CatCracking SeminargDüsseldorf, October 17-21, 2011

Online, Non-intrusive Trouble Shooting and Process Characterization of FCCU's using Gamma Ray and Tracer Technology

Presented by:Lee Robins and Andrew Shaw

Presentation Format

Introduction to Tracerco Process Diagnostics™ The Technology

Applications of the Technology for FCC Diagnostics pp gy g

Case Studies

Conclusion and Questions Conclusion and Questions

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Tracerco, who are we?

Tracerco: Part of Johnson Matthey Plc …leaders in environmental catalytic solutions, preciousin environmental catalytic solutions, precious metals and process technology

• Founded in London almost 200 years ago• Publicly listed FTSE 100 Company• Turnover excess $10bn • 10,000 employees in 50 countries

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Tracerco – Markets Served

Upstream Oil & Gas - Reservoir to Refinery

• Separator Studies• Flow Assurance• Pig Tracking

I t it A t

Downstream Industry – Refineries to Polymers

• Integrity Assessment• Flow Rate Studies

y y• Distillation Column Studies• Reactor system trouble shooting & vessel inspection• Heat Exchanger Leak TestHeat Exchanger Leak Test• FCC Unit Studies• Flow Assurance• Integrity Assessment

Pi li A• Pipeline Assurance

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The CompanyTracerco – Global Support

World leading technology specialists in radioisotope technology,

chemical tracers, measurement & instrumentation

R&D Centre at HQ plus science institutes worldwide

350+ qualified scientists, engineers and technologists

Winner Queen’s Award for Enterprise: Innovation 2003 and 2009

Winner Queen’s Award for Enterprise: International Trade 2005

ISO 9001:2000 certified

HQ - Billingham, UK, Aberdeen (Scotland)Argentina – Buenos Aires

ISO 9001:2000 certified

SCC 2006 certified

Australia – PerthAzerbaijan – BakuBrazil – Rio de JaneiroBelgium – BrusselsCanada – Sarnia, ON; Edmonton, ABGermany – OldenburgGermany OldenburgIndonesia – JakartaItaly – Vaprio d’Adda (MI)Malaysia – Kuala LumpurNetherlands – RotterdamNorway – BergenSingaporeThailand – BangkokUSA – Pasadena, TX; Corpus Christi, TX; Fresno, CA; West Valley City, UT; Merrillville, IN; Newark, DE; Baton Rouge, LA

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The Technology

P id di ti i t h l t i d i li t

Pioneers in radioisotope science…• Provide diagnostic scanning technology, tracer services, and specialist

nucleonic instrumentation to the Oil, Gas and Process Industries to enhance process plant performance

• Experts at seeing inside process plant to verify real time process conditions andExperts at seeing inside process plant to verify real time process conditions and equipment integrity - Online and non-intrusive : Insight Onsite

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The Technology – Gamma Ray Scan

• Gamma Scanning using sources and detectors to non-intrusively scan through vessels and pipelines to obtain accurate density/

I = IO e -μρxintegrity measurements

O

ρ

IO Iρ

GAMMA RAY μGAMMA RAY μ

x7

The Technology – Tracer Injection

• Tracer Injection using Unsealed Isotopes for tracking the different phases present in a particular process

• Gas, liquid, or solid form (individually measure hydrocarbon, steam and catalyst)• Follows process material into which it is injected

M it d b t ll t d d t t

Condition 1 HP Flare Normal Purge

• Monitored by externally mounted detectors• Process parameters can be measured

Condition 1 - HP Flare Normal Purge

8001000120014001600

Res

pons

e

Applications:• Flow Rate Measurements• Distribution Studies• Residence Times

0200400600800

0 2 4 6 8 10 12 14 16 18 21 23 25 27 29 31 33 35 37 39 41

Time after Initial Injection (seconds)

Det

ecto

r R • Residence Times• Leak Detection / Bypassing• Carryover• FCCU Efficiency Studies

