The Greener FCC Moving from Fuels to Petrochemicals HARVEY MCQUISTON AND STEVE SHIMODA TECHNIP STONE & WEBSTER PROCESS TECHNOLOGY GPS LISBON, NOVEMBER 14-16 2016
The FCC Alliance The FCC Alliance is a coalition of 4 companies dedicated to the promotion, development, and improvement of fluid catalytic cracking technologies to efficiently produce safer, cleaner, and higher quality petroleum based products for the benefit of our society.
Greening Trend of FCC The Greening Trend of FCC Since 1940 s, the primary role of FCC has been to produce gasoline from VGO In the 80 s the high price of crude pushed the FCC into processing more resid (more light products per barrel of crude) Newer FCCs are larger, more efficient, and on stream longer Preferred feedstock today is either resid or hydrotreated VGO The current trend is the petrochemical application of FCC to make propylene in favor of gasoline
Global Trend for Propylene by Source: 2013 Production ~ 80 Million tons (Mta) 2022 Production ~ 125 Million tons (Mta) 11% Other FCC 34% 25%-30% Other FCC 30%-35% Steam Cracking 55% Steam Cracking 40%-45%
Fuels vs Propylene Based FCCs 61 grassroots units licensed the FCC Alliance since 1981 22 propylene based FCC licensed since 2005 80% of FCCs licensed since 2005 are propylene based Fuels FCC (38) Propylene FCC (22)
Future Petrochemical Role for FCC Estimated incremental demand for propylene from FCCs by 2022 is expected to be 11 Mta Flexibility to shift FCC operation between max gasoline and max propylene Feedstock flexibility tight oil to hydrotreated VGOs to resids Integration of both new and existing FCCs with petrochemical facilities will greatly enhance economics
The FCC route to propylene
Resid FCC to Propylene R2P 2 stage regeneration for heat balance Cracking of resid feed in primary riser 2nd riser for light naphtha recycle cracking Propylene yield over 12 wt% Ethylene yield of 2 wt% can be recovered economically with integration of steam cracker Butylenes can be oligomerized to C8s & C12s and recycled to riser to increase propylene
Deep Catalytic Cracking to Propylene For high hydrogen content feeds (VGO and mild resids) Lower overall hydrocarbon partial pressure compared to FCC - Low operating pressure - High dilution steam Utilizes both riser and bed cracking Higher riser severity for primary cracking Secondary cracking of recycled C4s and light naphtha Propylene yields 15 to 20 wt% Ethylene yields of 5 wt%
HS-FCC Process High-Severity FCC for propylene Millisecond downflow reaction system for higher selectivity Both VGO and resid feeds Developed by JX Energy and Saudi Aramco in cooperation with King Fuad University Exclusively licensed by Technip and Axens Catalyst Downflow Regenerator Feed Injection Downflow Reactor Catalyst - Product Separator Catalyst Upflow Stripper with structured packing
Pre-Commercial HS-FCC Unit JX refinery: 382,000 bpsd Location: Mizushima, Japan 3,000 bpsd HS-FCC unit Started up in March 2011 Objectives achieved Yields confirmed Scale up criteria confirmed Operability & reliability demonstrated 2 commercial units are in design phase
Propylene From Catalytic Cracking 25 23 Propylene Yield %wt 21 19 HS-FCC 17 15 13 Resid to Propylene High Olefins FCC 11 9 Heavy Resids Light Resids VGO Hi-H2 VGO
Typical Cracking Yields by Unit Design Weight % FCC FCC RFCC Steam Cracking Unit Design Gasoline Gasoline w/ ZSM-5 High Olefins High Olefins Ethane Feed Ethylene 0.5-1.5 0.5-1.5 1-2 2-6 45-50 Propylene 3-5 6-9 10-12 15-25 1-3 Butylenes 6-8 6-8 12-14 13-17 1-2 Gasoline 45-55 50-55 28-35 22-40 1-3
Typical Operating Parameters Operating Parameter FCC FCC RFCC Steam Cracking Unit Design Gasoline Gasoline w/ ZSM-5 High Olefins High Olefins Ethane Feed 500-535 530-550 540-550 505-575 760-870 2 2 2 10 0.1-0.2 Pressure, Barg 1.7 1.7 1.7 1 1 Catalyst to Oil Ratio 7-8 8-9 9-10 15 - Dilution Steam, wt% 1-6 1-6 9.5-10.5 20-30 30-80 Recycle cracking No No Yes Yes - Reactor Temp., C Residence Time, Sec.
