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Introduction about KBR RFCC
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© 2009 KBR. All Rights Reserved.
Residue FCC Designfor Performance
and Reliability
Phil NiccumKBR
© 2009 KBR. All Rights Reserved.
You want to put Resid in the Cat Cracker?
♦ Will the resid harm the Cat Cracker?
♦ Do we have the FCC capacity?
♦ What else must be considered?
♦ What are the technology alternatives?
© 2009 KBR. All Rights Reserved.
What Cats LikeImportant Feed Characteristics
♦ Large Saturated
Hydrocarbons
♦ Clean
♦ Reliable Supply
© 2009 KBR. All Rights Reserved.
What Cats DislikeFCC Feed Characteristics to Avoid
♦ Vanadium Increases catalyst make-up
♦ Carbon Residue Increases coke make Increases required regenerator
size, air rate and catalyst cooler duty
♦ Aromatic Content Negative Impact on conversion
and yield selectivity
© 2009 KBR. All Rights Reserved.
Vacuum Distillation: FCC Feed Lost in Vacuum Residue
Direct Feed to FCC: Contaminant Issue (Metals and CCR)
Coking: Addresses Contaminant Issue Hydrogen Deficient Feed to FCC
Hydroprocessing: Addresses Contaminant IssueHigh Cost (TIC, H2, Catalyst)
ROSE: Addresses Contaminant IssueFeed to FCC not Hydrogen Deficient Low Capital and Operating Costs
Residue Upgrading Options for FCC Feed
© 2009 KBR. All Rights Reserved.
Residue FCC Processing ChallengesMore than just coke burning capacity
♦ Reaction System Minimize coke production
• Fine feed atomization and low operating pressure
♦ Regeneration System Manage heat generation from coke burning Minimize catalyst deactivation
© 2009 KBR. All Rights Reserved.
KBR FCC Rx System Technologies
♦ ATOMAX-2™ FEED NOZZLES Fine atomization,
excellent riser coverage
ATOMAXATOMAX™™
© 2009 KBR. All Rights Reserved.
DynaFluxDynaFlux™™
KBR FCC Rx System Technologies
♦ DYNAFLUX™ STRIPPING Better stripping efficiency, even in
high flux strippers
© 2009 KBR. All Rights Reserved.
KBR FCC Rx System Technologies
♦ RISER QUENCH TECHNOLOGY Higher mix zone severity,
improves gasoline yieldand octane
Fresh FeedFresh Feed
QuenchQuench
© 2009 KBR. All Rights Reserved.
KBR FCC Rx System Technologies
♦ CLOSED CYCLONES 30-40% less dry gas than
unducted riser termination
Closed CyclonesClosed Cyclones
© 2009 KBR. All Rights Reserved.
KBR FCC Regenerator Technologies
♦ Countercurrent Regeneration Only one stage needed for residue
processing
♦ Catalyst Cooler Reliably cool regenerator Generate valuable steam
© 2009 KBR. All Rights Reserved.
KBR FCC Regenerator Technologies
♦ Countercurrent Regeneration Only one stage needed for residue
processing
♦ Catalyst Cooler Reliably cool regenerator Generate valuable steam
Water In
Water /Steam Out
Catalyst In
FluidizationFluidizationAirAir
Catalyst Out
© 2009 KBR. All Rights Reserved.
Partial CO Combustion – Better for Residue
♦ Minimizes catalyst cooler requirements
♦ Reduces size of major equipment Regenerator vessel Regenerator cyclones Air blower
♦ Reduces catalyst makeup by limiting vanadium-induced deactivation
♦ Partial combustion does require CO Boiler or other CO destruction device
© 2009 KBR. All Rights Reserved.
V2O5 generated in oxidative environment:4 V + 5 O2 ----> 2 V2O5
Vanadia migrates to other particles via volatile vanadic acid:V2O5 + 3 H2O ----> 2 VO(OH)3
Old Catalyst(lots of vanadium)
New Catalyst(no vanadium)
Old Catalyst "New" Catalyst
BEFORE MIGRATION AFTER MIGRATION
(Vanadium equilibrated between particles)
Vanadium Mobility
© 2009 KBR. All Rights Reserved.
Complete Combustion – Better for Gas oils
♦ Simplifies Operation Avoids afterburning even during start-up
♦ Maintains regenerator temperature on HDT VGO
♦ Reduces NOx emissions
♦ Minimizes carbon on regenerated catalyst
♦ Does NOT require CO Boiler or other CO destruction device
© 2009 KBR. All Rights Reserved.
KBR Counter-current Regenerator
Spent Catalyst(high carbon)
+ Low O2
Regen Catalyst(low carbon)
+ High O2
DENSEPHASE
BED
cata
lyst
air
Air Distributor
Spent Cat Distributor
© 2009 KBR. All Rights Reserved.
Spent Catalyst DistributorOrthoflow™ FCC Installation
Self- Aerated Distributor
Troughs
Spent Cat Standpipe
© 2009 KBR. All Rights Reserved.
low O2
high O2
Spent Catalyst(high carbon)
Catalyst(low carbon)
Dense PhaseBed
+
+
cata
lyst
air
Regenerator Design ComparisonsKBR Counter-current Regeneration.
