Optimising FCC Operation

for a Changing Market

Masaru Marui
Sr. Product Line Manager

15th Grace EMEA FCC Technology Conference

April 2015
Barcelona Spain
1914 - 2014 A Century of Innovation
in the Oil and Gas Industry

© 2014 UOP LLC. All rights reserved. UOP 6611-1

Agenda

 Producing more propylene

– Market drivers
– FCC based technology
– Introducing Catolene for propylene
 Producing more diesel
– Market drivers
– Introducing the Catolene Process for diesel
– Introducing Maximum Distillate FCC

UOP 6611A-2
Propylene Supply & Demand

45
Steam Crackers Other On-Purpose
Delta Million Metric Ton (2009 Basis)

40
Required FCC Demand
35

30

25

20

15

10

0
2010 2011 2012 2013 2014 2015 2016 2017 2018 2019 2020

FCC positioned to fill the gap between propylene

supply and demand
UOP 6611A-3
Drivers for FCC Propylene

 Feed quality extremely important

 Feedstock cracking to naphtha olefins initiating
step for C3=
 Light olefin yield distribution controlled
by equilibrium
– Reactor temperature
– Reactor partial pressure
– Concentration of naphtha olefins
and product olefins

UOP 6611A-4
 UOP FCC Propylene Technology Portfolio

Conventional
R/FCC

Enhanced
C3= R/FCC
+ZSM-5
PetroFCCTM
Process
VGO Commercial Data Low P,
HTVGO Commercial Data High Rx T,
AR Commercial Data RxCatTM
HTAR Commercial Data
PetroFCC Operation 1
PetroFCC Operation 2

0 5 10 15 20 25

Propylene Yield, Wt-%FF

UOP 6611A-5
Propylene from FCC Revamp Examples
Reactor/Recovery Revamp
 Project Scope
– Feed quality improvement
– Catalyst system modification
– New gas concentration unit
– OptimixTM feed distributors
– Reactor revamp to UOP Vortex Separation (VSS™) System
 Results
– C3= doubled from 4.5 to 9.0 Wt-%

PetroFCC Revamp
 Project Scope
– Capacity expansion
– New PetroFCC reactor with RxCat
– New Combustor regenerator
– Product recovery expansion
 Results
– 80-85 vol% Conversion
– 15+ Wt-% C3=
UOP 6611A-6
Exclusive RxCat™ Technology Application

1) Heat balance Tunable riser

neutral recycle catalyst to oil
2) Catalyst and oil Tempers dry
contact temp gas production
decreases
3) Catalyst to oil Reaction
contacting flexibility
increases

RxCat Technology Enables

Higher Reaction Severity to
Drive Propylene Production
at Constant Dry Gas

UOP 6611A-7
Options for More FCC Propylene

 Revamp FCC to incorporate RxCat

– RxCat technology enables FCC severity increase at
constant wet gas compressor loading
• Produce less gasoline
• Produce olefinic LPG
 Add UOP Oligomerization (Catolene) Unit
– Oligomerize co-produced C4= & C5=
– Recycle oligomer (C8+ olefins) to FCC riser for
cracking to propylene

UOP 6611A-8
Catolene Technology is Based on Extensively
Proven Olefin Polymerization Technology
 Catolene technology leverages our extensive experience with:
– Catalytic Condensation Process technology
– Indirect Alkylation (InAlk™) technology
– Close to 80 years of SPA catalyst commercial application
and improvements
 Catalytic Condensation (“Cat Poly”) Process Technology:
– Commercialized in mid 1930’s
– Over 400 units licensed and designed (for making poly gasoline
and petrochemical olefins)
 UOP Indirect Alkylation (InAlk™) Technology:
– Evolved from Catalytic Condensation Process
– Developed to convert C4 into high quality alkylate blending material
– Commercialized in 2001
– 24 units licensed and designed

Simple, Inexpensive Well-Proven Technology

UOP 6611A-9
Improved Maximum Propylene
FCC Technology
C3= Yield
Fuel Gas

C3=/C3 Split
C3/C3=

Naphtha/LPG C3/C5
Separation

Deprop
C3
Main Separation

Heavy
Naphtha
C6+
FCC
Unit LCO C4/C5

HCO
Coke C4, C5
UOP Catolene
Oligomerization Unit

FCC Bottoms
C8+=
Catolene Unit
Recycle to FCC
produces synthetic
VGO Feed
naphtha for
Naphtha recracking in FCC
UOP 6611A-10
UOP Propylene Portfolio Enhanced
with Catolene Product Recycle

Conventional
R/FCC

Enhanced
+ Catolene
R/FCC

+ Catolene PetroFCC

0 5 10 15 20 25
Propylene Yield, Wt-%FF
Catolene Unit Extends FCC C3= Production Range
While Providing Flexible Fuel Production Capabilities
UOP 6611A-11
Catolene for Propylene Summary

 Catolene Process for FCC Max C3= / Gasoline

– Process technologies involved are well proven
(approaching 80 years)
– Utilizes commercially available catalyst
– Available for licence
 “Ideal” Candidate Characteristics
– FCC based refinery desiring more propylene
– FCC Unit and a Cat Poly Unit available for “repurpose”
– FCC and an InAlk Unit capable of producing olefinic
product by decoupling hydrogenation section
– Ability to recover propylene or a mixed
C3 cut

UOP 6611A-12
 European Diesel Market
North Europe Motor Gasoline Exports to
Drivers United States - Thousand bpd
• Slow economic recovery 500
450 from Northwest Europe
• Diesel deficit, gasoline demand decline 400
• Excess gasoline continues to grow 350
300
• Pressure on existing export markets 250
200
– USA Gasoline Imports Declining
150
– Competition from USA in LA and Africa 100
50
• Refinery shutdowns continue 0
– Refinery Utilization ~80%
© 2014 IHS