Complementary Processes for More Propylene PetroRiserSM - Dedicated 2nd riser for recycle of olefin-rich streams (light naphtha, C4s, and/or oligomerate Omega Process - Licensed by Asahi Kasei Chemicals - Converts olefin-rich C4-C5 stream to propylene FlexEneTM Process - Licensed by Axens - Oligomerization olefin-rich C4s to C8 to C12 oligomerate that can be recycled to FCC and cracked to propylene Metathesis - Combines ethylene with butylenes to make propylene
Unit with FlexEneTM ERU PGE PRU ATB PGP FLEXENETM HYVAHL Unit C8 and C12 OLIGOMERS PRIME G+ LIGHT NAPHTHA HEAVY NAPHTHA LCO SLURRY
R2P Unit with PetroRiserSM LT NAPHTHA TO PETRORISERSM
Grassroots Unit Study
Grassroot Unit Study Components R2P ERU FlexEneTM Omega Baseline grassroot petrochemical-centric resid FCC Upper bound for petrochemical-centric FCC Addition of Ethylene Recovery Unit (ERU) for upgrading off-gas to petrochemical feedstock Indirect conversion of C4 olefins to propylene via oligomerization and cracking Direct conversion of C4 and C5 olefins to propylene
Grassroot Study Definitions Case ID 1 2 3 4 5 R2P + TM FlexEne (Standalone) + TM FlexEne + ERU + ERU+ TM FlexEne Cracking Unit R2P Capacity, bpd 30,000 30,000 30,000 30,000 30,000 YES YES Description C2-C5 Conversion Units: ERU FlexEneTM YES YES C2=, kta 0 0 0 68 74 C3=, kta 237 283 326 283 326 Note: Contribution of FlexEneTM and Omega are considered to be similar YES
Grassroot Study Economic Evaluation Case ID Description Cracking Unit 1 R2P + TM FlexEne 2 (Standalone) 3 + TM FlexEne 4 + ERU 5 + ERU+ TM FlexEne R2P YES YES YES 458 943 (734) (69) 139 3.3 18.9 483 971 (734) (80) 157 3.1 20.0 C2-C5 Conversion Units: ERU FlexEneTM YES TIC(Total), $MM Revenue, $MM/Year Feed Cost, $MM/Year Opex, $MM/Year EBITDA, $MM/Year Payback Period, Years IRR(1) 356 862 (734) (54) 75 4.8 13.3 YES 358 885 (734) (55) 96 3.7 16.9 383 908 (734) (62) 112 3.4 18.2 (1) Design & construction = 4yrs, no contingencies & fees, operating years = 20yrs, tax rate = 0%, no depreciation tax shield, zero salvage value. TM (2) Contribution of FlexEne and Omega are considered to be similar.
