Maximize Benefits from your PRIME-G+ “the most advanced technology for FCC gasoline desulfurization”

Annick Pucci

1

Agenda

• Sulfur regulation

• Prime-G+ Commercial Update and Keys for Success

• Maximizing Prime-G+ benefits

• Quick tuning

• Advanced process control

• Improving Prime-G+ Performances • Catalytic arrangement

• Scheme modification

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Gasoline Sulfur Content in the World

3

Chile: 15ppm since 2010

EU: 10 ppm since 2009

Nationwide: 150 ppm 26 big cities at 50 ppm

to be expanded to 50 cities by 2015

Japan/ S Korea: 10 ppm since 2007

CA: 10 ppm for CARB 3 since 2008

US: Tier 3 10ppm by 2016

Source: IFQC, 2013

Gasoline S Specification Trends

4

Europe

EU 2005 Spec. 50 ppm S EU 2009 Spec. 10 ppm S

U.S / Canada

Tier 2 (2004-2006) 30 ppm S CARB 3 (California) 10 ppm S 2016 + Tier 3 10 ppm S

Japan / Korea

2007 Spec. 10 ppm S

Worldwide trends towards 10 wppm

Decrease S in cracked gasoline

while minimizing octane loss and

hydrogen consumption (Minimization of Olefin Hydrogenation & no Aromatics

Saturation & Cycle matching the FCC turnaround)

• Industrially proven with Axens Prime-G+ down to less than 10 ppm sulfur

• Prime-G+ the most widely used FCC gasoline HDS technology

FCC gasoline postreatment challenges

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Agenda

• Sulfur regulation

• Prime-G+ Commercial Update and Keys for Success

• Maximizing Prime-G+ benefits

• Quick tuning

• Advanced process control

• Improving Prime-G+ performances • Catalytic arrangement

• Scheme modification

6

Splitter

HCN

H2 Make-up

From FCC

Selective

Hydrogenation

Ultra Low S LCN to

Pool, TAME or Alky Unit

Ultra-Low Sulfur

Gasoline

LCN

SHU section

Splitter section

HDS section

Large majority of Prime-G+ references with a splitter

Prime-G+ typical block flow

Prime-G+ Selective

HDS

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Some Keys for Prime-G+ Success

• Performance • Catalytic performances ( activity / selectivity / stability)

• Process economics ( low CAPEX & OPEX – large revamp experience)

• Flexible technology

• Non regret investment

• Reliability

• fixed bed reactors – familiar to operators

• Easy control of product sulfur

• Single Source Supplier • R&D, Process Design, Catalyst, Start-up, Service such as…..

Training, Advanced Process Control, User’s conferences, Catalyst Management

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Catalytic

performances

Keys for Prime-G+ Success

Process

economics

Process

flexibility

Maximizing Benefits

Improving performances

9

Catalytic Performances

• Tailored, unrivaled Catalysts for octane retention and long cycle length • SHU Catalyst: Dienes and RSH removal

• Lead HDS Catalyst: Bulk HDS / controlled olefin saturation

• Polishing HDS Catalyst: Remaining HDS / RSH control / almost no olefin

saturation

• Arsenic trapping mass : for HDS catalyst protection against poisoning

• Reliability • 100 % of Guarantees Met

• Synchronization of Cycle length with FCC turnaround

• Catalyst Replacement Market

• 7 competition units went for Axens catalysts

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• Mercaptans Removal

• Doctor Test Negative

• Slight Octane Boost

LCN (65°C-) S = 10 ppm RSH < 2 ppm

H2

FRCN S = 2100 ppm RSH = 100 ppm

Industrial SHU performance

SHU Feed SHU Product

RON 94.0 94.3

MON 82.0 82.2

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Prime-G+ HDS Unit performance

0

100

200

300

400

500

600

700

0 250 500 750 1000 1250 1500 1750

days on stream

0

10

20

30

40

50

60

70

Feed Sulfur, wtppm Product Sulfur, wtppm

5.75 years cycle length at less than 10 ppm S 12

Catalytic

performances

Keys for Prime-G+ Success

Process

economics

Process

flexibility

Maximizing Benefits

Improving performances

13

Prime-G+ wide Design Range

Licensed Units - Design Range

• Unit Capacity: 2,500 - 115,000 BPD

• Feed Sulfur: 30 - 4,100 ppm

• Olefins Content: 9 - 45 vol. %

• Feeds: FCC Naphtha, Coker Naphtha, LSR, Heavy PyGas

• Product S < 10 ppm

• Cycle equivalent to FCC T/A demonstrated

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Very High HDS PG+ 1st Step / 2-Stage HDS