Europe: Gasoline (KBbl/d) Europe: Distillates (KBbl/d)

3,500 8,000
Production Consumption
Production Consumption
7,000
3,000
6,000
2,500
5,000
2,000 +0.9%
4,000
- 2.5%
1,500 3,000

1,000 2,000

UOP 6611A-13
Typical Limitations
on FCC Diesel Production
Impact of FCC Reactor Temperature
On Product Expansion
 Maximum LCO requires low

C2+ Volume Expansion

conversion operations at FCC
– Lower reactor temp
– Lower catalyst/oil

Reactor Temperature
 Lowering FCC conversion
typically not economic LCO and MCB Yield vs Conversion

– Volumetric expansion loss

Product Yield
– Bottoms yield increases faster
than LCO LCO
MCB

Conversion

FCC LCO Quality Limits

Blending into Diesel Pool

UOP 5834B-14
5830C-14
Distillate Solution 1: Catolene for Diesel
 Revamp FCC to incorporate RxCat technology
– RxCat tecnology enables FCC severity increase at
constant Wet Gas Compressor loading
• Produce less gasoline
• Produce olefinic LPG
 Add UOP Oligomerization (Catolene) Unit
– Oligomerize co-produced light olefins
• Produce High quality, low sulfur Diesel
(Cetane Number > 40)

UOP 6611A-15
Catolene for Diesel
Add-On to Existing FCC Complex
Fuel
Gas

LPG
Naphtha/LPG
Separation Alkylation Unit Alkylate

Heavy C3 to Light Naphtha

Main Column

Naphtha
FCC
Unit LCO

HCO UOP Catolene LPG & Gasoline

Oligomerization Unit

CSO

Diesel
VGO Feed
UOP 6611A-16
Catolene Process Catalyst
Achieves High Selectivity

Diesel Selectivity of Different Catalysts

80
Catalyst / Derived
70 Process Cetane
Competitor
< 36 UOP
Diesel Selectivity, %

60 Catalyst
New UOP > 40
50
+15%
40 Selectivity

30

20
10 Competitor
Catalyst
0
0.00 20.0 40.0 60.0 80.0 100.0
nC4= Conversion, Wt-%

New UOP Catalyst Offers

Superior Selectivity and Quality
UOP 6611A-17
Catolene technology Improves
Diesel Quality Produced from FCC

European Typical Catolene

Property Diesel FCC LCO Diesel
Density, kg/m3 <0.845 0.935 <0.81
Sulphur, ppmw <10 10,000 <20
Cetane Number 51 22 >40
Aromatics, vol% <11 90 <1

Improved Diesel Quality

Catolene Product
is a High-Quality Blend
Component for Diesel Pool

UOP 6611A-18
Process Yield Comparison
to Traditional Alternatives

Current FCC in Max Current FCC in

Gasoline Mode Max LCO Mode Modified FCC Complex
+ RxCat &
Technology Base Base Catolene Technologies
Reactor T (°C) 535 515 550
Regen T (°C) 700 692 725

Complex Yields
(Wt-%FF)
Dry Gas 4.0 3.0 4.0
LPG 16.0 12.5 20.0
Gasoline 46.0 36.0 30.0
LCO (Distillate) 16.0 27.0 34.0
Bottoms 12.0 16.0 6.0
Coke 6.0 5.5 6.0

Complex
Distillate 352 590 887
Cetane Barrels

UOP 6611A-19
Distillate Solution 2
Maximum Distillate FCC Revamp
 Hydrotreater/FCC Complex
– Realized CFHT-FCC synergies to increase distillate yield
– Integrated HCO cracking
– Optimized operating conditions for maximising distillate yield
– RxCat Technology
– Utilize high-matrix catalyst or additive
– Robust bottoms management system
– Distillate yield gain 20% and cetane index boost 5 - 8
– Payback <2 years
 Stand-alone FCC
– Enhanced HCO cracking for increased LCO yield
– Dual reaction zone approach
– Higher severity secondary zone
– Distillate yield gain up to 8%

UOP 5830C-20
Maximum Distillate FCC Revamp
CFHT/FCC Complex
Fuel
Gas

Distillate to
Diesel Pool
Naphtha/LPG LPG
Separation

Heavy

Main Column
FCC Naphtha
VGO / Resid CFHT with
Feed Unit RxCat
Unit LCO to
Diesel Pool

HCO Recycle Bottoms CSO

Management
System
Increase Diesel Production
over 20% and
Improve Cetene Index by 5-8
from FCC Complex
UOP 6611A-21
Maximum Distillate FCC Revamp
Standalone FCC
Fuel Gas

Naphtha/LPG
Separation LPG

Heavy

Main Column
Naphtha
FCC
VGO / Resid
with
Feed
RxCat
LCO to
Diesel Pool

Bottoms
Management CSO
System
HCO Recycle
Increase Diesel Production by
8 %-lv from FCC Complex

UOP 6611A-22
FCC Based Distillate Production Portfolio

Catolene Process integration

 RxCat Technology enables increased FCC light
olefin yield
 Catolene Process for Diesel
– Oligomerize FCC C3= / C4= / C5= to high
quality / low sulphur diesel
 Suitable for existing Cat Poly unit conversion

Maximum Distillate FCC Revamp

 Novel HCO recycle / cracking scheme
 RxCat Technology for regenerator temperature
management
Maximize refinery profit from existing FCC complex
UOP 6611A-23
UOP 6611A-24