation of
stock processed to very low pour point by MLDW shows that they can be used for most applications now filled
by inherently low pour point naphthenic stock.

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MLDW APPLICATIONS
GRASS ROOTS
The MLDW process can be used to de-wax a full
range of lube base stocks for automotive, marine
and industrial applications. Therefore, it can be
used as a complete replacement for solvent de-
waxing. Of course, this eliminates the production
of waxes. A typical flow scheme for a grass roots
installation as shown in Figure 4. Significant
economic advantages occur for using MLDW
over SDW in a grass roots situation. Hydrogen
availability and available utilities can significantly
effect the comparison:

 Investment costs are about 50% lower for

the MLDW application, if sufficient hydrogen
is available. About 20% investment savings is
still realized, even if hydrogen production
facilities must be added.
 MLDW operating costs are about 75% lower than those for SDW operations. Inclusion of an ancillary
hydrogen plant with MLDW will still result in significant reduction in operating of about 40% over SDW.
 Lube oil base stock yield with MLDW will be suffer to 115% vol. higher than those obtained with SDW. The
yield advantage for MLDW various depending on stock type being processed. The higher values are
obtained on the residual stocks which are difficult to de-wax and remove the oil adequately with SDW.
 The MLDW process will permit manufacture of very low pour point specialty oils from waxy crude,
whereas this would not be partial with SDW.

REPLACE EXISTING SOLVENT DEWAXING

MLDW can also be used to debottleneck existing
solvent de-waxing facilities by:
 Combining SDW/MLDW on all stocks.
 Processing the slowest filtering stocks on
MLDW and reminder on SDW.

The processing scheme in Figure 5 allows

continued production of saleable waxes while
permitting increased lube base stock production.
In this operation SDW temperature is rise to a
level that just permit this recovery of all sealable
wax in the primary filter wax cake. The resulting
higher than specification pour point SDW oil in
readily decreased to the required level by the
MLDW foot soil from the de-oiling step is mixed
with MLDW charge to recover additional lube
base stock that is typically rejected to catalytic
cracker feed or fuel oil. This scheme could

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provide a minimum investment debottleneck depending on the condition of the existing SDW lube base stock
capacity is increased through faster SDW filter rates and conversion of foot soil to lube base stock. In addition,
SDW costs are reduced due to a) lower refrigeration requirement, b) fewer ice problems and c) lower wax de-
oiling requirements.

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CASE STUDY
DAURA refinery have three de-waxing unit (one propane de-waxing plus two MEK de-waxing units) these units
are very costly from operational, maintenance viewpoints, economically the operational and maintenance cost of
the de-waxing units represent about 40 – 45% of the total production cost, which mean costly products and
less profit that cause difficulty to competition in the local and global markets…!

The question is how can DAURA refinery achieve its goals represented by increase its production capacity,
improve product quality with minimum return of investment and maximum profit…?THAT IS DAURA
CHALLENGE, DAURA refinery and EXXONMOBIL with JGC and JX-NIPPON partnership start to study applying
the MLDW technology in DAURA lubricants manufacturing to overcome DAURA challenge.

The study focused on three subjects:

 Products yields and properties[derivative from KIRKUK crude] table 9A.
 The ability of converting DAURA lube oil hydro-finishing unit No.3 to MLDW facilities by maximum using
of the existing equipment [The existing lube hydro-finishing unit designed to process 1650 - 1800 BPSD
[according to feed stock kind] derived from KIRKUK crude].
 The economical viewpoints.

TABLE 9A - MLDW PILOT PLANT PROGRAM FOR MRCTYPICAL PILOT PLANT OPERATING CONDITIONS AND YIELD
60HVI raffinate 150HVI raffinate
Heavy nuteral Bright stock
Hydrodewaxer LHSV, vol/hr/vol 0.42 0.52
Hydrotreator LHSV, vol/hr/vol 0.84 1.04
H2 circulation, SCF/B (at HDW reactor inlet) 2950 2390
H2 partial pressure, psig (at HDW reactor inlet) 400 390
Hydrodewaxing temperature, 0F 647 654
Hydrotreating temperature, 0F 516 550
H2 consumption, SCF/B 198 416
0
Pour point, F 20 15
Lube cut point, 0F 570 750
Yield, charge% wt vol Wt Vol
H2 -0.32 -0.7
C1 0.02 0.08
C2 0.35 0.28
C3 3.34 3.88
Total C1 – C3 3.71 4.24
i-C4 3.24 5.01 2.72 4.32
C4= 0 0 0.07 0.1
n-C4 0.98 4.43 2.56 3.93
Total C4s 6.22 9.44 5.35 8.35
i-C5 2.96 4.13 1.96 2.81
C5= 0.02 0.03 0.48 0.65
n-C5 2.03 2.8 0.35 0.49
Total C5s 5.01 7.06 2.79 3.95
Naphtha, 125 - 3300F 6.96 8.06 3.85 4.66
Distillate, 3300F - lube 2.17 2.23 1.74 1.81
Lube 76.25 74.8 82.73 81.69
Total 100 101.59 100 100.46

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According to the study results:

 Physical properties of base stocks de-waxed by both processes were equivalent Table 9B, with the exception
of VI and viscosity, the VI of light neutral were about 6 number; lower than those for equivalent SDW
stocks this difference in VI decrease with increasing base stock viscosity and was 1 degree with bright
stocks. On the other hand the product yields in all feed stock cases were found higher with MLDW case
compared with SDW case.