♦ Air travels up
♦ Catalyst travels down
♦ High carbon catalyst contacts low O2 gas minimizes burning rate and particle
temperature
♦ Low carbon catalyst contacts high O2 gas minimizes burning rate and particle
temperature
♦ Dense phase particle contact dissipates heat of combustion Prevents high particle temperatures
♦ Low particle temperature minimizes catalyst deactivation
© 2009 KBR. All Rights Reserved.
Regenerator Temperature ControlWhy use a Catalyst Cooler
♦ Provide feedstock and product flexibility Process high carbon residue feedstocks Process VGO feeds at high reaction
temperatures for maximum propylene
♦ Provide Process flexibility Optimize cat/oil ratio Optimize catalyst matrix and zeolite
♦ Minimize catalyst deactivation Reduce catalyst costs
♦ Minimize dry gas make at mix zone
KBR FCCU with Cat Cooler
© 2009 KBR. All Rights Reserved.
KBR Dense Phase Catalyst Cooler
SlideValve
CatalystReturn
FluidizationAir
Catalyst In Tubesheet
Tubesheet
InnerTube
Scabbard --Outer Tube
Water In
Water &Steam Out
© 2009 KBR. All Rights Reserved.
Dense Phase Catalyst Cooler TechnologyFlexibility for Cracking Heavy Feedstocks
© 2009 KBR. All Rights Reserved.
Key Features of Catalyst Cooler
♦ High Heat Transfer Coefficient♦ Flow-Through Design Provides
Heat Removal Flexibility♦ No Fluidization Impingement
on Tubes♦ 16 Coolers Operating Since 1990
with No Erosion Related Shut-downs
Water In
Water /Steam Out
Catalyst In
FluidizationFluidizationAirAir
Catalyst Out
© 2009 KBR. All Rights Reserved.
Key Features of Catalyst Cooler
♦ High Heat Transfer Coefficient♦ Flow-Through Design Provides
Heat Removal Flexibility♦ No Fluidization Impingement
on Tubes♦ 16 Coolers Operating Since 1990
with No Erosion Related Shut-downs
© 2009 KBR. All Rights Reserved.
Easy To Remove Tube Sheet
Easy Removalof Tube Bundle
From Top
Cooler Tube Bundle Lift at KPI
© 2009 KBR. All Rights Reserved.
Performance of Dense Phase Catalyst CoolerHeat Removal Duty vs. Catalyst Circulation Rate
50
60
70
80
90
100
110
120
130
0 20 40 60 80 100 120 140
Catalyst Circulation Rate Through Cooler (% of Design)
Cat
alys
t C
oo
ler
Du
ty (
% o
f D
esig
n)
© 2009 KBR. All Rights Reserved.
Regenerator Temperature ControlCat Cooler can adjust automatically to feed changes
712
716
720
724
728
Time (hours)
0
10
20
30
40
50
60
70
80
90
100
0 5 10 15 20 25
Cat Cooler Duty Cat Cooler Duty Regen Temp Regen Temp
Cat
alys
t Coo
l er
Dut
y (%
of d
esig
n)
Reg
ener
ator
Tem
pera
ture
(°C
)
© 2009 KBR. All Rights Reserved.
Example of Increasing Feed CCR and Metals
♦ 70,000 BPSD atmospheric resid direct to FCC
♦ Catalyst cost at $2,000/ton
♦ Va/Ni ratio is 1/1
© 2009 KBR. All Rights Reserved.
Dealing With Regenerator Bed Temperature
0
2
4
6
8
10
12
0 2 4 6 8
ConCarbon, wt%
Co
ke Y
ield
, wt%
Total BurnPartial Burn
Catalyst Cooling200 MMBtu/hr 400 MMBtu/hr
© 2009 KBR. All Rights Reserved.
Catalyst Makeup Costs
0
0.5
1
1.5
2
2.5
0 10 20 30 40 50 60
Total Metals, wppm
Cat
alys
t C
ost
, $/
bb
l Va/Ni=1 Va/Ni=4
Typically consider alternatives at 20 ppm total metals
© 2009 KBR. All Rights Reserved.
Other Advantages of Countercurrent
Regeneration
© 2009 KBR. All Rights Reserved.
Regenerator ComparisonsSide Entry vs. Center Entry with Catalyst Distributor
Side Entry Regenerator Center Entry with Spent Catalyst Distributor
© 2009 KBR. All Rights Reserved.
Catalyst(high carbon)
low O2
high O2
Spent Catalyst(low carbon)
Dilute PhaseBed
+
+
cata
lyst
air
Regenerator Design ComparisonsCo-current Regeneration
♦ Highest carbon catalyst contacts fresh air with 21% O2
♦ Rapid O2 transfer produces high burning rate
♦ Heat transfer to fluid bed is not rapid enough to prevent high particle temperatures
♦ High particle temperatures accelerate catalyst deactivation
© 2009 KBR. All Rights Reserved.
