Technip Stone & Webster Process Technology Offering in Refining

Transcription

1 Technip Stone & Webster Process Technology Offering in Refining High Severity Fluidized Catalytic Cracking (HS-FCC ): From concept to commercialization Alexander MALLER and Eusebius GBORDZOE Technip Stone & Webster Process Technology April

2 Evolving Family of FCC Technologies FCC Gasoline production from VGO RFCC Gasoline production from Resid ZSM-5 added to both FCC & RFCC for Petrochemicals DCC Petrochemical production from VGO R2P : Resid to Propylene Petrochemical and fuels production from Resid Direct & Indirect recycles HS-FCC : High Severity FCC Petrochemical production from VGO and Resid 2

3 Catalytic Cracking Technologies Propylene Yield %wt HS-FCC Incremental gains with recycles DCC Resid to Propylene High Olefins FCC Heavy Resid Light Resid VGO High H content VGO HS-FCC, a new member of the family

4 HS-FCC Technology Key features High ROT ( C) Ultra short contact time (0.5-1s) High C/O Ratio (25-30) Reaction Conditions Proprietary Catalyst Maximum Propylene Yield Unique Reaction System Rare earth free catalyst Low acid site density Patented formula Downflow reactor Tempest TM Separator Technip FIT

5 Selectivity by Short Contact Time FCC HS-FCC Down flow Riser Feed + Catalyst Feed + Catalyst Reactor Residence Time

6 HS-FCC Schematics Flue Gas Catalyst down flow Regenerator Feed injection Down flow reactor Hydrocarbon product Catalyst / Product separator Catalyst up flow Stripper using structured packing 6

7 HS-FCC Technology Development 3 DFRs to minimize scale-up risk x300 X100 X BPSD pilot at KFUPM Saudi Arabia 30 BPSD Demonstration plant in Ras Tanura, KSA 3,000 BPSD Semi-commercial unit in Mizushima, Japan 76,000 BPSD Commercial unit 7

8 Comparative Typical Operating Conditions Conv. FCC HP FCC DCC HS-FCC ROT 530 C (986 F) 550 C (1022 F) 580 C (1076 F) 600 C+ (1112 F+) Contact time 2-5 s 2-5 s 10 s s C/O RON Recycle None 93 RON LCN LCN None 96 RON 98+ 8

9 Comparative Yields (Hydrotreated VGO) Yields, wt % 100% 80% 1% 2% 10% 6% 7% 2% 1% 10% 11% 6% 6% 13% 2% 4% 6% 20% Fuel Gas Ethylene Sat.C3+C4s Propylene C4='s 60% 10% 19% 16% Gasoline LCO Slurry 55% 11% Coke 40% 48% 27% 33% 9 20% 0% 11% 4% 4% FCC 9% 3% 6% High Propylene FCC 7% 6% 6% DCC 8% 4.76% 6% HS-FCC

10 HS-FCC Feed Sources Topping unit Feedstocks with > 12wt% hydrogen are preferred to maximize propylene yield Vacuum distillation unit Vacuum Gasoil VGO De-asphalted oil DAO Atmospheric residue AR Vacuum residue VR Optional HDT Coker HCGO 10

11 Semi-Commercial HS-FCC Unit JX refinery: 400,000 BPSD Location: Mizushima, Japan 3,000 BPSD HS-FCC unit Operating Period: Objectives Met Confirmed yields Demonstrated operability & reliability Confirmed scale-up criteria Validated benefits of HS-FCC technology 11

12 HS-FCC Operation VGO + 80 % HC Btm (Feb.2012) 100% HDT VGO (Nov.2011) VGO + 50% DAO (Aug.2012) VGO + 90% AR (Feb.2014) Feed SG Reactor T, ºC C/O, wt/wt Conv, w% Light Olefins, w% C2= C3= C4= C5-220 Gasoline, w% RON Catalyst formulation fine tuned over time. 12

13 HS-FCC Commercial Design Parameters JX Mizushima Licensee A Capacity, BPSD # of DFR 1 3 Feed source HDT AR HDT AR + VR + VGO Feed SpGr Feed CCR, wt% ROT, DegC Contact time, ms C/O Yields: C3=, wt% Yields: C4= s, wt% Yields: Gaso., wt% Yields: Coke, wt%

14 Commercial Unit Configuration Flue Gas outlet Withdrawal well (WW) Regenerated Catalyst Standpipe (RCSP) Regenerator Regeneration air inlet Feed inlet Spent catalyst lift line Hydrocarbons outlet Downflow reactors (DFR) and Tempest Separator Spent Catalyst Standpipe (SCSP) Lift air inlet 14 Disengager/Stripper

15 Commercial Unit Features Disengager/Stripper: Stripper packing 15

16 Commercial Unit Features Withdrawal well: Packing 16

17 Commercial Unit Features Products Catalyst Catalyst 17 Downflow reactors: Packing Impact-type feed injectors Tempest separator

18 HS-FCC RETROFIT Study Objective Maximum increase in propylene production with minimum investment Technip S&W R2R selected for initial study Two stage regeneration Processing Resid Catalyst cooler Feedstock Types HS-FCC Downer Reactor HT-VGO Full range Naphtha 18

19 HS-FCCT RETROFIT Example What was determined? HS-FCC reactor capacity Required regenerator modifications Verified pressure balance Verified heat balance Mechanical design confirmed 19

20 HS-FCC RETROFIT Study Results RFCC Base Case RFCC with HT-VGO HS-FCC Feed Conditions Riser Feed Rate, BPD 70,319 65,000 Riser Feed API Riser Feed Con Carbon, wt% HS-FCC Feed Rate, BPD -- 25,000 HS-FCC Feed API HS-FCC Feed Con Carbon, wt% Key Product Yields Wt% Wt% Total H2-C2s C3= C4= Total C3-C4s Gasoline (C5-430 F) Operating Conditions: Riser Outlet Temp, F Riser Feed Preheat, F Riser C/O HS-FCC outlet Temp, F HS-FCC Feed Preheat, F HS-FCC C/O Catalyst Cooler Duty, MMBTU/Hr

21 Conclusion HS-FCC Technology: Turns FCC upside down to achieve higher selectivity cracking Utilizing high severity-rot, Cat/oil and catalyst formulation Uses already commercially proven FCC technology hardware Retrofit of existing FCC Units with HS-FCC feasible Additional retrofit studies in progress Offers refinery/petrochemicals integration opportunities for greater profits Demonstrated on VGO and resid feedstock in a semi-commercial plant 21

22 Technip Stone & Webster Process Thank you Technology Offering in Refining Alexander MALLER and Eusebius GBORDZOE Technip Stone & Webster Process Technology April 2016 The material appearing in this presentation is for general information purposes only. Technip S.A. and its affiliated companies ("Technip") assume no responsibility for any errors or omissions in these materials. TECHNIP MAKES NO, AND EXPRESSLY DISCLAIMS ANY, REPRESENTATIONS OR WARRANTIES, EXPRESS OR IMPLIED, REGARDING THE MATERIALS CONTAINED IN THE PRESENTATION, INCLUDING ANY IMPLIED WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE. Under no circumstances shall Technip, the other sponsors, presenters and any of their respective partners, officers, directors, employees, agents or representatives be liable for any damages, whether direct, indirect, special or consequential, arising from or in connection with the use of materials and information contained in the presentation. The materials contained in this presentation may not be reproduced, republished, distributed, or otherwise exploited in any manner without the express prior written permission of Technip. 22