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Axens, FCC
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1
Nicolas LAMBERT
Unveiling The Modern FCC in a Diesel & Petrochemical
Oriented Refinery
2
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
WRA - Abu Dhabi International Downstream, May 2015
3
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
WRA - Abu Dhabi International Downstream, May 2015
4
Middle East: Product Demand Will Be Driven By
0.04 0.10
0.49
0.13
0.72
0.28 0.35
0.67
0.0
0.5
1.0
Fuel oil Off Road Diesel
On Road Diesel Jet Kerosene
Motor Gasoline Naphtha
LPG Other*
Mbdoe
Incremental Demand
2014-2030
Other* = Kerosene ( Jet Kerosene), Refinery Gas, Ethane, Petroleum Coke, NGL, Lube oils, Bitumen, Paraffin Wax, Refinery Losses,
(25)
(50)
(Mt/y)
This region accounts for around 20% of the global demand growth
Demand growth in all categories, especially for Gasoline, Other and
on-road Diesel
WRA - Abu Dhabi International Downstream, May 2015
5
0.0
0.5
1.0
1.5
2.0
2.5
3.0
3.5
2014 2025 2035
> 500 ppm 51 - 500 ppm 11 - 50 ppm < 10 ppm
Mbpd (Mtpy)
(50)
(100)
(150)
ME Gasoline Demand by Sulfur Category
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
Source: Hart Energy WRFS 2014 ME Gasoline & Diesel Demand
0.0
1.0
2.0
3.0
4.0
5.0
6.0
2014 2025 2035
> 2000 ppm 500 - 2000 ppm 51 - 500 ppm
11 - 50 ppm
6
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
WRA - Abu Dhabi International Downstream, May 2015
7
The FCC Alliance
WRA - Abu Dhabi International Downstream, May 2015
8
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
WRA - Abu Dhabi International Downstream, May 2015
9
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
RS Riser Termination Device and Vapor Quench
Ensure limited thermal degradation of
products through reduction of residence
time and HC outlet temperature
> 25 references for RS, 13 operating
FCC Technology Features
WRA - Abu Dhabi International Downstream, May 2015
10
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
WRA - Abu Dhabi International Downstream, May 2015
11
World-class Integrated Project: SATORP Propylene, Aromatics & Fuels Production
Crude
Delayed
Coker
SR Naphtha
HCK VGO
HCGO
Naphtha
Aromatics Complex
ParamaX
Naphtha
HP FCC
Bleed
LPG
Coke
Propylene
Benzene Paraxylene
Gasoline
Pool
Gasoline
Light Naphtha, Raffinate
Toluene rich cut, Heavy Aro
Diesel
Kerosene
H2
Refinery : 400 000 bbl/d
FCC: 32700 bbl/d (183T/h)
Products:
Fuels: Gasoline, Kero, Diesel Petrochemicals: Propylene, Paraxylene (700 kta), Benzene
WRA - Abu Dhabi International Downstream, May 2015
Heavy Naphtha
VD
U
CD
U
12
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
WRA - Abu Dhabi International Downstream, May 2015
13
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
WRA - Abu Dhabi International Downstream, May 2015
14
Maximizing Distillate Production
Feed processing at Maxi
Distillate optimal conditions
ZSM-5 injection
Enhanced propylene
production through
conversion of
intermediate olefins
Light slurry recycle upstream feed
injection
Improved bottoms conversion
MTC usage
Improved global conversion
Co-processing of Coker HGO
Improved margins
Heavy Aromatics purge recycle
Improved heat balance
WRA - Abu Dhabi International Downstream, May 2015
15
Potential Improvements for Similar Scheme
WRA - Abu Dhabi International Downstream, May 2015
Delayed
Coker
HCK
Aromatics Complex
ParamaX
HP FCC
Coker HGO
Coke
Propylene
Benzene Paraxylene
Gasoline
Pool
Diesel
Kerosene
Heavy Aromatics
purge
VD
U
CD
U
Increased
capacity /
Heavier
crude
Slurry Oil
16
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
Compared with conventional VGO
Price spread considered: 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
Potential Opportunities for Similar Scheme
WRA - Abu Dhabi International Downstream, May 2015
17
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
Conclusions
WRA - Abu Dhabi International Downstream, May 2015
18
axens.net
WRA - Abu Dhabi International Downstream, May 2015
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