WORLDWIDE REFINERY PROCESSING REVIEW. Fourth Quarter 2017

Transcription

1 WORLDWIDE REFINERY PROCESSING REVIEW Monitoring Technology Development and Competition in One Single Source Fourth Quarter 2017 Fluid Catalytic Cracking Plus Latest Refining Technology Developments & Licensing HYDROCARBON PUBLISHING COMPANY Translating Knowledge into Profitability P.O. Box 815, Paoli, PA (U.S.A.) Phone: (610) / Fax: (610)

2 Review Fluid Catalytic Cracking 1. INTRODUCTION FLUID CATALYTIC CRACKING MARKET/TECHNOLOGY TRENDS & OPPORTUNITIES Introduction Market Conditions and Outlook Worldwide Product Demand Global Light Distillates Demand North America Europe Asia Pacific Global Middle Distillates Demand North America Europe Asia Pacific Global Petrochemicals Demand Expanding Propylene Consumption Bright Prospects in Aromatics Global Transportation Fuels Specifications Motor Gasoline Middle Distillates FCCU Emissions FCC Capacity Expansion on a Global Scale Current Status of FCC Catalyst Market Technology Directions, Competition, and Future Prospects Layout of Current Technology Competition Notable Trends in Current and Future Technological Offerings Processing Tight Oil Processing Resid Feeds Processing Biofeeds Producing High quality Gasoline and Increasing Yield Boosting LCO Yield and Quality Light Olefins Production Enhancement Propylene Production Butylene Production Aromatics Production Regenerator Pollution Abatement and GHG Concerns Process Modeling, Monitoring, and Control Benchmarking FCCUs for Optimum Performance FCCU Revamps for the Optimum Return on Investment Current R&D Trends Conclusion STATE OF THE ART TECHNOLOGY Introduction Commercial Processes and Hardware Axens CB&I /Lummus Technology Fuels Production Indmax FCC (I FCC) i

3 ExxonMobil/KBR Flexicracking III Orthoflow MAXDIESEL Propylene Production Petrobras Fuels Production Propylene Production Shell Global Solutions FCC MILOS Sinopec Clean Gasoline and Propylene Maximizing Iso paraffins Flexible Dual riser Fluid Catalytic Cracking Maximum Gas and Diesel Maximum Liquefied Gas and High octane Gasoline Propylene Production TechnipFMC/Axens Fuels Production Propylene Production UOP FCC MSCC Propylene Production Summary of Commercial FCC Processes and Hardware Other Commercial Hardware Beijing Huiersanji Green Chem Co Blasch Precision Ceramics Cat' Fine Management Technologies LLC ClearStak Fisher Klosterman Koch Glitsch Lawrence Pumps Tracerco/Johnson Matthey Commercial Catalysts and Additives Albemarle Cracking Catalysts to Increase Liquid Products Gasoline Olefins and Octane Additives Gasoline Sulfur Reduction Tight Oil Processing ACTION T AMBER T/UPGRADER T SO X Reduction Additives Bottoms Cracking Additives Microfine Reduction Catalyst Technology Catalyst Circulation Improvement Additives Combustion Promoters Light Olefins Production Ambur Chemical Co BASF Catalysts Cracking Catalysts to Increase Liquid Products Co catalysts Tight Oil Processing Gasoline Sulfur Reduction Formulations SO X Reduction Additives Microfine Reduction Catalyst Technology ii

4 Catalyst Circulation Improvement Additive Combustion Promoters Light Olefins Production Grace Catalysts Technologies Cracking Catalysts to Increase Liquid Products Gasoline Sulfur Reduction Formulations Tight Oil Processing SO X Reduction Additives NO X Reduction Additive Catalyst Circulation Improvement Additive Bottoms Cracking Additive Combustion Promoters Light Olefins Production Inst. Mexicano del Petróleo JGC Catalysts and Chemicals Johnson Matthey Process Technologies/INTERCAT JM Gasoline Olefins and Octane Additives Gasoline Sulfur Reduction Additives SO X Reduction Additives Tight Oil Processing Bottoms Cracking Additives Combustion Promoters Light Olefins Production Delta Coke Reduction Nalco Energy Services/Refining Process Services MVP NPP Rive Technology, Inc Sinopec Catalyst Co Diesel Maximizing Catalysts Gasoline Olefins Reduction Formulations Gasoline Sulfur Reduction Additives SO X Reduction Additive Light Olefins Production Summary of Commercially Available FCC Catalysts Summary of Commercially Available FCC Additives Alternative Catalyst Technologies Albemarle Grace Catalysts Technologies Johnson Matthey Process Technologies KBR Nippon Oil Advanced Process Control Systems ABB AspenTech Cutler Technology Corp Expertune Honeywell Advanced Solutions Invensys Petrocontrol Yokogawa Summary of Commercially Available Advanced Control Systems Process Models and Simulation AspenTech BASF Computational Particle Fluid Dynamics Eurotek Refining Services iii