Table 9B – Comparison of MLDW and SDW Base Stock Physical Properties and Composition
Base Stock Light Neutral Heavy Neutral Bright Stock
De-waxing Process MLDW SDW Raff. MLDW SDW Raff. MLDW SDW Raff.
Yield vol% 77 78 80 76 83 74
Visc., C.St. @ 400C 41.05 38.2 30.34 128.8 121.9 94.29 473.6 514.7 340.7
Visc., C.St. @ 1000C 6.18 6.03 5.43 12.78 12.66 10.99 30.57 32.81 28.37
Viscosity Index 95 101 115 92 95 101 95 96 113
Pour Point, 0C -12 -12 38 -12 -12 >46 -9 -9 >130
Gravity, API 29 29.2 31.1 26.4 26.7 28.2 24.7 24 25.2
Paraffins, wt% 19.4 24.5 37.9 14.1 218.3 --- 12.7 14.6 17.5
Naphthenes, wt% 46.9 42 34.7 43.3 39.1 --- 40 35.7 32.2
Aromatics, wt% 33.7 33.5 27.4 42.7 42.5 --- 47.3 49.7 50.3

 Lubricants products formulated with MLDW oils [by using same package and quantity of additives that
used with SDW lubricants case] exhibit superior viscometric lubrication performance at low temperatures
and equivalent performance at high temperatures to SDW oils, tables 10 – 12.

Table 10 – Low Temperature Pump ability Test of MLDW and SDW Hydraulic Oils

Transmission Fluids Gear Oil

Grade #1 Grade #2 SAE 80W-90
MLDW SDW MLDW SDW MLDW SDW
Kinematic Visc., C.St
@ 1000C 7.76 7.66 7.15 7.09 13.9 13.9
@ 400C 39.16 37.59 37.66 36.27 134 131
@ 00C 351 320 351 312 --- ---
Viscosity Index 173 179 156 162 100 103
Pour Point, 0F <-65 -40 <-65 -45 -20 -10
Brookfiled Viscosity, poise
00F 14.4 13 --- --- --- ---
-100F --- --- 24.6 22.2 --- ---
-150F --- --- --- --- 1160 1270
-400F 262 498 372 372 --- ---

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Table 11 – Low Temperature Viscosity Results: Transmission Fluids and Gear

MLDW SDW
Kinematic Visc., C.St
@ 1000C 12.24 12.22
@ 400C 87.41 87.41
@ 00C 1186 1203
Viscosity Index 135 134
Pour Point, 0C -40 -40
Hydraulic Pump Test Start –Up Time, minutes
400F 0.55 0.58
300F 0.95 0.85
200F 0.83 0.85
0
10 F 1.4 1.52
00F 1.85 Did not start in 2 minutes

Table 12 – Low Temperature Viscosity Results : Automotive and Commercial Engine Oils
SAE 10W SAE 30W SAE 15W-40 SAE 10W-30
MLDW SDW MLDW SDW MLDW SDW MLDW SDW
Kinematic Visc., C.St
@ 1000C 4.9 5.26 11.39 11.47 14.07 13.98 10.36 10.48
@ 400C 26.14 28.72 99.38 99.42 98.94 97.39 69.55 69.09
@ 00C 246 270 1729 1642 1255 1146 835 809
Viscosity Index 111 116 101 102 145 146 135 139
Pour Point, 0C -40 -25 -35 0 -40 -40 -35 -20
Dynamic Visc., poise
CCS
-100C --- --- 43 44 --- --- --- ---
-150C --- --- 80 89 25 26 --- ---
-200C 12 16 --- --- 48 50 34 36
-250C 23 32 --- --- 94 106 68 72
-300C 43 68 --- --- --- --- --- ---
MRV
-100C --- --- 43/44 51/52 --- --- --- ---
-150C --- --- 77 104 --- --- --- ---
-200C --- --- --- --- 69 77 --- ---
-250C 22 41 308 961 136 183 83 108
-300C 38 105 --- --- 381 604 190 305
-350C 80 324 --- --- --- --- 454 1029

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DAURA LUBE 2013 CASE STUDY
HYDROTREATER UNIT REVAMP

 There is an ability to converting the exiting oil hydro-finishing unit No.3 to MLDW technology to process
a nominal 1730 - 1800BPSD of two KIRKUK derived raffinate (SAE-30 and bright stock) to produce lube
base stock meeting specification pour points by adding two reactor vessels [de-waxing reactors] installed in
series with the existing reactor [hydro-finishing reactor]. Additional modifications include a adding new
light hydrocarbon recovery system plus some modification on the controlling system and heat exchanger
system Figure 6 below.

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DAURA LUBE 2013 CASE STUDY
HYDROTREATER UNIT REVAMP

 According to table 13 below the utilities consumption per barrel of feed stock for MLDW much less than
the utilities consumption in SDW which means decreasing in operational cost table 14, as well as less
environmental pollutant.

