ExxonMobil is the leading provider of advanced lubes manufacturing technologies for the 21st century that meet and exceed customer expectations for quality and profitability.

MSDW™ / MAXSAT™ / MWI™ catalysts

MSDW™ / MAXSAT™ / MWI™

The turn of the century marked a remarkable turning point in the lubes basestock manufacturing industry — no significant API Group I capacity has been added worldwide since then. In fact, Group I capacity has been steadily shut in. Conversely, Group II and Group III manufacturing capacity has been added, satisfying a slowly but steadily growing capacity demand now approaching 800 kBd. In both North America and Europe, the number of plants producing lube basestocks is now about a third of what it was in the early ’70s, but the average size of the plants increased by threefold.

Two key reasons may be attributed to this evolution. The first is the increase in overall basestock quality spurred by the automotive and transportation industry in its quest for higher fuel economy and lower overall emissions. The second is the emergence since the mid ’90s of more advanced hydroprocessing routes to the production of lubricant basestocks, especially for engine oil lubrication applications.

Proven performance - fantastic possibilities

Our advanced hydroprocessing technologies provide today’s base stock manufacturers with maximum value through exceptional process performance for yield, run length and durability and outstanding product qualities.

Blocked/broad-cut operationA typical configuration of a modern, all-catalytic plant is depicted in Figure 2. The Hydrocracker and the MSDW™/MAXSAT™ unit are operated in three modes, or “blocks”: a Light, a Heavy, and a DAO/ Bright Stock block. Each block produces one main basestock product and may produce one or more additional lube products depending on the specific

configuration. This scheme is typical of a lubes hydrocracker, where the hydrocracker operation is adjusted primarily to maximize lube production. There are also “hybrid” schemes, for example, where the hydrocracker is operated on a wide VGO cut feed, primarily for fuels production, with the MSDW unit operated either on a wide-cut UCO (UnConverted Oil) or fractionated UCO cuts.

Gasoline& Diesel

HC Bottoms

Solvent Extraction

RHC™ Unit

MLDW™ Unit Hydrofinishing

Solvent Dewaxing Hydrofinishing

Solvent Dewaxing Hydrofinishing

MSDW™ Unit MAXSAT™ Unit

Vacuum Distillation Solvent Dewax

MSDW™ Unit MAXSAT™ Unit

MWI™ Unit MAXSAT™ UnitHydrocracking

Hydrocracking

Group I

Dis

tilla

te/D

AO

Dis

tilla

te/D

AO

Slac

k W

axFT

Wax

Group I

Group II

Group II / III

Group II / III

Group II / III+

Group II

Group 1 Group 2 Group 3 Group 4

80 < VI < 120% sat < 90%% S > 0.03

80 < VI < 120% sat > 90%% S < 0.03

VI > 120% sat > 90%% S < 0.03

1 and 2-R AromaticsNaphthenes

Polar Compoundslso-paraffinsn-paraffins

Naphtheneslso-paraffinsn-paraffins

lso-paraffinsSingle

Component

Group 5

Very wideChemical Spectrum

PAOsPIOs

SYNTHETICEsters

Figure 1: API base oil classification reflects chemical composition

Figure 2: Typical configuration of a all-catalytic plant

However, the technology flexibility is such that a refiner can choose to operate the entire train by processing one single, wider-cut feed. This is commonly referred to as “broad cut” operation, where all the desired lube basestocks are

fractionated at the very end of the process. Each of the two configurations has advantages and disadvantages, as summarized in the tables below:

PROS CONS

Requires stock switching;more complex operation

Blocked pro: Lube product slate based on market demand.

Blocked con: Higher investment cost.

All products made tochosen specification

Intermediate tankage neededHigher overall lube recovery

Control VDU cuts upstreamto make product viscositySmaller process vessel sizes

PROS CONS

Limited grade fixes opsand sets plant sizeSingle feed; simple ops

Much lower total luberecovery with VI giveawayNo stock switching

Larger process vesselsNo intermediate tankage

PROS CONS

Requires stock switching;more complex operation

Blocked pro: Lube product slate based on market demand.

Blocked con: Higher investment cost.

