(R)FCC Product Flexibility with FlexEneTM
Christian Dupraz
2GTF ARTC 2012 - Bangkok
Agenda
Propylene & Regional Fuels Market Product Flexibility (R)FCC Options for High Propylene Yield Integrated FlexEne Configuration Selectivity of Propylene Production Additional Product Flexibility Opportunity Conclusion
3GTF ARTC 2012 - BangkokSource: Axens (2011)
2010 Production~ 75 Million tons (Mt)
On purpose production*
From Refineries (DCC/RFCC/FCC)From Steam crackers
52%36%
12%
02468
101214161820
2010 2011 2012 2013 2014 2015
Average Annual Growth Rate ~ 4.5% Additional propylene production Additional propylene production
from refineries > 4 Mt/yfrom refineries > 4 Mt/y
2010-2015: Additional Propylene Production by Source
Mt/y
Basis
Global Trend for Propylene Production Forecast by Source
* Metathesis, Olefins cracking, MeOH to propylene, C3 dehydrogenation
4GTF ARTC 2012 - Bangkok
Source: Axens & other sources (2010)
Market Structure2010 vs. 2020
Regional Trend for Fuels:Asia Pacific Growth in Motor Fuels
Other* = Kerosene ( Jet Kerosene), Refinery Gas, Petroleum Coke, NGL, Lubricants, Bitumen, Paraffin Wax, Refinery Losses,
0.0
0.5
1.0
1.5
2.0
2.5Mbdoe
Incremental Demand 2010-2020
11.0%
15.6%
13.1%3.7%
19.9%
14.8%
10.2%
11.7%
9.7%
14.0%
14.6%4.7%
21.3%
15.6%
9.2%10.9%
0%
20%
40%
60%
80%
100%
2010 202027.4
Mbdoe35.4
Mbdoe
2010-2020 AAGR2.6%
3.3%
3.6%
4.9%
3.2%
AAGR %/yr
Dies
el Jet
Gaso
line
Naph
tha
Jet KeroseneOn-road dieselOff-road diesel
Fuel Oil
Motor GasolineNaphtha
LPGOther*
Jet KeroseneOn-road dieselOff-road diesel
Fuel Oil
Motor GasolineNaphtha
LPGOther*
5GTF ARTC 2012 - Bangkok
Refinery FCC Options for Higher Propylene Production
High Severity, Specific Design & ZSM-5 Catalyst Addition
Very selective
Recycle of Light Naphtha (LN) or C4 Cut
Higher severity, 2nd Riser
Simplicity of recycle appears attractive
Are there alternatives which are more selective & flexible?
6GTF ARTC 2012 - Bangkok
High Severity Plus High ZSM5 AdditionIs There More Propylene Potential?
0
2
4
6
8
10
12
14
16
76 78 80 82 84 86Conversion, wt%
P
r
o
p
y
l
e
n
e
,
w
t
%
34
36
38
40
42
44
46
48
50
L
N
,
w
t
%
C3= with ZSM5 C3= witout ZSM5 LN with ZSM5 LN without ZSM5
Propylene & C5-160C LN vs Conversion & ZSM5*
*Basis: HDT VGO, Low RE catalyst with high ZSM5 content
7GTF ARTC 2012 - Bangkok
LN Recycle Cracking For Max PropyleneLimited Potential
Over 60 w% of olefins converted become aromatics!Increasing Conversion
Molar profile Feed=100
0
5
10
15
20
25
0 50 100 150 200 250
C
i
m
o
l
,
f
e
e
d
b
a
s
e
1
0
0
0
10
20
30
40
50
C3=
C4=
C5=
C6=
C7=
Aromatics
Low conversion, high gas yield & limited ultimate propylene potential when recycled to extinction
8GTF ARTC 2012 - Bangkok
02468
1012141618
0 20 40 60 80Butene Conversion, %
W
t
%
GasPropyleneGasoline
Full C4 cut is recycled (about 40% non-reactive paraffin) Conversion of C4 olefin via C8+ oligomer intermediates Severe conditions required: high gas yield & aromatics
* HDT VGO, Low RE catalyst with high ZSM5 content
C5+ Composition
0
10
20
30
40
50
60
0 20 40 60 80Butene Conversion, %
W
t
%
OlefinParaffinAromatics
Other Options:C4 Cut Direct Recycle Cracking
9GTF ARTC 2012 - Bangkok
Another Way: FlexEneFlexEneTMTMFlexFlexible AlkEneEne Oligomerization & Recycle
STEP 1
C4 olefins are transformed into C8 & C12 olefins (oligomers) in a PolyNaphtha (oligomerization) Unit
STEP 2
Oligomers are highly reactive and crack selectively toward propylene in FCC
FlexEne Light Olefin Processing Route
10GTF ARTC 2012 - Bangkok
FlexEne: Integration of Proven Technology: Polynaphtha & FCC
FCC Feed:VGO/Resid
PolyNaphthaTMOligomerization
PolyNaphthaTMOligomerization
C4 cut
Gasoline
DistillateMotorFuels
Recover Oligomers as Gasoline or Distillate to optimize G/D ratio
Recover Oligomers as Gasoline or Distillate to optimize G/D ratio
or
Fuel GasPropylene
LPGGasolineDistillateFuel Oil
C4 Raffinate
Recycle Distillate
Gasoline
Recycle Selected Oligomers to FCC Riser to Maximize Propylene
Recycle Selected Oligomers to FCC Riser to Maximize Propylene
Product RecoveryProduct Product RecoveryRecovery