TABLE 13 – MEK vs MLDW UTILITY CONSUMPTION PER BARREL BASE STOCK

MEK MLDW
Fuel (1000 Btu) 847 91
Power (KW) 5.2 3.7
Cooling Water (gal) 12.4 7.5
Solvents (gal) 0.15
Hydrogen (SCF) 250
Catalyst (Lbs) 0.04
HDT Catalyst (Lbs) 0.02
Men/Shift 3 1

 The expected operational cost of MLDW unit constituting 45% when compared with SDW cost table 14,
this means lowering the products cost by 65%.
TABLE 14 – MLDW vs MEK COST (As % of MEK)
MEK MLDW
Capital 100 60
Utilities 87 13
Catalysts/Chemicals 7 30
Other 6 2
Total 100 45

 The estimated total installed cost of the required revamp facilities is about 22 Millions US dollars while the
estimated cost to install new MLDW facilities is around 31 Million US dollars [this includes hydrogen cost].

DAURA feasibility study as below; show that the [IRR] for the project will not exceed 16month.

OPTION #1
NEW MLDW FACILTIES 31 MMUS$
Completion period 2 – 3 Years
Unit feed 41.21 MMUS$/Y
Utilities consumption 1.713 MMUS$/Y
Other cost (8% of the project cost) 2.48 MMUS$/Y
Products value 61.5 MMUS$/Y
IRR 23 MONTHS (1.92 YEAR)

OPTION#2
REVAMP THE EXISTING OHU 22 MMUS$
Completion period 9 – 11 Months
Unit feed 41.21 MMUS$/Y
Utilities consumption 1.713 MMUS$/Y
Other cost (8% of the project cost) 1.76 MMUS$/Y
Products value 61.5 MMUS$/Y
IRR 16 MONTHS (1.34 YEAR)

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DAURA LUBE 2013 CASE STUDY
HYDROTREATER UNIT REVAMP

According to the above results theoption #2 has the advantages on option #1 from the rate of investment and
project completion period.

DAURA refinery have two bottleneck with this technology represented by eliminate the wax production and
decreasing the yield and VI in light stock…? but according to the fact that DAURA refinery have three de-
waxing unitwhich gives the refinery high flexibility to use the MLDW technology.

DAURA technical team study shows that the better ways to adopted the MLDW technology is by combination
MLDW process application [grass root and replacing the existing SDW] by shutdown one of its de-waxing units
and replace it with the MLDW unit to process bright stock [slowest filtration rate stock] and heavy neutral
plus the light neutral wax free oil from the remaining SDW units for transformer, refrigeration and special
lubricants applications , while the two de-waxing unit will process the light neutral and the extra capacity of
heavy neutrals.

CONCLUSION
The MLDW process is unique in that it can dewax full slate of lube raffinate into finished low pour base stocks
and has many advantages over solvent de-waxing.Conventional solvent de-waxing (SDW) is used typically to
reduce the pour point of waxy raffinate to specification finished lube levels. Solvent de-waxing is expensive
from investment, operating and maintenance viewpoints. In addition, efforts to minimize the amount of oil
which is in entrained with the wax adds to the complexity and cost of SDW. Furthermore, the solvent de-
waxing processes have practical limitations as to the degree of pour point reduction possible. For example, it is
not practical to solvent de-wax waxy raffinate from paraffinic crude to very low pour points (-400F to -600F)
required for transformer and refrigeration service. Solvent de-waxing must be followed by a finishing step in
some applications to insure final product quality. Typically a separate clay percolation or a hydrogen treatment
step is required which in solves expensive intermediate product storage.

The MLDW offers the following advantages over solvent de-waxing:

 Lower capital investment – half that of solvent de-waxing.
 Reduce operating costs – dramatically lower utility costs.
 Greater ease of operation.
 Safer operation – no volatile, toxic organic solvents.
 Improved lube yield – boosted yield in especially in heavy stocks.
 Permit the manufacture of very low pour and cloud point oils from paraffinic stocks – better cold
cranking in base oils.
 Eliminate the need for a separate product finishing operation.
 Highly flexible process.

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DAURA LUBE 2013 CASE STUDY
HYDROTREATER UNIT REVAMP

REFIRNSIES
1. Smith, K. W., W.C. starr and N.Y. Chen " Anew process for de-waxing lube base stocks, Mobil lube de-
waxing, "American Petroleum Institute 45th Midyear Refining Meeting, May 1980.
2. Graven, R. G., and J.R. Green, "Hydrodewaxing of fuels and lubricants using ZSM-5 type catalyst,"
Australian Institute of petroleum congress, September 1980.
3. F.A. smith "CATALYST DE-WAXING, POUR POINT, VISCOSITY AND VI RELATIONSHIPS", "7th
national scientific-technical conference with international participation on lubricants and bitumen
Pleven, BULGARIA, May 1990.
4. MOBIL RESEARCH AND DEVELOPMENT CORPORATION REPORT "MLDW pilot plant work on
DAURA refinery stocks" 1984, 1989 and 1990.

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