NEKTOR-4G

ACHIEVE®-100

Commercial Examples from Western European Refinerie s

NEKTOR-4G: Introduction

� NEKTOR-4G Technology

� Refinery Information

� Catalyst Reformulation Objective

� NEKTOR-4G: E-Cat Analysis

� NEKTOR-4G: Unit Data

2

� NEKTOR-4G: FCC SIM Analysis

� Conclusion

NEKTOR-4G

NEKTOR-4G incorporates Advanced Metals Tolerance an d Flexible Hydrogen Transfer

Higher DiffusivityMatrices

Flexible

3

Click to edit text styles

Flexible HydrogenTransfer

HigherActivity

Advanced MetalsTolerance

Dual ZeoliteTechnology

NEKTOR-4G: Refinery Information

� Western European Refinery� Processes >200,000 barrels per day

� UOP design� Throughput >8,000 m3/day

� Processes ca. 25% atmospheric resid

� Unit targets � Max resid processing

4

� Max resid processing

� Min slurry

� Max LPG olefins

NEKTOR-4G: Catalyst Reformulation Objectives

� Catalyst reformulation took place in 2014� NEKTOR-ULCC � NEKTOR-4G

� Objectives were� Allow increase resid processing by relieving the regenerator T constraint

� Maintaining unit conversion

� Main catalyst properties required were

5

� Low delta coke

� Coke selective bottoms cracking

NEKTOR-4G: E-cat Analysis

� Coke selective bottoms cracking improved with NEKTOR-4G

� Intrinsic bottoms cracking activity unchanged

10

11

12

slur

ry y

ield

(w

t%)

bottoms to coke

10

11

12

slur

ry y

ield

(w

t%)

slurry vs. conversion

6

6

7

8

9

4.0

4.5

5.0

5.5

6.0

6.5

slur

ry y

ield

(w

t%)

coke yield (wt%)

NEKTOR-ULCC NEKTOR-4G

6

7

8

9

66 68 70 72 74 76 78

slur

ry y

ield

(w

t%)

conversion(wt%)

NEKTOR-ULCC NEKTOR-4G

NEKTOR-4G: E-cat Analysis

� NEKTOR-4G resulted in lower delta coke

0.80

0.85

0.90

0.95

1.00

delta

cok

e (w

t%)

delta coke vs. conversion

0.80

0.85

0.90

0.95

1.00

delta

cok

e (w

t%)

delta coke vs. (Ni+V/4-0.4/0.33*Sb)

7

0.60

0.65

0.70

0.75

0.80

66 68 70 72 74 76 78

delta

cok

e (w

t%)

conversion(wt%)

NEKTOR-ULCC NEKTOR-4G

0.60

0.65

0.70

0.75

0.80

2,50

0

2,70

0

2,90

0

3,10

0

3,30

0

3,50

0

3,70

0

3,90

0

4,10

0

4,30

0

delta

cok

e (w

t%)

(Ni+V/4-0.4/0.33*Sb) [mg/kg]

NEKTOR-ULCC NEKTOR-4G

70

72

74

76

78

Con

vers

ion

(wt%

)

E-cat Activity (wt%)

NEKTOR-4G: E-cat Analysis

� Similar e-cat activity

8

66

68

22/1

1/13

11/0

1/14

02/0

3/14

21/0

4/14

10/0

6/14

30/0

7/14

18/0

9/14

07/1

1/14

27/1

2/14

15/0

2/15

06/0

4/15

Con

vers

ion

(wt%

)

NEKTOR-ULCC NEKTOR-4G

NEKTOR-4G: E-cat Analysis

� E-cat activity was achieved at lower UCS for NEKTOR-4G� compensated by higher surface area

� Lower UCS reduces H-transfer reactions and drives towardslower delta coke

24.33

24.34

24.35

UCS [A]

120

125

130

SA [m2/g]