5 KBC Advanced Technologies Petrobras Shell Topnir Systems Summary of Commercially Available Process Models and Simulation Software Resid Fluid Catalytic Cracking RFCC Processes RFCC Additives and Catalysts PLANT OPERATIONS AND PRACTICES Feed Considerations Effect of FCC Feed Contaminants on Unit Operation Impact of VGO Hydrogen Content on FCC Operation Minimizing Diesel range Material in FCC Feed Waxy Crudes as FCC Feeds Optimizing FCC Feed Preheat Temperature Processing Tight Oil Expected Changes to Product Slate Heat Balance Concerns Delta Coke Concerns Improving FCC Gasoline Output and Quality Enhancing Gasoline Octane FCC Gasoline Sulfur Reduction Lowering FCC Gasoline Olefinicity Lowering the Benzene Content of FCC Gasoline Variables Influencing Gasoline Aromatics Content FCC Gasoline Stability Revamping FCC Naphtha Splitter to Dividing Wall Column Design Effect of Long term Storage on FCC Gasoline Quality Increasing FCC LCO Production Catalyst Modifications to Improve FCC LCO Yields Improving LCO Recovery from the Main Fractionator Increasing Production of Light Olefins in the FCCU Improving FCC Propylene Production Propylene Production with Resid Streams Managing Revamp Costs for Producing/Recovering Higher Yields of FCC Propylene Balancing Propylene Production with FCC Fuel Products Increasing FCC Isobutane and Isobutylene Production Factors Influencing the FCC Propylene to Butylene Production Ratio Reducing Acetone in Butylene and Butane Streams Resid Fluid Catalytic Cracking Responding to Opportunity Crudes Fouling Prevention for Resid Processing Proper Feed Injection System Design for RFCCUs Dual Regenerator Designs for RFCCUs Running an RFCCU on Lighter Feeds: Maintaining Regenerator Temperature Processing Hydrotreated Resid Feeds New Method for Feedstock Characterization and Yield Predictions for a RFCCU RFCC Slurry Pumps Design and Service Life Uses for RFCC Slurry RFCCU Operational Issues and the Lessons Learned Operational Monitoring, Process Simulation and Unit Optimization Multivariate Statistical Modeling Monitoring Fresh Feed Flowrate Monitoring Entrained Oxygen Sources in FCC Fuel Gas Monitoring Bottoms Level in the Main Fractionator Measuring Cyanide Content in CO 2 Rich FCCU Flue Gas iv

6 FCCU Health Monitoring Inspecting and Monitoring Expansion Joints in Catalyst Standpipes Vapor Line Sampling Applying Advanced Simulation Techniques Debottlenecking the Gas Concentration Unit of a FCCU Benchmarking FCCUs for Optimum Performance Fouling, Degradation, and Erosion Problems Slurry Exchanger Fouling Fouling in Main Air Blower Dipleg Plugging and Fouling Coke Deposits in the Reactor Plenum Chamber Refractory Material Degradation in FCCU Catalyst Transfer Lines Hot Spots in FCCU Piping and Transfer Lines Mitigating Erosion Problems in FCCUs Preventing Hydrates Formation in FCC Gas Concentration Equipment FCCU Hardware Considerations and Improvements Reactor Reactor Design Riser Nozzle Design and Metallurgy Optimizing Riser Mixing Improving Air Steam Distribution Minimizing Coke Buildup in the Reactor Methods to Control Secondary Cracking in the FCC Reactor The Lifetime of Reactor Cyclones Regenerator Available Configurations for Catalyst Regeneration Meeting Regenerator Temperature Constraints Regenerator Combustion Mode: Effect on Contaminant Mobility and Activity Operating Partial Burn Regenerators in Total Combustion Mode Benefits and Drawbacks of Oxygen Enrichment in Regenerators Minimizing Inerts Entrained in Catalyst Exiting the Regenerator Reactor and Regenerator Internals Stripper Vessel Improving Stripper Performance Measuring Stripper Efficiency Main Fractionator Overhead Line Coking and Corrosion Avoiding Salt Deposition Problems Preventing Collector Tray Leaks Dealing with High Ash Content Benefits of a Staged Revamp on a FCCU Main Fractionator Isolation Valve Considerations Sulfidation Corrosion of the Bottoms Circuit Catalyst Management Reducing Rare Earth Use Evaluating FCC Catalyst Selection Additives for Feed Flexibility Pre blending of Additives with Catalysts Effect of Changing Catalyst Formulation on FCC Performance Catalyst Losses from the FCCU Diagnosing the Cause Catalyst Properties Operating Conditions Equipment Design Mechanical Conditions Refinery Experience with Loss Detection and Reduction Catalyst Circulation Problems v