Run 1 Run 2 Run 3

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Applications of the Technology – FCCU’s

Improving profitability, increasing yields and reducing downtime are all key parameters for any FCCU. Tracerco Diagnostic Solutions

th l t h i il bl t ff ti l ‘l k i id ’ kiare the only techniques available to effectively ‘look inside’ a working FCCU to accurately measure:

·feed and catalyst distribution in the riser feedfeed and catalyst distribution in the riser feed zone

·catalyst and vapour traffic velocities and slip through the riser

·determination of efficiency of the riser termination device

·flow distribution through the reactor and stripper

·cyclone distribution/operating characteristics

·reactor/stripper residence times

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Applications of the Technology – FCCU’s

Technology used in 5 keysections of FCC unit:• Riser

Di t Ch b• Disengagement Chamber• Stripper• RegeneratorRegenerator• Stand-pipe

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Applications of the Technology – FCCU’s

• When is the technology used?When is the technology used?• Trouble-shooting exercises

• Fast responsep• Process optimisation trials

• Immediate results• Pre-shutdown investigations

• No effect on processC i i i t i l• Commissioning trials

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Applications of the Technology – FCCU’s

BenefitsBenefits• Minimise shut down time• Increase production capacityp p y• Reduce operating costs

• Minimise raw materials• Reduce utilities• Identify catalyst losses

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Applications – Riser Study

C t l t D it P fil• Catalyst Density Profile• Coke Deposits• Velocity slip ratios• Velocity - slip ratios• Residence times• Distribution of feed, ,

steam & catalyst

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Applications – Cyclones and Disengagement Chamber

R id ti• Residence times• Distribution• Cyclone blockages• Cyclone blockages• Cyclone efficiency• Vapour underflowp• Carryover

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Applications – Stripper Section

R id ti• Residence times• Velocities• Distribution• Distribution• Steam underflow• Catalyst Bed y

Level• Dip-Leg Catalyst

L lLevels

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Applications – Regenerator and Stand Pipe

Ai di t ib ti• Air distribution • Cyclone efficiency• Catalyst distribution• Catalyst distribution• Carryover

• Stratification of catalyst• Slugginggg g• Catalyst Flow Patterns• Catalyst Density Profiles

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CFD vs Real time data

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Case Studies – Regenerator Bed Level Scans

Th diff t ti• Three different operatinglevels of the Regenerator

• Gamma Scan at each condition to optimize the bed level and reducebed level and reduce catalyst carryover.

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1000 10000

Case Studies – Scan of Internal Cyclones to locate Blocked Cyclone

2’

4’

Exte

0’

6’

8’

10’

rnal Lining0

12’

14’

16’

18’

20’

Plugged Cyclone Dipleg

Bracing

22’

24’

26’

Flapper Valve

Manway

26

28’

30’

Catalyst

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Case Studies – Scan of Internal Cyclones to locate Blocked Cyclone – example 2

• Cyclone A was blocked.

TRACERCO Diagnostics FCCU StudyCyclone Scan

Cyclone A was blocked. • The blockage

commenced at elevation 500mm, in the narrow ,part of the cyclone, but the catalyst had backed up to elevation 6300mm.

• Above elevation 6300mm, the blockage cleared and the scan profile from that point upwards is identical to that of Cyclone B.

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Case Studies – Catalyst Distribution in Riser

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Case Studies (Tracer) - RTD Maldistribution

TRACERCO Diagnostics FCCU StudyRTD Vapour Inlet Distributionp

200

250

150

atio

n In

tens

ity

Pick-up fromOverheads Line

50

100

Rad

ia

040 42 44 46 48 50 52 54 56 58 60

Time (seconds)

RTD1 Inlet RTD2 Inlet RTD3 Inlet

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Case Studies (Tracer) – Vapour Underflow