9

24.26

24.27

24.28

24.29

24.30

24.31

24.32

24.33

22/1

1/13

11/0

1/14

02/0

3/14

21/0

4/14

10/0

6/14

30/0

7/14

18/0

9/14

07/1

1/14

27/1

2/14

15/0

2/15

06/0

4/15

NEKTOR-ULCC NEKTOR-4G

90

95

100

105

110

115

120

22/1

1/13

11/0

1/14

02/0

3/14

21/0

4/14

10/0

6/14

30/0

7/14

18/0

9/14

07/1

1/14

27/1

2/14

15/0

2/15

06/0

4/15

NEKTOR-ULCC NEKTOR-4G

NEKTOR-4G: FCC Unit Data – FCC SIM Analysis

NEKTOR-ULCC ���� NEKTOR-4G

�Average calibration factors generated by FCC SIM on NEKTOR-4G test runs

� These average calibration factors were used in the predicti on� i.e. what NEKTOR-4G would have given with the feed and unit conditions

during the NEKTOR-ULCC catalyst periodNEKTOR-ULCC ConditionsNEKTOR-4G Calibration

10

� 1.7 wt% higher conversion with NEKTOR-4G

�ZSM-5 content lower for NEKTOR-4G

� 9 °C lower regenerator dense bed temperature with NEKTOR-4G

STD conversion 1.7 wt%STD slurry -1.2 wt%STD LCO -0.5 wt%STD gasoline 2.3 wt%LPG -0.3 wt%MAT 0.0 wt%CAR 0.2 MT/dayRgT -8.7 Ccat/oil 0.2 wt/wt

ave P2O5 content -0.12 wt%

NEKTOR-4G Calibration DELTA

E-cat Data

NEKTOR-4G: Conclusions

� The reformulation from NEKTOR-ULCC to NEKTOR-4Gresulted in:� lower regenerator temperature� lower delta coke catalyst

� increased unit conversion

� The catalyst reformulation objective was successful� NEKTOR-4G improved unit operating flexibility by allowing more resid

11

� NEKTOR-4G improved unit operating flexibility by allowing more residto be processed if required

ACHIEVE®-100: Introduction

� ACHIEVE® Catalysts

� Refinery Information

� Catalyst Reformulation Objective

� Catalyst Change-out Monitoring

� ACE Pilot Plant Study

12

� ACHIEVE®-100: E-Cat Analysis

� ACHIEVE®-100: Unit Operating Data

� ACHIEVE®-100: FCC SIM Performance Evaluation

� Conclusion

ACHIEVE®

ACHIEVE® first launched to address challenges in the USA resulting from shale/tight oil cracking

� Breakthrough technology, ACHIEVE® 400 boosts FCC naphtha octane and butylene yielding economic uplift ~$3-5M/yr

Expanding platform series for new market challenges

� ACHIEVE® 100 – High activity for light feedstocks

� ACHIEVE® 200 – Coke-selective bottoms conversion

13

� ACHIEVE® 200 – Coke-selective bottoms conversion

� ACHIEVE® 300 – Octane and propylene selectivity

� ACHIEVE® 400 – Octane and butylene selectivity

� ACHIEVE® 800 – Maximum metals tolerance and resid conversion

Tailor Made Catalyst Formulas Allow You to ACHIEVE ® the Advantage

ACHIEVE®-100: Refinery Information

� United Kingdom Refinery� UOP design

� Mainly VGO feed

� Unit operating targets� Max conversion

� Min slurry

� Max LPG olefins

14

ACHIEVE®-100: Catalyst Reformulation Objective

� Catalyst reformulation took place in 2014

� Objectives were� Increase unit conversion

� Decrease slurry yield

� Allow FCC to run at max throughput

� Main catalyst properties required were

15

� Intrinsic activity

� Slurry cracking� Matrix activity

� ACHIEVE®-100 was selected after ACE pilot plant testing

ACHIEVE®-100: ACE Pilot Plant Study

ACE pilot plant testing predicted the following con version and yield shifts on moving from the BASE catalyst to ACHIEVE ®-100:

