Strategies for Metals Management in Resid FCC Units ERTC. November Dr. Vasilis Komvokis, Technology Manager

Transcription

1 Strategies for Metals Management in Resid FCC Units ERTC. November Dr. Vasilis Komvokis, Technology Manager

2 Lessons from FCC history BASF analyses Ecat and operating data from over 200 units These data are used to drive R&D and innovation programs Chart Legend Resid > 3000 ppm Ni+V Gasoil < 3000 ppm Ni+V Lessons from FCC history, PTQ 2017/Catalysis, 37-45

3 FCC can process a range of feeds Concarbon (wt%) Ni+V 7,000 6,000 5,000 4,000 3,000 2,000 1, Gasoil Resid Average Gasoil Resid Average Increasing proportion of heavy FCC feed More contaminant metals (Ni, V, and Fe) on Ecat Lessons from FCC history, PTQ 2017/Catalysis, 37-45

4 Question? Which target is most important for your refinery? A Bottoms upgrading B Distillate maximisation C Gasoline maximisation D Propylene maximisation

5 Strong demand for light products Bottoms, vol% Gasoline, vol% Gasoil Resid Gasoil Resid Average LCO, vol% LPG Olefins, vol% Gasoil Resid Gasoil Resid Average Lessons from FCC history, PTQ 2017/Catalysis, 37-45

6 Technologies for multiple targets Improved heavy feed upgrading Performance and Environmental Contaminant metal management Maximising FCC performance and yields with catalyst innovations, ERTC 2017 / Newspaper

7 Catalyst technology features Zeolite Y Pore Diameter of 7.4 Å 7.4 Å FCC Feed ß scission Zeolite Y Naphtha Olefins ZSM-5 Hydrogen transfer Zeolite Y C 5 -C 12 Paraffin C 3 = and C4=

8 Pore architecture BASF animation to develop understanding of pore features BASF animation of an engineered pore architecture What is a Pore? Engineered Pore Architecture Surface Pore porosity connectivity x x x x Pore Pore dimensions volume x x x x 7 8

9 Importance of Surface Porosity Surface Pores Minimal Optimized Diffusion of feed Poor Excellent Threshold to added Fe Low High Resulting liquid yield Low High

10 Metal passivation technologies Metal Effect Metal Mobility Technologies Nickel Dehydrogenation: Increase H 2 and coke Low mobility Specialty Alumina Boron-based Technology (BBT) Vanadium Zeolite destruction High mobility Rare Earth based Activity reduction Ca and Mg based Dehydrogenation High zeolite content Iron Added iron can block catalyst surface hindering access to pores Low mobility High porosity and engineered pores Maximising FCC performance and yields with catalyst innovations, ERTC 2017 / Newspaper

11 Case study: Fortress NXT trial Q2-Q Catalyst Testing CMDU deactivation CRU testing Catalyst Selection Based on: Lab study Tech proposal Catalyst Trial 6-month trial with Fortress NXT

12 Catalyst design / technologies Zeolite- and Matrix cracking LCO/gasoline Rare earth per zeolite LPG/gasoline ZSM-5 C3s and C4s

13 Equiv. Ni and gas & coke factors 5, ,000 4,500 4,000 3,500 3,000 Ni+V/4+Fe/10-4/3Sb FCF FDGF Clear reduction in gas & coke factors, for similar variation in equiv. Ni Reduced gas & coke, unlocked potential to increase %Resid in feed

14 Gas & Coke factors vs. Eq. Nickel Gas Factor vs Eq. Nickel (Ni+V/4+Fe/10-4/3Sb) Competitor Fortress NXT Coke Factor vs Eq. Nickel (Ni+V/4+Fe/10-4/3Sb) Competitor Fortress NXT ,500 4,000 4,500 5,000 5,500 3,500 4,000 4,500 5,000 5,500 Refinery observed drop in regenerator bed temperature This enabled the refinery to increase %Resid in feed

15 Gasoline & Bottoms vs FACT Gasoline %ACE vs FACT Competitor Fortress NXT Bottoms %ACE vs FACT Competitor Fortress NXT Higher gasoline yield Lower bottoms (slurry) yield And higher LPG+Gasoline

16 Fortress NXT trial summary Trial achievement Improvement observed Notes Coke factor Reduced by 18% Reduction in regenerator temperature allowed feed Gas factor Reduced by 2% quality to be deteriorated. Resid in feed Increased by 7% These benefits allowed the Bottoms yield (slurry) Reduced by 4% Gasoline production Increased by 2% refinery to increase FCC profitability. Catalyst addition rate Reduced by 5% After optimization, refinery increased Resid in Feed by ~7%

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