TRACERCO Diagnostics FCCU StudyRTD Dip-leg Vapour Distributionp g p

30

35

300

350Vapour Returning up

Disengagement Chamberwith Stripping Steam

Pick-up fromOverheads Line

15

20

25

atio

n In

tens

ity

150

200

250

5

10

15

Radi

a

50

100

150

Vapour UnderflowResponse

040 60 80 100 120 140 160 180

Time (seconds)

0

RTD1 Dipleg Top RTD2 Dipleg Top RTD3 Dipleg Top Overheads 2 (2nd Y-axis)

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Case Studies (Tracer) – Cyclone Blockage

Results from distribution study

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Case Studies (Tracer) – Stripper Maldistribution

Gross maldistribution East/West maldistribution

East side maldistributionEast side maldistribution

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Case Studies – Stripper Upgrade

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Case Studies (Tracer) – Stripper Maldistribution

TRACERCO Diagnostics FCCU StudyStripping Steam Distribution

B f

1000

1200Before

600

800

diat

ion

Inte

nsity

200

400

Rad

030 32 34 36 38 40 42 44 46 48 50

Time (seconds)

Stripper Top N Stripper Top E Stripper Top S Stripper Top W

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Case Studies (Tracer) – Stripper Maldistribution

TRACERCO Diagnostics FCCU StudyStripper Steam Distribution - Top

Aft

160

180

200

6400

7200

8000After

80

100

120

140

iatio

n In

tens

ity

3200

4000

4800

5600

20

40

60

80

Radi

800

1600

2400

3200

025 35 45 55 65 75

Time (seconds)

0

Stripper Top N Stripper Top E Stripper Top S Stripper Top W Strip Steam In

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Case Studies – Effectiveness of Equipment Upgrades (e.g. RTD’s)

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Case Studies (Tracer) – Vapour Maldistribution in Dip Legs

Vapour Distribution in RTD Dip-Legs

160 40

100

120

140

ty 25

30

35

60

80

100

Rad

iatio

n In

tens

i

15

20

25

0

20

40

0

5

10

030 35 40 45 50 55 60 65 70 75 80

Time (seconds)

0

Riser 1 Dip-Leg Bot N Dip Leg Bot S

Detector DistributionDi L B tt N th 40%

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Dip-Leg Bottom North 40%Dip Leg Bottom South 60%

Case Studies (Tracer) – Vapour Distribution Above Air Grids

FCC Regenerator Air Grid DistributionLower Air Grid Injection

Position Percent Area

Air 1 14 4%Air 1 14.4%Air 2 13.4%Air 3 4.0%Air 4 6.0%Air 5 10.5%Ai 6 5 3%Air 6 5.3%Air 7 7.4%Air 8 10.6%Air 9 5.3%

Air 10 10.0%Ai 11 5 8%Air 11 5.8%Air 12 7.3%

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Case Studies (Tracer) – Vapour Distribution Cyclone Inlets

FCC Regenerator Cyclone DistributionLower Air Grid Injection

Position Percent Area

N Cyclone 12.3%NE Cyclone 14.9%

E Cyclone 12.7%SE Cyclone 10.9%y

S Cyclone 12.5%SW Cyclone 13.2%

W Cyclone 10.7%NW Cyclone 12 7%NW Cyclone 12.7%

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Example of Tracer Results - (Link to animation)

Conclusion

• Scanning and Tracer injection/detection are the only techniques that allow you to effectively ‘look inside’ your FCCU whilst in t at a o you to e ect e y oo s de you CCU stnormal operating conditions.

• The perfect technology to:• Troubleshoot operating problemsTroubleshoot operating problems• Carry out a Process Optimisation Study• Plan a Turnaround more efficiently

C t ‘b li ’ t d f th it d i C i i i• Carry out a ‘baseline’ study of the unit during Commissioning or after a Turnaround

• Measure Efficiency gains after a Retrofit• CFD modelling has limitations. Tracerco measurement data can

be used to complement/enhance CFD modelling for more accurate analysis.

Thank you and any Questions?lee.robins@tracerco.com - andrew.shaw@tracerco.com

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