7 Catalyst Backflow Diagnosing the Cause of Catalyst Deactivation Maintaining FCC Ecat Activity Disposing of FCC Ecat Catalyst Unloading and Impact on Profits Energy Efficiency and Environmental Emissions Improving FCC Energy Efficiency Key FCC Variables to Monitor for Energy Efficiency Improvements Heat Recovery in the Main Fractionator for Propylene Recovery Recovering H 2 in FCC Offgas Installation of a Power Recovery System Reducing Environmental Emissions from the FCCU FCC Feed Pretreatment Use of Electrostatic Precipitators to Reduce FCC Emissions Proper Two stage Cyclone System Design Effect of FCC Operating Variables on SO X Emissions Hydrocarbons in Flue Gas Stream Flue Gas Scrubbers to Reduce FCC SO X Emissions SO X Additives to Meet Ultra low SO X Emission Levels Effect of Regenerator Operations on NO X and CO Emissions Effect of O 2 Availability and Discharge Design on Regenerator NO X Emissions Selective Catalytic Reduction Units for NO X Reduction Lowering FCC NO X Emissions Nitrates in Purge Water Lowering CO Emissions during FCCU Startup Options to Reduce Particulate Matter Emissions from Regenerators Preventing Clogging of FCC Flue Gas Equipment Measuring Sulfur Content in FCC Flue Gas FCCU Safety Considerations Preventing Vapor Over pressure Events during Startup Emergency and Unplanned Shutdowns Loss of Fractionator Bottoms Cooling Operating in Dry Circulation Mode Improving Catalyst Slide Valve Design to Improve Unit Safety Relief Valves in the FCCU Blinds between Reactor and Main Fractionator Tunable Diode Laser Analyzers in FCCUs Preventing ESP Safety Incidents FCCU Revamps for the Optimum Return on Investment REFINING R&D ALERT! Introduction Gasoline Reformulation Patents Research Gasoline Yield Enhancement Process Catalyst Patents Research LCO Yield and Quality Light Olefins Yield Maximization Process and Unit Design Multi stage Cracking Non VGO Feedstocks Patents Research vi

8 Integrated Process Schemes Other Patents Research Catalyst ZSM Patents Research Other Zeolitic Catalysts Patents Research Additives Other Heavy Oil and Resid Cracking Process Catalysts and Additives Aromatics Production Integrated Process Schemes Production of Both Light Aromatics and Light Olefins Process Catalyst Biofeeds and Fischer Tropsch Feeds Process Patents Research Catalyst Patents Research NO X, SO X, CO, and PM Emissions Reduction Process Catalyst Preparation and Properties of Catalysts and Additives Metal resistance Properties Patents Research Preparation Procedures and Equipment Other Patents Research Hardware Injection Devices Separators and Cyclones Stripping Devices Regenerator Patents Research Fractionation Tower Slurry Oil Equipment and Handling Other Process Monitoring, Control, and Optimization Patents Research Other Process Integration Recycle or Disposal of Spent FCC Catalyst Patents vii

9 Research Other WORLDWIDE INSTALLED CAPACITY CONSTRUCTION Recent Construction Activity Completed Construction Projects REFERENCES viii