BASE ACHIEVE-100 Delta

Standard Conversion [wt.% ff] 65.3 66.5 1.2

16

Standard Conversion [wt.% ff] 65.3 66.5 1.2

Standard LCO (221-338°C) [wt.% ff] 20.9 21.1 0.2

Standard Slurry (>338°C) [wt.% ff] 13.8 12.4 -1.4

Coke [wt.% ff] ---3.4--- ---3.4--- 0.0

Coke On Catalyst [wt.%] 0.69 0.60 -0.09

ACHIEVE®-100: E-cat Analysis

� Main catalyst deactivating metals show only minor v ariations

100

200

300

400Normalised V (ppm)

0.01

0.02

0.03Normalised Na (wt%)

17

-400

-300

-200

-100

0

02/0

3/14

21/0

4/14

10/0

6/14

30/0

7/14

18/0

9/14

07/1

1/14

27/1

2/14

15/0

2/15

06/0

4/15

BASE ACHIEVE-100

-0.03

-0.02

-0.01

0.00

02/0

3/14

21/0

4/14

10/0

6/14

30/0

7/14

18/0

9/14

07/1

1/14

27/1

2/14

15/0

2/15

06/0

4/15

BASE ACHIEVE-100

ACHIEVE®-100: E-cat Analysis

� Total surface area remained relatively unchanged

� Matrix surface area increased accordingly for ACHIE VE®-100

140

150

160

170

180Surface Area (m2/g)

25

30

35

40

45Matrix Surface Area (m2/g)

18

100

110

120

130

140

02/0

3/14

21/0

4/14

10/0

6/14

30/0

7/14

18/0

9/14

07/1

1/14

27/1

2/14

15/0

2/15

06/0

4/15

BASE ACHIEVE-100

0

5

10

15

20

25

02/0

3/14

21/0

4/14

10/0

6/14

30/0

7/14

18/0

9/14

07/1

1/14

27/1

2/14

15/0

2/15

06/0

4/15

BASE ACHIEVE-100

ACHIEVE®-100: E-cat Analysis

� E-cat activity was maintained with ACHIEVE ®-100� Catalyst addition rates were similar for both catalysts

73

74

75

76

77

78ACE E-cat Activity wt%

1

2

3

4Normalised CAR (MT/day)

19

68

69

70

71

72

73

02/0

3/14

21/0

4/14

10/0

6/14

30/0

7/14

18/0

9/14

07/1

1/14

27/1

2/14

15/0

2/15

06/0

4/15

BASE ACHIEVE-100

-4

-3

-2

-1

0

02/0

3/14

21/0

4/14

10/0

6/14

30/0

7/14

18/0

9/14

07/1

1/14

27/1

2/14

15/0

2/15

06/0

4/15

ACHIEVE®-100: E-cat Analysis

� Intrinsic slurry cracking improved with ACHIEVE ®-100

8.0

8.5

9.0

9.5

Slu

rry

w

t%

0.3 – 0.5 wt% slurry yield reduction

20

6.0

6.5

7.0

7.5

72 73 73 74 74 75 75 76 76 77 77 78

Slu

rry

w

t%

Conversion wt%

BASE ACHIEVE-100

ACHIEVE®-100: E-cat Analysis

CONSTANT COKE

� Conversion equivalent at constant coke with ACHIEVE ®-100

� Improved slurry cracking with ACHIEVE ®-100

8.5

9.0

9.5

76

77

78

Co

nve

rsio

n

wt%

21

6.0

6.5

7.0

7.5

8.0

3.5

4.0

4.5

5.0

5.5

6.0

Slu

rry

w

t%

Coke Yield wt%

BASE ACHIEVE-100

72

73

74

75

76

3.5

4.0

4.5

5.0

5.5

6.0

Co

nve

rsio

n

wt%

Coke Yield wt%

BASE ACHIEVE-100

ACHIEVE®-100: Unit Operating Data

� Large fluctuations in feed density and feed basic nitrogen

0.928

0.930

0.932

0.934

0.936

0.938

Specific Gravity @ 60/60

0.06

0.07

0.08

Basic Nitrogen (wt%)

