Unveiling The Modern FCC in a Diesel & Petrochemical Oriented Refinery Nicolas LAMBERT
Agenda
Market Trends Modern FCC Capabilities with Regards to the Petrochemical Industry Recent Application Case Review: SATORP Potential Further Improvements and Deeper Integration of Similar Scheme
Agenda
Market Trends Modern FCC Capabilities with Regards to the Petrochemical Industry Recent Application Case Review: SATORP Potential Further Improvements and Deeper Integration of Similar Scheme
Middle East: Product Demand Will Be Driven By … Mbdoe
Incremental Demand 2014-2030 (Mt/y)
(50) 1.0
0.72 (25) 0.5
0.67
0.49 0.28
0.0
0.04 0.10
This region accounts for around 20% of the global demand growth Demand growth in all categories, especially for Gasoline, Other and on-road Diesel
0.35
0.13
Fuel oil
Off Road Diesel
On Road Diesel
Jet Kerosene
Motor Gasoline
Naphtha
LPG
Other*
Other* = Kerosene (≠ Jet Kerosene), Refinery Gas, Ethane, Petroleum Coke, NGL, Lube oils, Bitumen, Paraffin Wax, Refinery Losses, …
ME Gasoline & Diesel Demand
Source: Hart Energy WRFS 2014
Gasoline Specifications Timeline Gasoline Quality Highlights
« Regular » grade (RON 90 or 91) will be gradually replaced by RON 95
« Premium » grades (> RON 95) currently offered (Kuwait, UAE, Qatar)
MTBE will be the main Octane Number enhancer after 2015
ME Gasoline Demand by Sulfur Category 3.5
(150) 3.0
ME Diesel Demand by Sulfur Category (300) 6.0
Mbpd
(250) 5.0
(Mtpy)
2.5
(200) 4.0
(100) 2.0
(150) 3.0
1.5
Mbpd (Mtpy)
(100) 2.0
(50) 1.0
(50) 1.0
0.5 0.0 0.0
2014 2014 > 500 ppm
2025 51 - 500 ppm
11 - 50 ppm
2035 < 10 ppm
2025
> 2000 ppm
500 - 2000 ppm
11 - 50 ppm
<10 ppm
2035 51 - 500 ppm
Need for high quality, low sulfur diesel and gasoline
Agenda
Market Trends Modern FCC Capabilities with Regards to the Petrochemical Industry Recent Application Case Review: SATORP Potential Further Improvements and Deeper Integration of Similar Scheme
The FCC Alliance
FCC Technology Features
Stripper packing
Prevents the loss of valuable products
Allows operation at higher ROT for same regenerator/MAB capacity
> 60 references, >30 operating
Feed injectors
Ensure proper feed distribution to maximize catalytic reactions while minimizing thermal reactions
> 100 references
FCC Technology Features
Catalyst cooler and MTC (Mix Temperature Control)
Allows operation at higher severity/coke make at full conversion vs. unit mechanical design
> 65 references for Catalyst Cooler
RS² Riser Termination Device and Vapor Quench
Ensure limited thermal degradation of products through reduction of residence time and HC outlet temperature
> 25 references for RS², 13 operating
Agenda
Market Trends Modern FCC Capabilities with Regards to the Petrochemical Industry Recent Application Case Review: SATORP Potential Further Improvements and Deeper Integration of Similar Scheme
World-class Integrated Project: SATORP Propylene, Aromatics & Fuels Production SR Naphtha Crude
U D C
Benzene Paraxylene
Aromatics Complex ParamaX™
Naphtha Naphtha
Light Naphtha, Raffinate Toluene rich cut, Heavy Aro H2
Gasoline Pool
Heavy Naphtha
Kerosene Diesel U D V
VGO
Bleed
HCK
Gasoline
HP FCC
Propylene
HCGO
Delayed Coker
LPG
Coke
Refinery : 400 000 bbl/d
Products:
FCC: 32700 bbl/d (183T/h)
Fuels: Gasoline, Kero, Diesel
Petrochemicals: Propylene, Paraxylene (700 kta), Benzene
Closing the Heat Balance: Tailor-made Solutions
Turbulent Regenerator with Swage and Air Rings HCO/Slurry recycle to Stripper or Riser Air Heater & Torch Oil injection able to operate continuously Added benefit: more valuable energy recovered from flue gas thanks to a lower acid dew point
Agenda
Market Trends Modern FCC Capabilities with Regards to the Petrochemical Industry Recent Application Case Review: SATORP Potential Further Improvements and Deeper Integration of Similar Scheme
Maximizing Distillate Production Heavy Aromatics purge recycle Improved heat balance MTC usage Improved global conversion
ZSM-5 injection Enhanced propylene production through conversion of intermediate olefins
Feed processing at Maxi Distillate optimal conditions
Co-processing of Coker HGO Improved margins
Light slurry recycle upstream feed injection Improved bottoms conversion
Potential Improvements for Similar Scheme
Increased capacity / Heavier crude
Benzene Paraxylene
Aromatics Complex ParamaX™
U D C
Heavy Aromatics purge
Gasoline Pool
Kerosene Diesel U D V
HCK HP FCC
Coker HGO Delayed Coker
Propylene
Slurry Oil Coke
Potential Opportunities for Similar Scheme
Coker HGO co-processing (10-15%) • No penalty on C3= production through severity increase • Yields interesting quantities of LCO • No impact on LCN quality • Helps improving the heat balance • Marginal impact on downstream hydrotreatment • Additional revenue could be as high as 16 MMUSD/year › C o m p a r e d w i t h c o n v e n t io n a l V G O › Price spread c ons idered: 200 USD/ton
Heavy Aromatics purge / Slurry Oil recycle • Disposal of low value cuts / Nil fuel oil production • Direct contributor to the heat balance (coke production) • Yields minor amounts of valuable products
Conclusions
More than ever, the FCC unit can hold a predominant place in the refining scheme, whichever are the production objectives Deeper integrations between refinery and petrochemical complex pave the way for further enhancements of the FCC technology oriented towards petrochemical bases production Opportunities must be seized to improve FCC operation and margins
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