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commercial operation
A FCC process provides a high light olefin yield from a wide variety of feedstocks
utilising high severity reaction conditions and a novel down flow reaction system
Nicolas Lambert Axens IWAO Ogasawara JX Nippon Oil & Energy
Ibrahim Abba Saudi Aramco Halim Redhwi King Fahd University of Petroleum & Minerals
Chris Santner Technip Stone & Webster Process Technology
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axens.indd 1
Features of HS-FCC
PTQ Q1 2014 39
12/12/2013 10:58
60
FCC
Reaction T,C
500-550
Contact time, s
25
Catalyst/oil, wt/wt
5-8
Reactor flow
Up flow
50
40
30
Table 2
20
10
75
80
85
90
Conversion, mass%
B
25
20
15
10
5
0
75
80
85
90
Conversion, mass%
HS-FCC catalyst
Commercial FCC catalyst (octane catalyst)
Commercial FCC catalyst (activity catalyst)
+10% ZSM-5 additive
+10% ZSM-5 additive
+10% ZSM-5 additive
High catalyst/oil
Increased catalytic cracking
Table 1
Highly selective catalyst and
additive system
Optimised reaction conditions
Down flow, short contact time
reaction system with rapid catalyst
separation.
The balance of these elements
40 PTQ Q1 2014
axens.indd 2
HS-FCC
550650
0.51.0
2040
Down flow
Catalyst system
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Gasoline, mass%
Gasoline, mass%
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rev aveva.indd 3
axens.indd 3
AMACS
Compressor suction drums:
It happens in petrochemical
plants, refineries, and anywhere
else that the gas approaching
a compressor is wet. Traces of
aqueous or organic liquid escape
the inlet knockout drum, often
intermittently, and silently damaging the compressor. Telltale signs
include pitting corrosion, salt
deposits, and diluted lubricants.
Typical 1980s mist eliminator technology
Cooler
Stage 1
Stage 2
Knockout
drums
amacs@amacs.com
Revamps
2013 41
31
PTQ Q1 2014
10/09/2013 11:20
11/12/2013 20:06
100
Dry gas
90
Yield, mass%
80
LPG
Propylene
10.5%
70
Propylene
10.6%
60
50
Gasoline
40
20
LCO+
10
0
RON
99
RON
98
30
Coke
Figure 6 Bench scale vs demonstration scale results on low sulphur VGO at high severity
without ZSM-5
Air outlet
Catalytic
circulation
hopper
Injector
Main air
Air outlet
Separator
Catalytic
circulation
hopper
Total height: 35m (115ft)
Catalyst circuit
Lift air
Figure 7 500 b/d equivalent cold flow testing to scale up and optimise the reaction system
42 PTQ Q1 2014
axens.indd 4
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11/12/2013 12:17
R&D history
Feed SG
Reactor T, C
Conv, w%
Light olefins, wt%
C2=
C3=
C4=
C5-220 gasoline, wt%
RON
VGO +
HC Btm
0.845
575
93.2
39
4
19
16
35
98.5
HDT
VGO
0.879
595
83.7
34
4
17
13
34
98.1
VGO+
AR
0.915
600
82.4
31
3
15
12
34
98.4
Table 3
Semi-commercial unit
Catalyst
VGO +
DAO
0.891
580
83.0
31
3
15
13
34
98.1
Feed
Feed
CFD
simulation
Assembly of a large
number of small reactors
Feed
30
Catalyst
Injectors
25
20
15
10
5
0
DFR
(down flow
reactor)
Feed A
Feed B
Feed C
Feed D
0
10
15
20
25
Experimental data,
mass%
30
Separator
Product
Product
Quench
Catalyst
Figure 8 Combined kinetic and hydrodynamic modelling assists design and scale-up
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axens.indd 5
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43
11/12/2013 12:17
25
23
DCC
21
HS-FCC
19
17
15
13
HP-FCC
11
9
R2P
Heavy residuals
Light residuals
VGO
H1-H2 VGO
Petrochemicals
Steam
cracker
C2
Mixed C3
VGO
resid.