22

0.918

0.920

0.922

0.924

0.926

02/03/14

21/04/14

10/06/14

30/07/14

18/09/14

07/11/14

27/12/14

15/02/15

BASE Period ACHIEVE-100 Period

0.03

0.04

0.05

02/03/14

21/04/14

10/06/14

30/07/14

18/09/14

07/11/14

27/12/14

15/02/15

BASE Period ACHIEVE-100 Period

ACHIEVE®-100: Unit Operating Data

� ROT was used to control cracking severity and compensatefor the changes in feed quality

540

545

550

Riser Oulet T (°C)

23

525

530

535

02/03/14

21/04/14

10/06/14

30/07/14

18/09/14

07/11/14

27/12/14

15/02/15

BASE Period ACHIEVE Period

ACHIEVE®-100: Unit Operating Data

� No change in dry gas yield at same ROT as expected

� No change in hydrogen yield for a given e-cat Ni level

2.0

2.5

3.0

3.5

Dry

Gas

(w

t%)

Dry Gas vs. ROT

0.04

0.05

0.06

0.07

Hyd

roge

n (

wt%

)

Hydrogen vs E-cat Ni

24

0.0

0.5

1.0

1.5

528

530

532

534

536

538

540

542

544

546

548

Dry

Gas

(w

t%)

ROT (°C)

BASE ACHIEVE-100

0.00

0.01

0.02

0.03

-150

-100

-50

0 50 100

150

Hyd

roge

n (

wt%

)

Normalised E-cat Ni (ppm)

BASE ACHIEVE-100

ACHIEVE®-100: Unit Operating Data

� 1-2 wt% higher conversion for ACHIEVE ®-100 at constant feeddensity and feed basic nitrogen

0

2

4

6

8

wt %

Normalised Std Conversion vs. Feed Density

0

2

4

6

8

wt %

Normalised Std Conversion vs. Feed Basic Nitrogen

25

� Ultimately a direct comparison of both periods was difficul tdue to the changing feed quality and unit operating conditio ns� FCC SIM model was utilised to compare catalyst performance

-6

-4

-2

0.914

0.916

0.918

0.920

0.922

0.924

0.926

0.928

0.930

Feed Density (g/cm3)

BASE ACHIEVE-100

-6

-4

-2

0.035

0.040

0.045

0.050

0.055

0.060

0.065

Feed Basic Nitrogen (wt%)

BASE ACHIEVE-100

ACHIEVE®-100: FCC SIM Performance Evaluation

BASE ���� ACHIEVE®-100

�Average calibration factors generated by FCC SIM onACHIEVE®-100 test runs

� These average calibration factors were used in the crossprediction as a means of direct comparison of the catalysts� i.e. what ACHIEVE®-100 would have given with the feed and unit

conditions during the BASE catalyst periodBASE Conditions

26

BASE ConditionsACHIEVE-100 Calibration Factors

Delta

Conversion wt% 1.3Slurry wt% -0.6LCO wt% -0.7LPG wt% 0.8Gasoline wt% 0.4C4= wt% 0.4C3= wt% 0.2MAT wt% -0.2CAR MT/day 0.0RgT °C -3.3Cat/Oil wt/wt 0.3

� 1.3 wt% higher conversion with ACHIEVE ®-100

� 0.6 wt% lower slurry with ACHIEVE ®-100

LPG and Gasoline Yield Analysis difficult due to multiple changes in ZSM-5 additive additions.

ACHIEVE®-100: Conclusion

� ACHIEVE-100 helped refinery meets its objectives� Increase unit conversion

� Decrease slurry yield

� Allow FCC to run at max throughput

� No hydrogen / dry gas penalty observed

� Max FCC throughout could be maintained irrespective of

27

� Max FCC throughout could be maintained irrespective of worsening feed quality

� Significant improvement to the FCCU economic perfor mance was achieved

� Refinery is now using ACHIEVE-100 on a permanent ba sis

QUESTIONS?