Grassroot Unit Study Summary IRR, % 170 24.0 160 23.0 150 22.0 140 20.0 120 18.2 110 18.8 100 21.0 20.0 18.9 19.0 18.0 16.9 17.0 90 16.0 80 15.0 70 13.3 14.0 30 10.0 + OMEGA + ERU 11.0 + FlexEne + ERU 40 + ERU 12.0 + Omega 50 + FlexEne 13.0 (Standa lone) 60 R2P + FlexEne EBITDA, $MM/Year 130 20.5 IRR, % EBITDA, $MM/Year
FCC Revamps Opportunities for Propylene 24-oct.-16 23
FCC Revamp to Comparison of Operating Parameters FCC Operation Design Range Mode Feed Rate, Mtpa 1.20 0.6 1.20 1.03 Reactor Temp, C 522 520-540 530 Reactor, kg/cm²g 1.26 1.20-1.50 1.20 Steam to Riser, kg/h 7600-12,600 Parameter Mode of operation is within design range
FCC Conversion to Operating Data vs. Study Estimates Mode of Operation FCC Feed Rate, Mtpa 1.20 1.03 Dry Gas, wt% 2.91 5.07 C3=, wt% 6.01 14.50 Total LPG, wt% 20.27 34.49 Gasoline, wt% 48.78 39.00 Conversion, wt% 84.52 85.70 Yield shift to higher value products
FCC Revamp with PetroRiserSM Dedicated 2nd riser for recycle of light naphtha, C4s, and/or oligomerate (FlexeneTM) Utilizes high riser temperature with post-riser quench for incremental propylene and ethylene Catalyst cooler effect Can be added to existing FCC or RFCC
HS-FCC Revamp Example HSFCC reaction module suitable for addition to existing FCC regenerator in parallel with existing reactor Simultaneous fuels and petrochemical operation possible Shared catalyst and heat balance with existing unit Catalyst cooler effect to existing unit Incremental reactor effluent can be processed in parallel recovery section
Revamp Unit Study
Pre-Revamp Base Case Fuel Gas Propane Sat Gas Plant Isomeriza tion Butane C5/C6 Isomerization LPG Propane Reformer Naphtha Naphtha HDS Kerosene HDS Kerosene Jet A 1 Alkylation CDU VGO HTU VACUUM TOWER Alkylate C 3 = FCC PP LCO FCC Gasoline ULSD ULSD LCGO Alkylatio n Atm Gasoil V D U Kerosene Jet A 1 Diesel HDS Diesel Heavy Sour Crude Gasoline BENZ OUT FCC HTU C3= FCCU Slurry HSF O HCGO Delayed Coker Fuel Oil Petroleum Coke
Option 1: Petro-RiserSM Fuel Gas Propane Isomeriza tion Butane Sat Gas Plant C5/C6 Isomerization LPG Propane Reformer Naphtha Naphtha HDS Kerosene Jet A 1 ULSD Alkylation CDU Alkylatio n Atm Gasoil FCC Gasoline Heavy Sour Crude VGO HTU Vacuum Tower ULSD LCGO Alkylate C 3 = FCC PP LCO Tight Oil Kerosene Jet A 1 Diesel HDS Diesel NEW PREFLASH TOWER Gasoline BENZ OUT Kerosene HDS FCC HTU C3= FCCU Slurry HSF O Fuel Oil V D U HCGO Vacuum Btms ATB TO NEW PETRORISERSM Delayed Coker Petroleum Coke
Option 2: FCC Conversion to VACUUM TOWER
Shifts from Fuels to Plastics Base Petro-Riser Option 1 Option 2 X FCC to Conversion X Total Potential Plastics, kta 73 104 453 Total Fuels, BPD 126 103 92 Gasoline 75.17 53.82 46.13 Jet+Diesel 50.27 48.54 45.31
Translate into Big Economic Impact Base Petro-Riser Option 1 X FCC to Conversion Delta Gross Margin, $MM/Yr Option 2 X Base 194 235 Delta CAPEX (From Base) 100 275 Payback period, months 6.2 14.0
Conclusion Propylene demand continues to grow at a rate of 4% and FCC is expected to contribute 30% of new incremental demand. Most new FCC units will be based on propylene production and integrated with petrochemical facilities, but these new units will not completely meet expected demand alone. The latest FCC technology can also be applied to existing FCC units to shift from fuels to petrochemical mode of operation, producing not only a higher margin product slate, but also displacing some of the fuels products that contribute to greenhouse gases.
Thank you HARVEY MCQUISTON AND STEVE SHIMODA TECHNIP STONE & WEBSTER PROCESS TECHNOLOGY GPS LISBON, NOVEMBER 14-16 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.