1. Small modular catalytic units for production of high-octane unblended gasolines through the process of Zeoforming
The process of Zeoforming, an effective method for production of high-octane unblended gasolines (Based on the results of industrial operation of a Zeoforming-40 installation)
Zeoforming is a technology for catalytic conversion of low-octane gasoline fractions (straight-run gasoline fractions of oils and gas condensates) into high-octane unblended gasolines proved at pilot to industrial levels.
Zeoforming has been adjusted:
Pilot level:
At the Urengoy Gas Condensate Processing Plant, Nizhnevartovsk Gas Processing Plant, Luginetskoe Oil Field (Tomsk Region), Volgograd Refinery, Orenburg Gas Processing Plant.

2. Demonstrational level:
A 5,000-ton/year Zeoforming installation for unblended gasoline production from stable gas gasoline has been in operation at Nizhnevartovsk Gas Processing Plant since September 1992.
Industrial level:
An industrial Zeoforming installation of 40,000 ton/year capacity with respect to straight-run gasoline fraction (“Zeoforming-40”) began to operate in Poland in February, Lurgi Company (Germany) was the general contractor and designer. The commercial products of the installation are unblended Eurosuper-95 gasoline and liquefied gas. All the guarantee parameters presented by "Zeosit" are fully met: the octane number of the gasoline is 95 RON and total yield of both commercial products not less than 92-95%. During the start-and-adjustment works, new additional possibilities of the process and the catalyst were tested which may allow a still higher efficiency in future installations (i.e., an increased yield of the commercial products, octane number of the gasoline, and catalyst lifetime) without making the investments or running costs higher.

3. Process parameters: Advantages:
Temperature, оC
Pressure, MPa
WHSV of the feedstock, ton/ton of cat. per hour
Advantages:
In contrast to Reforming, the process of Zeoforming does not require:
► a hydrofining stage to remove sulphur and nitrogen-containing compounds from the raw material
► either hydrogen or any related compressor equipment
► expensive catalysts based on noble metals ,
which decreases the capital and running costs.
The catalysts are based on an environment-friendly system.
The installations can operate autonomously.

4. Being autonomous, these mini-plants are useful in remote regions or regions difficult of access where oil, gas condensate, or other hydrocarbon raw material are produced. They are expedient in meeting the demand in motor fuels of the local population as well as geologists and oilmen.
Depending on the type of the raw material and the chosen production mode, RON-80 or RON gasolines can be produced at one and the same installation.
The gasoline yields are: when RON-80 gasoline is produced – 80-92%, when RON gasoline is produced – 65-85%.

5. Expenditure rates of the main and auxiliary materials№
Units, Apparatus, Production Stages
Materials,
Measure units
Approximate expenditure rate per 1 ton of the feedstock 1
Reactors
Catalyst, kg/ton 2
Regeneration and purging
Nitrogen, nm3/ton
~ 3 3
Catalyst regeneration
Air, nm3/ton
~ 18 4
Cooling down the technological flows
Recycled cooling water (t=25°C), ton/ton
0-12* 5
Providing for the rectification process
Water vapour, ton/ton
0-0.15* 6
Furnace section
Fuel gas, nm3/ton
15-25* 7
Pumps, compressors, fans ABO
Electric power, KWt·hour/ton
15-25**
* - depends on the chosen process flow-sheet
** - depends on the chosen process flow-sheet and the capacities of the chosen electrical receivers

6. Diagram of conversion of oil fractions or gas condensate into motor fuels through different processes:
Diagram 1. Conventional scheme (Reforming and isomerisation)
Gasoline fraction
26%
iso-paraffins
8.5%
Gasoline fraction 35%
Hydrogen-containing gas
High-octane component 22%
C5-C6 9%
Fuel oil 30%
Diesel fuel 35%
Feedstock
Blending unit
Fractioning installation
Hydrofining installation
Reforming installation
Unit of gas desulphurisation
Hydro-isomerisation installation H2

7. Fractioning installation Zeoforming installation
Diagram 2. Zeoforming technology
(Verkh-Tarskoe oil is taken as an example)
High-octane gasoline
25-28%
Fractioning installation
Zeoforming installation
Fuel gas 1%
Feed-stock
Gasoline fraction 35%
Diesel fuel 35%
Liquefied gas
6-9%
Fuel oil 30%
Fuel oil 30%

8. (the data concern the production of gasolines of 92 to 95 RON)
Dynamics of costs and profits depending on the capacity of a Zeoforming installation
(the data concern the production of gasolines of 92 to 95 RON)
Starting the installation

9. Comparative analysis of the net present value (NPV) for the installations of high-octane gasoline production via Zeoforming and Reforming

10. Range of the benzene content in Zeoforming gasolines (1) and Reforming gasolines (2) depending on the octane number of the gasoline 70 75 80 85 90 2 4 6 8 10 12
Reforming gasolines
Zeoforming gasolines
Benzene content, %wt.
MON of the gasoline 1

11. Range of the aromatic content in Zeoforming gasolines (1) and Reforming gasolines (2) depending on the octane number of the gasoline 80 70
Reforming gasolines 60 2 50 1
Aromatic content, %wt. 40
Zeoforming gasolines 30 20 10 65 70 75 80 85 90
MON of the gasoline

12. Zeoforming vs. Reforming: key parameters
Additionally required for Reforming
The reaction temperature, оC
Pressure, atm.
5-15
3-35
Hydrogen equipment
Is not required
Is required
Raw material hydrofining
Desulphurisation Unit
Raw material
Hydrocarbon fractions C5 –240оC; olefin-containing gases; oxygen-containing compounds
Hydrocarbon fractions C6 –180оC (naphthenes)
Catalyst
Contains no noble metals; ecologically safe
Contains Pt, Pd; may contain other heavy metals
Final product
High-octane gasoline ready for use, with benzene content 1-3% vol. The second desired product is liquefied gas The second desired product is liquefied gas, a fuel both for domestic purposes and for automobiles
High-octane aromatic component of gasoline which needs blending, with benzene content 5-15% vol.
Blending Unit

13. Zeoforming vs. Reforming: key parameters
Continuation
Parameter
Zeoforming
Reforming
Additionally required for Reforming
Gasoline yield :
Motor gasoline :
Depend on blending conditions
Blending Unit
RON-80
RON-92
«Euro-super-95»
- for fraction оС
80-90%
65-75%
60-67%
- for fraction оС
85-92%
70-85%
Permissible sulphur content in the raw material
is not limited
less than % wt.
Desulphurisation Unit
Sulphur content in the gasoline produced
depends on the sulphur content in the raw material but does not exceed 0.05% wt.
no more than % wt.
Catalyst lifetime
proved to be at least hours at the industrial installation Zeoforming-40 in Poland
Costs of the catalyst: Zeoforming – $ /ton; Reforming – $ /ton
Economic characteristics
For capacities thousand tons/ year, the investments are repaid in less than 1.5 – 2.5 years
Is profitable for capacities above thousand tons/year