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

Improved FCC Riser Design

Feed Distributors

UOP 5381D-02

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

UOP 5381D-09

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

UOP 5381D-28