11GTF ARTC 2012 - Bangkok
FlexEne Provides Highest Selectivity for Light Olefins to Propylene
Oligomer cracking is more selective with lower impact on Wet Gas Compressor (WGC)
Less gas & aromatics formation for higher ultimate propylene yield when recycled to extinction
Relative Propylene Selectivity v Recycle
0.0
0.5
1.0
1.5
2.0
2.5
Direct C4 LCN C4 Oligomers
P
r
o
p
y
l
e
n
e
/
W
e
t
G
a
s
(
m
o
l
/
m
o
l
)
12GTF ARTC 2012 - Bangkok
0%
10%
20%
30%
40%
50%
60%
70%
80%
90%
100%
Max Gasoline
FCC alone
Dry gasLPG w/o C3=C3=GasolineDistillateDCO Coke
Flexibility Example:FlexEne Applied to C4 or C3/C4 Cut
13GTF ARTC 2012 - Bangkok
Product Flexibility - Gasoline Case
FCC C4 cut
Propylene
Distillate Gasoline
Motor Fuel
Motor Fuel
FCCGasoline Mode
PolyNaphthaGasoline Mode
P
r
o
d
u
c
t
s
P
r
o
d
u
c
t
s
Propylene for Max Gasoline
14GTF ARTC 2012 - Bangkok
0%
10%
20%
30%
40%
50%
60%
70%
80%
90%
100%
Max Gasoline
FCC alone
Max Gasoline
FCC + FlexEne
Dry gasLPG w/o C3=C3=GasolineDistillateDCO Coke
Flexibility Example:FlexEne Applied to C4 or C3/C4 Cut
Recycle of oligomerized C4 or C3/C4 Cut
15GTF ARTC 2012 - Bangkok
Product Flexibility - Distillate Case
Propylene
DistillateGasoline
Motor Fuel
Motor Fuel
FCCDistillate Mode
PolyNaphthaDistillate Mode
P
r
o
d
u
c
t
s
P
r
o
d
u
c
t
s
FCC C4 cut
Propylene for Max Distillate
16GTF ARTC 2012 - Bangkok
0%
10%
20%
30%
40%
50%
60%
70%
80%
90%
100%
Max Gasoline
FCC alone
Max Gasoline
FCC + FlexEne
Max Distillate
FCC + FlexEne
Dry gasLPG w/o C3=C3=GasolineDistillateDCO Coke
Flexibility Example:FlexEne Applied to C4 or C3/C4 Cut
Recycle of oligomerized C4 or C3/C4 Cut
17GTF ARTC 2012 - Bangkok
Product Flexibility - Propylene Case
FCC C4 cut
Propylene
Gasoline&
Distillate Motor Fuel
Motor Fuel
FCCPropylene Mode
PolyNaphthaConversion Mode
P
r
o
d
u
c
t
s
P
r
o
d
u
c
t
s
18GTF ARTC 2012 - Bangkok
0%
10%
20%
30%
40%
50%
60%
70%
80%
90%
100%
Max Gasoline
FCC alone
Max Gasoline
FCC + FlexEne
Max Distillate
FCC + FlexEne
Max Propylene
FCC + FlexEne
Dry gasLPG w/o C3=C3=GasolineDistillateDCO Coke
0.0
1.0
2.0
3.0
4.0
5.0
G
/
D
G/D
Flexibility Example:FlexEne Applied to C4 or C3/C4 Cut
Recycle of oligomerized C4 or C3/C4 Cut
19GTF ARTC 2012 - Bangkok
PolyNaphtha Puts the Flex(ibility) in FlexEne
Flexibility to vary Gasoline vs Distillate ratio: Gasoline Mode: 100% Gasoline Distillate Mode: 70% Jet-Diesel / 30% Gasoline
Option to recover oligomers or recycle crack Simple fixed bed process with fully regenerable
Si-Al catalyst Low cost alternative to alkylation Can be extended to C3-C9 olefinic streams
A separate PolyNaphtha Oligomerization unit provides superior yields and greater flexibility
20GTF ARTC 2012 - Bangkok
FlexEne Advantages
Combination of 2 widely proven processes FlexEne adds ~ 3%wt absolute to C3= yield FlexEne effect is cumulative over and above the
effect of temperature & ZSM-5 FlexEne can target increased C3= or Motor
Fuels (G or D) via selection of recycle cut Flexibility to change product target. May be extended to C3-C9 cuts depending on
market demand (G/D, C3=/G, etc.)
21GTF ARTC 2012 - Bangkok
Resid Application: Soukhna Refinery & Petrochemical Complex
R2P (Resid to Propylene) Technology 68,000 bpsd R2R technology, >10 wt% Propylene FlexEneTM, Gasoline & Propylene mode Feed: API=23, CCR=3, S = 1.6 wt%
Location: Soukhna, EgyptSource: Google Earth
22GTF ARTC 2012 - Bangkok
VGO Application:PETRON Bataan Refinery
High Propylene FCC (HP FCC) 35,900 bpsd 250 000 ktpa of Propylene FlexEneTM, Gasoline & Propylene mode Feed: VGO + Hydrotreated Coker Gasoil
Location: Bataan, Philippines Source:Petron
23GTF ARTC 2012 - Bangkok
Conclusion
Strong demand for Propylene & regional demand for all fuels - product flexibility desired
LN & C4 recycle to FCC is not selective for added propylene and no impact on distillate
FlexEne combines proven FCC & PolyNaphthatechnology to optimize production of propylene, gasoline, jet or diesel = Flexibility
FlexEne has been applied in 7 projects over the last 3 yrs
(R)FCC Product Flexibility with FlexEneTM
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