PG+ 1st Step = Prime-G+ Selective Hydrogenation Unit (SHU) + Splitter

FCC

FRN

HDT

1&2

SHU LSG

LN

Prime-G+ Processing Schemes

FCC

FRN HDT SHU

LSG

Low / Moderate HDS 1-Stage HDS

Moderate / High HDS PG+ 1st Step / 1-Stage HDS

2-Stage HDS

FCC

FRN

HDT

SHU LSG

LN

FCC

FRN HDT

1&2 SHU

LSG

<10 ppm S achievement Staged investment 15

Catalytic

performances

Keys for Prime-G+ Success

Process

economics

Process

flexibility

Maximizing Benefits

Improving performances

16

Process Economics

• Low CAPEX

• Simple scheme & fixed bed reactors

• Low OPEX

• Low hydrogen consumption

• Large revamping experience • Reuse of existing idle equipment (Gasoline

splitter, HDT reactors…)

• Retrofit of idle units (NHDT , DHDT, Isomerization units, Semi-reg reformers…)

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Catalytic

performances

Keys for Prime-G+ Success

Process

economics

Process

flexibility

Maximizing Benefits

Improving performances

18

Maximize benefit by quick tuning

• After start-up • Operating feed is often different from design • Feed properties are fluctuating a lot • Product S specification often needs to be modified based

on market demand or gasoline pool optimization

Prime-G+ can accommodate Major parameters to be optimized

• For Performances adjustment • SHU & HDS Catalysts Temperature • LCN yield

• For energy minimization • Splitter Reflux Ratio minimization • HDS Quench & Heater optimization

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Operational Fine Tuning: Splitter Reflux Ratio Minimization

From

SHU

HCN

To HDS

section

LCN

• Splitter reflux is fixed at basic engineering phase as a result of • LCN/HCN separation quality

• Design feed

• sulfur in LCN

• Depending on actual processed feed and gasoline pool constraints, reflux and LCN draw may be slightly adjusted

S

• Main benefits • On-spec LCN thus resulting in minimum

octane loss in downstream HDS

• HP Steam / fuel gas savings in reboiler

• Electricity / cooling water savings in overhead condensers

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Advantages of APC

Fine tuning is neglected too often!

• To secure pool in case of high fluctuation of feed quality or product spec • Over-quality S is systematically targeted More octane loss

• APC only capable to control gasoline Pool S without S over-quality in Prime-G+ • As Licensor, Axens is in a unique position to boost

your Prime-G+ performance by using proprietary models for APC

• APC benefits are quickly quantifiable

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Sulfur

Average = 10.08632

StDev = 0.44321

4 4.5 5 5.5 6 6.5 7 7.5 8 8.5 9 9.5 10 10.5 11 11.5 12 12.5 13 13.5 14 14.5 15 15.5 16

Sulfur Distribution with & without APC

Product Sulfur Content

+ 1.2 ppm

Average without

APC

Target Value

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Splitter

HCN

H2 Make-up

From FCC

Selective

Hydrogenation

LCN

APC Strategy

Prime-G+ Selective

HDS

Blend

Controlled Diolefin

Hydrogenation Cut-point

optimization and internal

reflux control

Sulfur Control

Maximization of Octane Retention

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0 7 14 21 28

APC Startup – Industrial Plant

Hours

APC OFF TUNING APC ON

MON Loss: -20% MON

Loss

Product Sulfur

On Spec +/- 0.5ppm

H2 Make-up

HDS Temp

H2 Make-up -20%

WABT -3°C

Minimize OPEX

Maximize Run-length

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Prime-G+ APC : Why Work With Axens ?

• Prime-G+ is not a simple HDS process

• APC is not only Sulfur Control, but also • Octane Loss minimization • Run Length maximization • Energy Consumption minimization.