All products made tochosen specification

Intermediate tankage neededHigher overall lube recovery

Control VDU cuts upstreamto make product viscositySmaller process vessel sizes

PROS CONS

Limited grade fixes opsand sets plant sizeSingle feed; simple ops

Much lower total luberecovery with VI giveawayNo stock switching

Larger process vesselsNo intermediate tankage

EMRE HYDROFINING™

Process (wax and lube)

UOP Lomax

Hydrocracking Process

UOP Isomax ProcessUOP HDC Unibon™ Process

(hydrotreating and hydrocracking)

UOP HC Unibon™

Process (hydrocracking)

UOP Unicracking

Process (UOP & Unocal)

UOP & Albemarle

enter alliance

UOP & EMRE

enter alliance

EMRE MLDW™ Process

(lube dewaxing

EMRE MSDW™ Process

(hydroisomerization)

EMRE MAXSAT™

Process (lube saturation)

EMRE MWI™ Process

(wax hydroisomerization)1950

1960 1970

1980 1990

2000 Present

MSDW™ / MAXSAT™ technology advantageHigh-performance catalytic isomerization dewaxing is the preferred route for the production of the high-quality engine oil basestocks demanded by today’s vehicles. MSDW/MAXSAT is EMRE’s premier lube catalytic dewaxing and hydrofinishing technology. A typical process configuration is a two-reactor system. The first reactor primarily transforms the linear paraffins (wax) into high-quality lube products (isoparaffins) and accomplishes some saturation of the aromatic compounds. The second reactor deeply saturates aromatics to impart outstanding color and stability.

A typical size MSDW/MAXSAT unit is between 10 and 20 kBd. This proven technology is capable of processing a very wide range of feedstocks, varying from hydrotreated or hydrocracked VGOs and DAOs to hydrotreated raffinates and slack waxes. Typical products are basestocks in the API Group II to III+ range, with viscosity grades as low as 2 and as high as 25 cSt at 100°C, depending on the feed.

Table 1: Blocked operation

Figure 3: History of UOP’s hydrocracking & EMRE’s hydroisomerization process

Table 2: Broad-cut operation

Performance you can trust• Yield and selectivity• Activity and run length• Robustness and durability

Exceptional product quality• Low temperature properties• Stability• Water white color

To put the true value of the yield advantage of the MSDW™ catalyst system in context, consider this: for an average MSDW unit, at current product prices, a difference of one percent in yield of basestock product is worth between $2 million and $4 million per year over producing diesel fuel, or about $7 million to $8 million per year in revenues.

Maximizing basestock product yield is obviously important. But when you operate an MSDW unit, even the by-product is valuable. This is because the majority of the conversion product from the MSDW catalyst system is diesel fuel with essentially no sulfur, an excellent cetane number, and outstanding low-temperature properties. This product is often blended with other distillates to actually increase the quality of the diesel pool or supplement sources of arctic-grade diesel!

Energy lives hereIn today’s world, standing still corresponds to stepping backward. At EMRE we have active R&D to continue to boost yield, further improve tolerance to heteroatom contaminants, and broaden the range of acceptable feedstocks. We are now on our third generation of the MSDW catalyst system, with better activity, selectivity and polar tolerance than the original catalyst we used in our first deployment in 1997.

Activity Yield S/N Tolerance1st gen Basic Basic Basic2nd gen + ++ +3rd gen ++ ++ ++

WAX MOLECULE(~180 VI; +35ºC pour pt)

ISOPARAFFIN MOLECULE(~150 VI; -18ºC pour pt)

BULKY OIL MOLECULE(~100 VI; -18ºC pour pt)

large oil moleculecannot enter zeolite pore

UNCHANGED BULKY OIL MOLECULE(~100 VI; -18ºC pour pt)

40

30

20

10

0

-10

-20

-30

-40

100N, 150NGroup III

150N, 500NGroup II+

150N, 500NGroup II 2nd Generation

3rd Generation

Time on Stream (Years)

Del

ta T

empe

ratu

re, º

C

3rd Generation

The catalyst makes all the differenceAt the heart of the process is a system of proprietary shape-selective catalysts containing zeolites and small amounts of noble metals. They are specifically designed to isomerize n-paraffins and saturate aromatics with maximum selectivity to lubes and minimal cracking to fuels.

