Nicolas Lambert, FCC Technology Manager, Axens
Transcription
Nicolas Lambert, FCC Technology Manager, Axens
Unveiling The Modern FCC in a Diesel & Petrochemical Oriented Refinery Nicolas LAMBERT 1 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 WRA - Abu Dhabi International Downstream, May 2015 2 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 WRA - Abu Dhabi International Downstream, May 2015 3 Middle East: Product Demand Will Be Driven By… Mbdoe Incremental Demand 2014-2030 (Mt/y) This region accounts for around 20% of the global demand growth (50) 1.0 0.72 (25) 0.5 0.67 0.49 Demand growth in all categories, especially for Gasoline, Other and on-road Diesel 0.35 0.28 0.0 0.04 0.10 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, … WRA - Abu Dhabi International Downstream, May 2015 4 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 2035 11 - 50 ppm < 10 ppm 2025 2035 > 2000 ppm 500 - 2000 ppm 51 - 500 ppm 11 - 50 ppm <10 ppm Need for high quality, low sulfur diesel and gasoline WRA - Abu Dhabi International Downstream, May 2015 5 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 WRA - Abu Dhabi International Downstream, May 2015 6 The FCC Alliance WRA - Abu Dhabi International Downstream, May 2015 7 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 WRA - Abu Dhabi International Downstream, May 2015 8 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 WRA - Abu Dhabi International Downstream, May 2015 9 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 WRA - Abu Dhabi International Downstream, May 2015 10 World-class Integrated Project: SATORP Propylene, Aromatics & Fuels Production Crude CDU SR Naphtha Benzene Paraxylene Aromatics Complex ParamaX™ Naphtha Naphtha Light Naphtha, Raffinate Toluene rich cut, Heavy Aro H2 Gasoline Pool Heavy Naphtha Kerosene VDU Diesel VGO HCK Bleed Gasoline HP FCC Propylene HCGO Delayed Coker Refinery : 400 000 bbl/d FCC: 32700 bbl/d (183T/h) LPG Coke Products: Fuels: Gasoline, Kero, Diesel Petrochemicals: Propylene, Paraxylene (700 kta), Benzene WRA - Abu Dhabi International Downstream, May 2015 11 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 12 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 WRA - Abu Dhabi International Downstream, May 2015 13 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 WRA - Abu Dhabi International Downstream, May 2015 14 Potential Improvements for Similar Scheme CDU Heavy Aromatics purge Gasoline Pool Kerosene Diesel VDU Increased capacity / Heavier crude Benzene Paraxylene Aromatics Complex ParamaX™ HCK HP FCC Coker HGO Delayed Coker Propylene Slurry Oil Coke WRA - Abu Dhabi International Downstream, May 2015 15 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 › 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 WRA - Abu Dhabi International Downstream, May 2015 16 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 WRA - Abu Dhabi International Downstream, May 2015 17 axens.net WRA - Abu Dhabi International Downstream, May 2015 18