Catalyst Interior Particle Temperature Rise
Com
bust
ion
Rat
e
Time
Lowest O2, high coke, controlledheat release,
little diffusional resistance
Highest O2, high coke,rapidheat release,
little diffusion resistance
♦ Concurrent Regeneration Rapid burning results in rapid temperature increase inside the particle Burning rates remain relatively high during the first 25-30% of combustion Temperature spike inside the particle Temperature rise- water- metals all combine to deactivate catalytic sites
♦ Countercurrent Regeneration Much lower burning rates mitigates interior temperature rise Burning rates remain well below cocurrent for most of the combustion Lower burning rates allow the heat to be dissipated to flue gas
ΔT
empe
ratu
re
Cocurrent
CountercurrentAdditional
Deactivation
Temperaturespike
© 2009 KBR. All Rights Reserved.
Commercial Catalyst ActivityImprovement From Counter-Current Regeneration
BASE CASECo-Current
REVAMPCounter-current Delta
Catalyst Data:
Surface Area, m²/g 143 162 +18
Avg. bulk density, g/cc 0.90 0.88 -0.02
Pore volume, cc/g 0.34 0.39 +0.05
MicroActivity, wt% 68.5 73 +4.5
© 2009 KBR. All Rights Reserved.
low O2
high O2
Spent Catalyst(high carbon)
Regen Catalyst(low carbon)
DensePhaseBed
+
+
cata
lyst
air
Mechanism of KBR FCC NOx Reduction
When spent catalyst distributedacross top of regenerator bed...
NO produced in bottom of bedcontacts carbon near top of bed
2 C + 2 NO ----> 2 CO + Nitrogen
Less than 10% of nitrogen in cokeburns to NOx in Counter-CurrentRegeneration
© 2009 KBR. All Rights Reserved.
Two Stage Units Add Complexity
♦ Higher Investment (up to 20%)
♦ Operations More Complicated
© 2009 KBR. All Rights Reserved.
Major Equipment Summary
10 (for full burn)
1 (for partial burn)CO Boiler
21Orifice Chambers
10Catalyst Transfer Line Expansion Joints
42Catalyst Transfer Lines
21Flue Gas Slide Valves
32Catalyst Slide Valves
32Major Reaction Vessels
Two Stage RegeneratorKBR Orthoflow
© 2009 KBR. All Rights Reserved.
Total Installed Costs
120.4 %--Delta Cost
1401011640Total $(000)
13701140Bulk Materials
300250Catalyst Storage Drum
23701300Flue Gas System
41203900Air Blower
58505050Converter
Two Stage RegeneratorKBR Orthoflow
© 2009 KBR. All Rights Reserved.
Percent of Total Installed Cost
120.4100.0Total (%)
11.79.8Bulk Materials
2.62.1Catalyst Storage Drum
20.411.2Flue Gas System
35.433.5Air Blower
50.343.4Converter
Two Stage RegeneratorKBR Orthoflow
© 2009 KBR. All Rights Reserved.
Orthoflow™ FCC ConverterMaximum Operating Flexibility
FCC Type VGO Resid Complete Partial
R2-R X X
High Efficiency X X X
KBR Orthoflow™ X X X X
FEEDSTOCK COMBUSTION
♦ CONCLUSION: The Orthoflow™ regenerator handles VGO’s or Resid’s in complete or partial combustion without compromise
© 2009 KBR. All Rights Reserved.
Regenmax Technology
© 2009 KBR. All Rights Reserved.
Orthoflow™ RegenMax™
Spent Catalyst
Regen Catalyst Air
Flue Gas
CatalystBed
Spent Catalyst
Regen Catalyst Air
Flue Gas
CatalystBackmixingAirCatalyst
UpperBed
LowerBed
Regenmax™ TechnologyBaffle Provides Staging In Single Vessel
UpperBed
LowerBed
Baffle
© 2009 KBR. All Rights Reserved.
Regenmax™ Technology
RegenMax™ ModelRegenMax™ Baffle
© 2009 KBR. All Rights Reserved.
Photo of Regenmax™ Baffle
© 2009 KBR. All Rights Reserved.
Regenmax™ Benefits
♦ Burns catalyst clean in partial CO combustion Without requiring an increase in catalyst inventory or unit size
♦ Achieves this in a single, simple regenerator vessel Less costly than building
two-stage regenerators
♦ Feedstock operatingflexibility Can switch to complete
combustion when desired
© 2009 KBR. All Rights Reserved.
Reliability of Regenmax™
♦ Baffle does not interferewith catalyst flow fromupper bed to lower bed High percentage of
open area Unique design limits
backmixing
♦ No change in densityprofile in bed
♦ No flooding or otherflow problems
© 2009 KBR. All Rights Reserved.
KBR Orthoflow Advantages for Residue Processing
♦ Reaction Features Low Pressure – Short Contact Time Minimizes gas and coke
♦ Regeneration Features
Ultimate regenerator operating flexibility accommodates the reactor heat demand
• Full or partial CO combustion• Dense phase catalyst cooler
Economy of design and operation• Single stage regeneration• Minimize catalyst deactivation• Low NOx emissions Mobil Altona
© 2009 KBR. All Rights Reserved.
Thank you very much…
Questions?