These catalysts, manufactured at our own facilities, display superior activity and selectivity and unsurpassed tolerance to nitrogen, sulfur, and aromatic contaminants in the feed. Even a temporary degradation in feed quality, which might irreversibly

poison other catalysts, will require only a temporary increase in operating temperature with minimal impact on aging and virtually no impact on product yield.

In fact, to date none of the more than 20 commercial units operating with MSDW™ catalyst has changed the catalyst fill due to aging, poor performance due to feed contamination, refinery upsets or reaching end of cycle. Two of the units have operated for more than 12 years, with one still using the original catalyst fill.

Figure 4: Process

Figure 5: ExxonMobil selective dewaxing HDW catalyst aging with more advanced catalysts

©2017 ExxonMobil. ExxonMobil, the ExxonMobil logo, the interlocking “X” device and other product or service names used herein are trademarks of ExxonMobil, unless indicated otherwise. This document may not be distributed, displayed, copied or altered without ExxonMobil’s prior written authorization. To the extent ExxonMobil authorizes distributing, displaying and/or copying of this document, the user may do so only if the document is unaltered and complete, including all of its headers, footers, disclaimers and other information. You may not copy this document to or reproduce it in whole or in part on a website. ExxonMobil does not guarantee the typical (or other) values. Any data included herein is based upon analysis of representative samples and not the actual product shipped. The information in this document relates only to the named product or materials when not in combination with any other product or materials. We based the information on data believed to be reliable on the date compiled, but we do not represent, warrant, or otherwise guarantee, expressly or impliedly, the merchantability, fitness for a particular purpose, freedom from patent infringement, suitability, accuracy, reliability, or completeness of this information or the products, materials or processes described. The user is solely responsible for all determinations regarding any use of material or product and any process in its territories of interest. We expressly disclaim liability for any loss, damage or injury directly or indirectly suffered or incurred as a result of or related to anyone using or relying on any of the information in this document. This document is not an endorsement of any non-ExxonMobil product or process, and we expressly disclaim any contrary implication. The terms “we,” “our,” “ExxonMobil Chemical” and “ExxonMobil” are each used for convenience, and may include any one or more of ExxonMobil Chemical Company, Exxon Mobil Corporation, or any affiliate either directly or indirectly stewarded.

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Gasoline& Diesel

HC Bottoms

Solvent Extraction

RHC™ Unit

MLDW™ Unit Hydrofinishing

Solvent Dewaxing Hydrofinishing

Solvent Dewaxing Hydrofinishing

MSDW™ Unit MAXSAT™ Unit

Vacuum Distillation Solvent Dewax

MSDW™ Unit MAXSAT™ Unit

MWI™ Unit MAXSAT™ UnitHydrocracking

Hydrocracking

Group I

Dist

illate

/DA

OD

istilla

te/D

AO

Slac

k W

axFT

Wax

Group I

Group II

Group II / III

Group II / III

Group II / III+

Group II

Heater

Reactors

Fuel Gas

Fuel Gas

Vac.

Stm

H/PStripper

High-TempFlash

Waxy OilCharge

MakeupHydrogen

RecycleCompressor

Low-TempFlash

Vac. Stripper

Stm

Vac.

Vac. Dryer

Amine & WaterScrubbers

WildNaphtha

HDW HDF

Lube

ExxonMobil advantagesExxonMobil, its heritage companies Exxon and Mobil, and its affiliates worldwide have literally generations of experience in lubes manufacturing. ExxonMobil operated and often pioneered the development of lube basestock manufacturing throughout the world.

• Mobil’s MLDW™ catalytic dewaxing technology using ZSM-5 zeolite-based catalyst was deployed in 1979 at the Adelaide, Australia Refinery.

• MSDW™ technology was commercialized at the Jurong Refinery in Singapore in 1997. • Raffinate HydroConversion (RHC) was commercialized in Exxon’s Baytown Refinery in 1999. • MWI™ (Mobil Wax Isomerization) was deployed at the Fawley, UK Refinery in 2003.