HS-FCC
Mixed C3
LCN
Oligomers
recycle
Polymer grade
propylene
PRU
Oligomerisation
Polynaphtha
Paraffinic
raffinate
Aromatics
complex
Paramax
HCN
Polymer grade
ethylene
Bz + PX + OX
Fuels
44 PTQ Q1 2014
axens.indd 6
evaluate yields and product properties for widely different feeds and
to demonstrate equipment reliability. Preliminary results showing
yields for several blends of VGO,
hydrocracker (HC) bottoms, DAO
and atmospheric residue are shown
in Table 3. Combined light olen
(C2-C4) yields of 30-40 wt% have
been demonstrated with 15-19 wt%
propylene and 4 wt% ethylene. The
yield of butenes is similar to propylene and offers opportunities for
greater petrochemical integration,
including oligomerisation and the
FlexEne conguration for even
higher
propylene
production.7
These results are without the use of
post-separator quench injection,
which will improve olen selectivity further. The catalyst system
continues to be optimised for the
various feeds.
When viewed from a petrochemicals perspective, the ethylene
www.eptq.com
11/12/2013 12:18
also
integrated
solutions
forfor
steam/
ofWith
most Crude
refinery
off-gases,
reduc10
Very
Heavy
Upgrading
Long
Term
R&D
Wadsworth
D, LC-Fining
options
heavy
Technip
Stone
& Webster
Process
the
option
to
operate
at 11
Opportunities,
1994.
oil
upgrading,
Proceedings
of
the
NPRA
Annual
energy
generation
and
CO2
tion
in
natural
gas
and
water
conventional severity
or high sever- Technology are now offering
8
2consumption,
Yui S, Chung K H,and
Syncrude
upgrader
revamp
Meeting,
San Diego,
CA,Liquide
9-11 Marchcan
2008. also
handling.
Air
the
recovery
of
ity, the refiner6will have the ability HS-FCC technology on behalf of
improves
quality,
Oil Gas J, 2007, Vol. 12
Ordorica-Garcia
G, Croiset E, Douglas
P,
forproduct
EOR
sequestration.
an (over-the-fence)
supply
CO
the HS-FCC
Global Alliance team.
to 2select
an or
operating
mode and provide
105,With
46, 52.the configuration
Elkamel
A,
Gupta
M,
Modeling
the
energy
shown
in of air gases, power and steam,
4suited to the
prevail3feedstock
Chrones J, best
Germain
R R, Bitumen and
heavy demands
greenhouse
gas emissions of the
FlexEnecompression/liquefaction
isand
a mark
of Axens.
and
Figure
7,
the
feedstock
to
the
MPG
CO
2
ing
economic
A 1989,
high Canadian
2 conditions.
oil
upgrading
in Canada,
Fuel Sci Tech Int,
oil sands industry, Energy Fuels, 2007,
transportation.
unit
is
normally
reduced
to
that
References
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ers,
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J
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bePetroleum,
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C syngas
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0.44
0.67
0.43
0.30 of
+
liquid, %
Depending
on study
the
conversion
surplus
integration
with can
a petrochemical
3 Del0.99
Poso
M,
Development
of ultra
selective
4.76 differences
3.14
1.42vacuum
2.25in hydroconversion
1.85
1.79
gas, % S, 4.51
residue
conditions,
6power
Sayles generation
S,Fuel
Romero
Understand
rate
of
the
units,
the
heavy
bottom
with
gas
turbines
complex is shown in Figure 10.
cracking
technology,
2nd
IFP
and
S&W
FCC
Today,
2010,
150,from
255. 10-20%. Using
between
thermal
and of hydrocracking,
Feed andCatal
formulation
yield
willWoodlands,
range
or the production
chemicals/
Forum,
The
Texas,
1996.
Ding F, Ng S H, Xu C, Yui S, Reduction of
Hydrocarbon Process, 2011, Sept, 37.
Air
Liquide Global
E&C Solutions
fuels. Alliance
Air Liquide
Global E&C 15
4 Abul-Hamayel
M A, Comparison
of
downer
for commercialisation
light
cycleof
oilOptiFuel
in catalytic
cracking ofpilot
bitumen7Global
Martinez
J, Sanchez
J L, Ancheyta
J, Ruiz
R application
Figure
3
Changes
in
pilot
plant
yields
with
Technology:
plant
Lurgi
MPG
technology-based
Solutions
can
provide
the
applicaand
riser
based
fluid
catalytic
cracking
process
HS-FCC
technology
is the derived crude HGOs through catalyst
selection,
S,The
A
review
of
process
aspects
and
modeling
runs
at
Penn
State
University
hydrogen
production
allows a
ble
technologies
(see
Figure
7).
