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XVI Foro de Avances de la Industria de la RefinaciónJune 30 - July 1, 2010Mexico City
© 2010 UOP LLC. All rights reserved. UOP 5413-01
Robert Mehlberg, Lisa Wolschlag & Keith CouchUOP LLC, A Honeywell Company
UOP FCC Innovations Developed Using Sophisticated Engineering Tools
New Diagnostic Tools Provide New Opportunities
Deviations From Benchmark Performance Gasoline Selectivity: Conversion: Dry Gas:
World Scale FCC 200 kBSD 9 foot ID riser 300+ tonne/min catalyst circulation
How to Achieve Benchmark Performance in the Most
Economical Way?UOP 5381D-03
Tracer Data Shows 3 Regimes
14 Mar 2007 Gas Injection
0
200
400
600
800
1000
Time, seconds
Res
pons
e, c
ount
s
Riser Ex Top – Avg
Late Peak
0.0 1.0 2.0 3.0 4.0 5.0 6.0 7.0
Early Peak
Mathematical Composite of Pathologies Matches Tracer Data and Observed Yield Problems
ChannelingNormal
CompositeWall Flow
Low Conversion
High Coke and Gas
UOP 5381D-04
Scale-Up Challenges Riser Hydraulics
-0.9
-0.8
-0.7
-0.6
-0.5
-0.4
-0.3
-0.2
-0.1 0 0.1
0.2
0.3
0.4
0.5
0.6
0.7
0.8
0.9
-0.9
-0.8
-0.7
-0.6
-0.5
-0.4
-0.3
-0.2
-0.1
0
0.1
0.2
0.3
0.4
0.5
0.6
0.7
0.8
0.9
27-3024-2721-2418-2115-1812-159-126-93-60-3
lb/ft3CFD Prediction
Actual Riser Gamma Scan
Riser
2500mmAbove Feed
RegeneratedCatalyst
Standpipe
Dense Core
Vapor Annulus
Dense Core
9 ft
Vapor Annulus
UOP 5381D-05
Dual Radius Feed Distributors
6 inner distributors Tips at identical elevationPositioned to avoid adjacent spray
What did the CFD Model Indicate?UOP 5381D-06
Dual Radius FeedDistribution
Eliminates Dense Core
Looks like we have a solution
but will it work?
Dense Core impacts yields of big riser
High slip and asymmetry
impact yields of any size
riser
Density lb/ft3
UOP 5381D-07
CFD Predicts Dense Core Elimination
More symmetrical density profile Catalyst density
variation reduced by 50% Unit performance
met design targets
Successful solution to conversion problem improved confidence in CFD as a design tool
Gamma Scan Confirms Core Elimination
UOP 5381D-08
Optimix Feed Distributor Development
Optimix (ER) – Weld Overlay Tip
Previous Optimix Tip New Standard Optimix (ER) Tip
Optimix (ER) - Ceramic Tip
WeldOverlay
Ceramic Tip
PreviousTip
Optimix Feed Distributor Development
New Standard
UOP 5381D-10
Ceramic Tips Prove to be Successful
Metallic Tip Ceramic Tip
18 Months of Operation Prove Superior Performance of Ceramic Distributor Tips
UOP 5381D-11
Changes to Base Engineering Design First “dual radius” cyclone installation in a
combustor style regenerator Normal Losses 0.04 lb/bbl 0.07 at higher
velocity (caught by TSS) Uneven secondary cyclone wear after 6 years
Inner Radius Cyclone Pairs
Combustor Disengaging
Arms
Outer Radius Cyclone Pairs
Regenerator Scale-Up Creates Challenges
UOP 5381D-12
Tee Disengager DevelopmentBase Case
0.95 m/s
4-9 m/s
High Gas Velocities Re-entrained Catalyst and Overloaded Inner Cyclones
Disengager
Cyclone Inlets
Dipleg Outlets
Gas Velocity m/s
UOP 5381D-13
Elephant Trunk Improves Performance
1-3 m/s
Elephant Trunk 1.05 m/s
Velocities at the Dipleg Outlets Reduced 70-90%
Cyclone Inlets
Disengager
Dipleg Outlets
Solution applies to All Combustor SizesUOP 5381D-14
Elephant Trunk Improves Combustion Kinetics
