TechnipFMC RFCC Technology converts bunker fuels into high value products for African refiners Eusebius Gbordzoe, Harvey McQuiston and Steve Gim ARA Week March 13 2017 TechnipFMC Process Technology
What is Bunker Fuel? Blend of atmospheric tower bottoms (fuel oil), distillate and various streams In 2015 global fuel oil production ~8.9 million BPD ~ 3.1 million BPD used as a bunker fuel 35% of total bunker fuel was used for fuel oil Fuel oil is also used for: Electricity generation Heating Industrial He (It) Ain t Heavy, He s (It s) My Brother (Bunker) Posted on February 29, 2016 by Ryan Couture ARA 2
Bunker Fuel Demand Falling Stricter environmental regulations and records keeping for marine fuel Post processing to reduce sulfur increases fuel price Distillate fuel more expensive Alternate fuels such as LNG SOx abatement equipment required on ships to comply with environmental regulations Excess residual oil expected as ships switch to cleaner fuels Refiners can reduce fuel oil production with RFCC technology. ARA 3
Bunker Fuel Sulfur Limit Established ECA Regions Africa- Non- ECA region Sulfur -3.5 wt% then 0.5wt% in 2020 ARA 4
Bunker Fuel Production: Simple/Topping Refinery 70% Gas Naphtha Kerosene Gas Oil Crude Oil 100 % Crude Distillation Unit(CDU) Fuel Oil/(Bunker Fuel) 30% ARA 5
Bunker Fuel Production: Refinery with Vacuum Tower, & VGO FCC Gas, Naphtha 70% Kerosene Gas Oil (Distillate) Crude Oil 100% Crude Distillation Unit(CDU) VGO 20% FCC 19% Gas LPG including propylene Gasoline LCO Coke (to regenerator) Atmospheric Residue 30% Vacuum Tower Slurry 1% Fuel Oil/(Bunker Fuel) VTB 10% 11% ARA 6
Bunker Fuel Production: With RFCC (No Vacuum Tower Required) 70% Gas, Naphtha Kerosene Gas Oil (Distillate) Crude Oil 100% Atmospheric Residue 30% Crude Distillation Unit (CDU) RFCC 27.5% Gas LPG including propylene Gasoline LCO Coke (to regenerator) Slurry/Fuel Oil/(Bunker Fuel) 2.5% ARA 7
TechnipFMC RFCC Advantage Refinery Configuration Fuel Oil/ Bunker Fuel production from 100 units of crude oil % Reduction Simple 30 Base Refinery with Vacuum tower and VGO FCC 11 63 Refinery with RFCC 2.5 92 Eliminating Vacuum tower and adding RFCC reduces fuel oil production by 92% RFCC converts fuel oil/atmospheric resid to Gasoline LPG-can produce up to 12 wt% propylene from resid LCO/diesel Slurry- can be used to satisfy refinery internal energy needs ARA 8
TechnipFMC: Leading the Way in RFCC 80% market share for Resid processing Propylene Gasoline LCO/diesel R2R RFCC units running for more than 30 years at full design or higher capacity High customer satisfaction, many repeat customers (34 units by 12 companies) Mechanical reliability in unit design and ease of operation are key for success Flexibility of operating modes ARA 9
RFCC Typical Feed Properties Hydrotreated and unhydrotreated API: 18-31 CCR: 2-5 wt% Sulfur: 0-3 wt% Ni+V: 15-55 ppmw ARA 10
RFCC Typical Operating Range Typical riser outlet temperature Gasoline mode : 510-530 ºC Propylene mode: 530-550 ºC LCO/diesel mode: 500-510 ºC Cat/Oil : 6-9 (Depending on processing objective) Yield range Propylene: 2-12 wt% Gasoline: 12-46 wt% (12wt% for max LCO mode) LCO: 8-50 wt% (50 wt% for max LCO mode) Coke: 5-10 wt% Slurry: 8-12 wt% ARA 11
TechnipFMC R2R FCC Unit 2 nd Stage Regenerator Reactor Riser Hot regenerated catalyst converts oil into valuable products Coke deposits on the catalyst RS2 to separate catalyst from vapor products Stripper Removes hydrocarbons from spent catalyst before it enters the regenerator 1st stage regenerator Operates in partial combustion mode Partially regenerates spent catalyst Minimizes hydrothermal deactivation of the catalyst 2nd stage regenerator Operates in full combustion mode Fully regenerates spent catalyst Provides heat required for oil vaporization and cracking Catalyst cooler Removes excess heat from regenerator Catalyst Cooler 1 st Stage Regenerator WDW Stripper Riser ARA 12
Critical Hardware for Resid Processing Superior feed injectors by TechnipFMC Designed for resid feeds Droplet size for optimum feed vaporization Minimum coke production Optimum dispersion steam Utilizes dense catalyst in feed zone for maximum heat transfer and droplet vaporization Improves yield Feed Zone ARA 13
Critical Hardware for Resid Processing TechnipFMC Riser termination device (RS 2 ) Rapid separation of products from catalyst Reduce post riser cracking Start-up without filling up the main fractionator with catalyst TechnipFMC Proprietary Packing Efficiently strip hydrocarbons from catalyst Recovers valuable products Reduces regenerator temperature Riser Packing ARA 14
Unique R2R Two Stage Regeneration for Resid Processing Minimizes heat rejection from resid processing Partial combustion in first stage Overall cooler regeneration Minimizes catalyst thermal deactivation Rejection of water of combustion in first stage Minimizes hydrothermal deactivation of catalyst Increases metal tolerance Catalyst make-up rate is lower using R2R design Lowers operating cost 2 nd Stage 1 st Stage ARA 15
Critical Hardware for Resid Processing TechnipFMC Proprietary Catalyst Cooler Controls regenerator temperature Essential for processing resid Removes excess heat Generates steam for refinery use Uses individual tubular modules to eliminate tubesheet Single tube failure can be isolated to keep unit on-line 100% turn-down flexibility Low cost cold-wall carbon steel construction Catalyst Cooler ARA 16
Conclusion Eliminate vacuum distillation unit Atmospheric tower bottoms (used as bunker fuel) sent to RFCC RFCC converts bunker fuel to valuable products Gasoline, diesel, LPG, propylene (if desired) and LCO Minimizes fuel oil production We are a Leader in RFCC technology Tailored design to your needs Excellent tech service support Our proprietary FCC/RFCC technology can be used to revamp existing FCC/RFCC units Upgrade existing units to modern technology Increase unit throughput and reliability Extensive revamp experience with UOP, Kellogg, Exxon, Shell etc FCC units. ARA 17
Africa?- Non- ECA region Sulfur -3.5 wt% then 0.5wt% in 2020 ARA 19