at high
severity
conditions:
a pilot
of reactors
systematic
process
Process
Technol,
2007, 88,
833. plant study,
ofproduct
ebullated bed
for hydrocracking
of Fuel
Petroleum
Science
Technology,
22,
refiner
to
transform
these
Besides
MPG
technology,
including
research,
development,
16 Botchwey C, Dalai A K, Adjaye2004.
J,residues
Kinetics
heavy
oils, Catalcatalyst
Rev Sci Eng, 2010,
52, 60.
vessels
needed
for
additive
mixing
Albemarle
has
designed
an
addi5
Redhwi
H,
Meeting
olefins
demand
in aa
into
an
amount
of
hydrogen
that
air
separation,
CO
shift,
syngas
8pilot
Yui S,work,
Producing
crude oil of bitumen-derived gas oil upgrading using
30quality
b/d synthetic
demonstration
novel
FCC
technology,
18th
World
Petroleum
and
storage.
tion
system
to
ensure
proper
mixing
balances
the
refinerys
needs.
cleaning,
Lurgi
Rectisol,
PSA
and
commercial
NiMo/Al
from
Canadian
oil
sands
bitumen,
J
Jpn
Petrol
O
catalyst,
Can
J
Chem
unit testing, and ongoing semi2 3
Congress,
South
Africa,
2005. andseen
The
with
of 2008,
the solid
and
portions
MPG
is 478.
aimprovements
proven
reliable
methanation,
theliquid
company
also and
has
Inst,
51, 1. operation
2004,yield
82,
commercial
and testing
at Eng,
6
Okazaki
H,
High
severity
Fluidized
Catalytic
this
technology
are
hypothesised
to
to
avoid
solids
settling.
The
supply
9technologies
S, Athabasca
oil sands
produce
quality 17
Yui S, Sanford
Kinetics of
technology
for E,securing
thearomatics
hydrofor
sulphur
recovery
theYui3000
b/d scale.
These
successful
Cracking
(HS-FCC)
go
for
propylene!,
20th
be
the
result
of
reactions
in
both
the
consists
of
a
liquid
carrier
and
the
diesel
and jet fuels, Oil Gas J, 2000,
98, 47, hydrogenation
bitumen-derived
Can
supplyofto
a refinery. gas
It oils,
further
(preferably
sinceVol.oxygen
results andOxyClaus,
the modelling
tools gen
World
Petroleum
Congress,
Doha, 2011.
58.
Chem Eng,
1991,
69,
1087.
liquid
and
vapour
phases,
which are
additive
supplied
to the refinery
in Javoids
the
production
of
petroleum
is
available),
technologies
for
chemdeveloped for further scale-up 7 Ross J, (R)FCC product flexibility with FlexEne,
10
Yui S,
H, Processing
sands
Yui S,and
Sanford
E, Mild
hydrocracking
of
directly
influenced
the additive.
bags
or Chung
bulk Kshipments
foroilmixing
coke,
helps
to by
consume
much
icals
as
methanol
and 18
WRA Downstream
Asia,
2011
and
make is(such
the
technology
ready
bitumen
syncrudes
R&D focus,
Oil Gasfor
J, bitumen-derived
coker
andSingapore,
hydrocracker
heavy
The
active
sites
of
the
additive
are
on-site.
The
additive
injection
natural gas and water. In
propylene)
and fuelsAxens
production
www.axens.net.
commercialisation.
and less
2001,
Vol. 99,
17, 46.minimises
oils: kinetics,
yields, andcatalyse
product
intended
to product
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the size of gas
3
technology,
as light
the
worldwide
properties,
IndIncrease
Eng Chem
Res,
1989,
28,
1278.
Projected
yields
forolefins
commercial
8 Dharia
D,
production,
19
Yui
S,
Removing
diolefins
from
coker
industrial
standard
for
clean
syngas
application
of OptiFuel
Technology
Hydrocarbon
Processing,
April 2004.
naphtha
necessary
before
hydrotreating,
Oil
production,
it
provides
a
clean
9 Roux R, Upgrading of heavy cuts into max
Gas
J, 1999,
97, 36.
hydrogen
product
and Predicted
enables
olefins
through
HS-FCC,Base
JPI Petroleum
Refining
20
Chang A-F,
Liu Y2012
A, capture.
Predictive
modeling of
economic
carbon
Conference,
Tokyo,
and www.axens.net.