• To minimize Octane Loss, it is mandatory to use HDS inference based on Kinetic model

• Axens is in a unique position to offer you the best APC strategy

R.O.I. typically below 6 months 25

Prime G+ Users’ Conference

• Technical Conference

• Exclusively reserved for licensees

• Forum of Exchange

• Best practices and operational issues

• Good Feedback from Past Conferences

• 7 conferences already organized.

the 8th conference is scheduled in 2014

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Catalytic

performances

Keys for Prime-G+ Success

Process

economics

Process

flexibility

Maximizing Benefits

Improving performances

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Client Needs After 1st start-up Market demand is evolving, more frequent needs • Capacity increase

• Processing of higher end boiling point gasoline • Co-processing of more refractory / alternative

feeds • Progressive implementation of tighter sulfur

specifications in gasoline pool • Requirement for

• increased octane retention • increased cycle length • reduced utility consumption

With minimum investment cost 28

Improved Performances After 1st Start-Up

• Low Cost Options • Use latest generation catalyst • Use new reactor internals • Rearrangement of catalytic volume

• Medium/High CAPEX options • Scheme modifications

• Adding a gasoline splitter • Adding additional reactors • Adding a second HDS stage

• Energy efficiency : Heat integration • Rearrangement of HX train

Maximum reuse of existing equipment 29

Improved Performances : Low cost solutions

• Increased octane retention

Higher selectivity catalyst

• Increased cycle length

Higher activity/stability catalyst

Unrivalled tailored Prime-G+ catalysts

HR 845 HR 841 HR 806

PG+ SHU PG+ Main HDS PG+ Polishing

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Axens R&D strategy

Catalyst formulation

Lab scale screening

Industrial process

Reactor internals

Process development

Operating conditions

Axens is committed to continuously improve its

existing products 31

Prime-G+ Catalyst Management

• Perform analysis of spent catalyst for Recovery of maximum value from spent catalyst (regenerability diagnostics vs level of contaminants)

• Optimization of the catalyst loading for achievement of required performance at minimum refill cost

• Access to the Pool of Axens Regenerated Catalysts

• New internals

Regenerated (Axens)

Regenerated (Client)

Fresh

(Axens)

Optimized Loading Diagram

Optimize customer revenue through catalyst life cycle

Simplify & ease catalyst change out activities 32

0%

10%

20%

30%

40%

50%

60%

70%

80%

90%

100%

0 200 400 600 800 1000

Days

DT

pro

gre

ssio

n

TC1-1 % TC1-2 % TC1-3 % TC1-4 % TC1-5 % TC00 % TC2-1 % TC2-2 % TC2-3 % TC2-4 %

Case Study : Hy Mix Improved Distribution

Conventional Distributor

Abnormal DT progression

Hy-Mix Tray + Dense Loading

Smoother operation

After Hy-Mix: Ideal profile maximize catalyst activity & stability

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Easy to implement & moderate capital expenditure

Single stage HDS section with SHU

Low Sulfur

Gasoline to Mogas

Mild HDS

Prime-G+ Scheme Modifications

H2 Make-up

FRCN

HDS SHU

STARTING SITUATION

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Low Sulfur Gasoline to Mogas

Intermediate HDS

H2 Make-up

FRCN

HDS

Add a Splitter

Prime-G+ 1st Step

HCN 65°C+

ULS LCN to Pool, TAME or Alky Unit

Split

ter

SHU Polishing HDS

Add a Polishing HDS reactor

Moderate revamp cost for : Tighter S , Longer cycle , Lower octane loss

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HCN 65°C+

FRCN

Split

ter

SHU HDS

H2 Make-up

2nd Stage HDS

ULS Gasoline to Mogas

H2S

ULS LCN to Pool, TAME or Alky Unit

1st Stage HDS

Minimum product sulfur Optimize cycle, minimize octane loss & H2 cons.

2-stage Prime G+ High HDS

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Splitter

H2 Make-

up

FRCN

Prime-G+

SHU

Ultra Low S

FRCN

High

Purity

Ether

MeOH

Regain octane with Prime-G+ & TAME

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25% Olefin reduction & 0.1 bar RVP reduction

Prime-G+ HDS

TAME

Process Scheme Modifications: Energy Efficiency

Process scheme selection is not only based on performances but more frequently on environmental

and utility criteria

• Improvement of the unit by thermal integration by addition of exchangers

• AXENS can provide expected CO2 footprint of the installed scheme by estimating emissions associated to each utility

• Axens can propose key modifications of your Prime-G+ in order in order to reduce CO2 emissions

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Conclusion (1/2)

• PRIME-G+ leading technology For selective HDS of FCC gasoline • 214 references /148 running units: 100% guarantees met • Benefits of

• Flexible and reliable technology • large revamping experience • Long run length at <10 ppm S • Reduced octane loss

• Unrivalled Products

• Benchmark catalysts: HR 845/ HR 806/ HR 841 • Proven ACT-979 arsenic guard • New products to come

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Conclusion (2/2)

Revamp scenario ranking

Skills (Technology Licensor + Catalyst Supplier)

Catalyst management

Best strategy for APC

Ensure the success / Improve your performance

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