0102030405060708090
100110
0 20 40 60 80 100Time (secs)
% V
apor
Ent
erin
g C
yclo
nes
More plug flow – Less short
circuiting– No dead zones
Residence time increased 26% Reduced afterburn
– Dense bed 1198°F– Afterburn: 8°F
Lower excess O2 = lower NOx
Elephant Trunk Disengager has Benefits for All Sized Combustors
Tee Disengager
Elephant Trunk Disengager
UOP 5381D-15
T
RegeneratedCatalystMain Air
SpentCatalyst
Dense Phase
Bubbling Bed Regenerator Layout
Spent Catalyst
Riser
Gull Wing Slots
Air Grid
Regen Catalyst Standpipe
100°F
UOP 5381D-16
Tracer Analysis to Quantify Actual Performance
Cyclone 1
Cyclone 2
Cyclone 3
Cyclone 4
Cyclone 5Cyclone 6
Cyclone 7
Cyclone 8
Cyclone 9
Cyclone 1014%12%10%8%6%4%2%0%
Gull Wing Design Caused Catalyst and Air Maldistribution
Ideal DistributionActual Distribution
+100°F
UOP 5381D-17
Gull Wing
Distributor Development
Gull WingDistributor
Piped SpentCatalyst
Distributor
Piped Distributor Provides Better Distribution with the Same Lift Air Requirement
UOP 5381D-18
Piped Distributor Improves Catalyst/Air Mixing
Gull Wing
CFD Predicted Catalyst Density ProfilesPiped Distributor
UOP 5381D-19
Tracer Results Validate Piped Distributor
14%12%
8%6%
4%2%
0%
10%Cyclone 1
Cyclone 3
Cyclone 4Cyclone 5
Cyclone 6
Cyclone 7
Cyclone 8
Cyclone 9
Piped Spent Catalyst Distributor Provides Homogeneous Flow Distribution
Ideal DistributionActual Distribution
Dilute phase ΔT: 100° 15°F Excess O2:
2% 1%
UOP 5381D-20
The ∆Coke Challenge
RxCat
“Also Wants” Retain existing
equipment Lower coke
yield Improved
regenerator performance
“Wants” Higher throughput Higher conversion Less dry gas
UOP 5381D-21
1) Heat balance neutral recycle
2) Catalyst and oil contact temp decreases
3) Riser C/O and Delta Coke increase
4) Regenerator temperature increases
5) CO promoter requirement reduces
6) Excess O2requirement reduces
More Selective
YieldsLower Emissions
RxCat™ Solution for Low Delta Coke
UOP 5381D-22
Effect of RxCat on Unit Performance
1250
1270
1290
1310
1330
ElevatedPremix
ElevatedOptimix
+ AFStripper
+ VSSRTD
+ RxCat
Reg
ener
ator
Den
se B
ed, °
F
6
8
10
12
14
16
Ris
er C
at/O
il
Regen Temp
Cat/Oil
(0) (4)
Regen S. P.Cat/Oil
Base
(1)
(2)
(3)
RxCat Technology Offers Both Increased Throughput and Product Yields
UOP 5381D-23
Refiner #1 - Americas: Apr ‘05−Regenerator temp control
Refiner #2 – Asia: Mar ‘08−Regenerator temp control
Refiner #3 – Asia: Feb ‘08− Propylene Production
Refiner #4 – Asia: Apr ‘09− Propylene Production
6 More RxCat Systems in Construction
RxCat Technology Commercialization
UOP 5381D-24
MxR Chamber Elimination
MxR Chamber
Regen Catalyst
SpentCatalyst
Challenges Revamp hydraulics and
schedule Catalyst inventory Capital cost
UOP 5381D-25
MxR Chamber Elimination
New Mixing Riser Available 4Q 2010
SpentCatalyst
Regen Catalyst
MxR Chamber
RegenCatalyst
SpentCatalyst
Low DP Internals
UOP 5381D-26
Concluding Remarks
FCC is key refinery infrastructure so continued development is vital Advanced diagnostic and design tools are accelerating
process developments and innovations UOP is delivering technological innovations
confidently, quickly and with reduced risk
These 5 innovations are commercially proven and cost effective
UOP 5381D-27