Coke
32.2%
28.5%
large-scale
integrated
refinery
reaction
Dry gas
5.6%
4.4% and
Lurgi Rectisol,systems
MPG, OxyClaus
and
Purisol
are
fractionation
from
plant
data.
1:
C
+
liquid
yields
62.2%
67.1%
Nicolas
Lambert is Technologist in Part
Axens
3
marks
of Air processes,
Liquide Global
E&C
Solutions
hydrocracking
Energy
Fuels,
2011,
Middle Distillates & Conversion Business Line,
(Lurgi
GmbH). Selexol is a mark of UOP, a
25,
5264.
focusing
FCC technology. He is a graduate
Table 4 oncompany.
Honeywell
of Arts & Mtiers ParisTech.
Iwao
Ogasawara
is Facility
Planner
of
Technical
Max-Michael
Weiss
is over
Director
Innovation,
cracking
reactions
the
strictly
&
Engineering
Service
Department,
Refining
Clean
Conversion,
with
Air
Liquidethat
Global
E&C
thermal
coking
reactions
occur
Technology
&
Engineering
Division,
JX
Nippon
Solutions/Lurgi
GmbH. He graduated
in the traditional
delayedas Diplom
coker
Oil & Energy
Corporation.
Heengineering)
holds BS andfrom
MS
Chemie
Ingenieur
(chemical
operation.
During
development,
it
degrees
in chemical
engineering.
the
Technical
University
of Karlsruhe, Germany.
Anton
Alvarez-Majmutov
is
an
NSERC
Visiting
has
been
observed
that
OptiFuel
Ibrahim AHeurich
Abba is isChief
Technologist
of the
Helmut
Director
for Refinery
Fellow
at CanmetENERGY
working
on bitumen
Technology
shifts
the
delayed
coker
Chemicals
Research
Division
of
Saudi
Aramco
Applications in the HyCO Product Line in
upgrading
process
modelling
and simulation.
yieldsEngineering
towards
more
valuable
Research
&
Development
Center.
He
holds a
Global
& Construction
Solutions
He
holds
a
PhD
from
Mexican
Institute
of
products,
with
reduced
amounts
of
PhD
the University
British Columbia.
of
Airfrom
Liquide.
He studiedofprocess
technology
Petroleum
(IMP).
Halim
Redhwi
is
the
CEO
(A)
of
Dhahran
dry
gas
and
coke.
at the Technical University of Braunschweig.
Techno-Valley
Company
a Professor
in
Delphine
Roma
is the and
Global
Marketing
Jinwen
Chen is aEngineering
Senior Research
Scientist and
the
Chemical
Department,
King
Pilot
plant
verification
Manager in charge of the refining industry
Group
Leader atofCanmetENERGY.
He holds
Fahd
University
Petroleum
& Minerals,
Saudi
within
Air Liquide and
Global E&C
Solutions.have
She
Albemarle
OFTG
aArabia.
PhD inHechemical
engineering
from
Tianjinin
holds
BS,
MS,
and
PhD
degrees
holds
an MSc and
engineering
degree
from
the
conducted
a
series
of
pilot
plant
University.
chemical
engineering.
cole
Chausses
in Paris. (PSU).
runsdes
at Ponts
PennetState
University
Chris Santner
is Senior
Director
of Catalytic
Stefan
Walter
is Head
of Department,
The scope
of these
has
been
Mugurel
is studies
a Lead
Process
Cracking Munteanu
Refining
Technology
Gasification
Technologies,
withwith
Air Technip
Liquide
Engineer
at
CoSyn
Technology,
a
division
of
to
quantify
the
benefits
of
the
techStone & Webster
Process Technology.
He holds
Global
E&C Solutions/Lurgi
GmbH.
He
WorleyParsons,
in
Edmonton,
Canada.
He
holds
nology
as
a
function
of
additive
BS and MS as
degrees
in chemical
engineering
graduated
Diplom
Verfahrensingenieur
afrom
PhDthe
inUniversity
chemicalfeed
engineering
from Laval
composition,
properties
and
of
Houston.
(process engineering) from the Technical
University,
Canada.
operating
conditions.
University of Aachen, Germany.
your experts
A Member of Unitherm-Cemcon Group
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n
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n
ACID/TAIL GAS
LIQUID SULFUR
SPENT ACID
CHEMICAL/PETROCHEMICAL RESIDUES
Variante 4a
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air
liquide.indd 64
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