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Nieskens PDF
Nieskens PDF
Im
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Imp
ation
ent
ro
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ve
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m
Design
R&
ion
Subject of this
presentation
ra
t
D
Tro
/
g
ubleshootin
Inspection
e
Op
LPG
Naphtha
Crude
Crude
Distilling
Unit
Hydro
Treater
Platformer
Hydro
Desulph.
Unit
Kero/Gasoil
High
Vacuum
Unit
Flashed
Distillate
LPG
Mogas
Kero
Gasoil
Fuel Oil
Cat Cracker
Hydro
Desulph.
Unit
Gasoil
COMPLEX
Residue Upgrade
(>370 oC) in relation to
FCC process ability
Pres., barg
P
Flue gas
Reactor
2.0
T
P
525
2.0
L
700
Steam
Riser
350
Fractionator
Air blower
Slurry
oil
Flashed Distillate /
Long residue
Air
Shell Global Solutions
FCC Process
Hydrocarbon/steam vapour to
Main Fractionator & work-up
FCC OPERATING
CONDITIONS
Typ.
Feedrate, t/d
5000
Feed temperature, C
250
Riser temperature, C
525
25
7.5
3750
Regenerator temperature, C
700
250
Typical.
Typical range
Dry gas
LPG
Gasoline
LCO
2-5
8 - 18
(C5 - 221 C TBP)
(221 - 370 C TBP)
HCO + SO (370 +
C TBP)
Coke
40 - 55
14 - 25
6 - 15
4-8
FCC CATALYSTS
Real
app
400
REQUIREMENTS:
200
Umb
Umf
0.01
0.1
vg = v [cm/s]
1
10
100
9
10
2007
Shell Global Solutions
-
Den Haag
Amsterdam
Houston
Kuala Lumpur
Bangalore
11
Shell Global
Solutions
Shell
Advised
Fluid Catalytic Crackers
Cat Cracking Services
1990
2007
30 units, being
- Shell owned or
- alliances
MONGSTAD
DEER PARK
MARTINEZ
NORCO
CONVENT
PUGET SOUND
PORT ARTHUR
SARNIA
MONTREAL EAST
PERNIS
STANLOW
Coryton
BERRE
REICHSTETT
PETIT COURONNE
43 units, being
- Shell Owned or
- Joint ventures, or
- Third Party
HARBURG
Miro
RELIANCE
YOKKAICHI
SEIBU
TOA
GEELONG
CLYDE
Tupras
Petrotrin
ECOPETROL
CARDON
BUENOS AIRES
DURBAN
PORT
DICKSON
SRIRACHA
SINGAPORE
Shell = 1.0
MM bbl/d
(> 53 MM tons/a in 23 FCC units:
6/2 US/Canada; 7/2 AsiaP/South; 6 EUR)
Margin:
@ 40 USD/t FCC > $ 2 bln/a
@ 120 USD/t FCC > $ 6 bln/a (2006)
Shell Global Solutions
13
1260
1080
740
730
670
520
430
140
510
170
50
50
80
75
16000
1900
12 %
1750
510
30%
14
The original.
Big inventory , high C/O
Poorish cat., Much coke
Lowish temps CCR<0.3
Zeolite catalyst
Riser Cracking
Stripper-baffles inside
reactor. CCR < 1.5
Complete Combustion
2000s :
Additives
ZSM-5 for
octane improvement
light olefins (C3=, C4=)
16
This is development
Improving Product Yields (while increasing residue in feed)
For a 5000 t/d unit, any 1 % conversion
increase equates a gain of 1 million Euro
per year gross margin
In 2000s
Dry Gas Down
LPG + Gasoline + LCO
further optimized
All with more difficult
feedstock
Shell Global Solutions
17
18
19
20
21
Unit yields
70 wt% conversion (4.8% dry gas, 17.2 % LPG, 50.7 % gasoline),
11.3 wt % LCO,
22
D ~ 1.5 m
23
Shell High
Performance
Feed Nozzles
1.
2.
3.
4.
Yield Shifts
(%wt on feed)
Dry Gas
- 0.3
LPG
- 0.5
Gasoline (C5-176C)
+ 0.7
LCO
+ 0.1
Coke
constant
24
25
26
27
4. Reliable Diplegs
28
99.4
94.4
96.9
94.6
Major issues and learning (2002 2005) T/A errors unrelated to design :
2003 :
-
2004
-
coking in the slurry recycle loop, due to 2002 T/A maintenance errors that
mayways of individual trays in main fractionation were left open
crack in regenerator overhead line due to an error in 2002 T/A that a repair was
not carried out resolved by adding an expansion joint
2005
29
1.
Reliable design
2.
3.
Feed characterization
4.
Catalyst selection
Feed
Operation
Design
30
1)
2)
3)
4)
5)
6)
7)
8)
9)
Hardware, R&R
Hardware, other Equipm ent
Coking
O ther Process Conditions
Hum an Error
Instrum entation and Safeguarding
Utilities
Scheduling/M argin
O utside FCC Com plex
32
2007:
CCR optimal at ~6 max.
33
Catalyst Selection
Objective: catalyst cost reduction + margin
optimisation
Testing properly aged catalysts in our pilot
plant, using actual feedstock and process
conditions tailored to your operation
Translating pilot plant results to your
commercial unit using the Shell FCC
Process Model (SHARC)
Ranking according to value added
Independence from catalyst producers
34
35
36
Economic Benefit
Catalyst
Selection
Example
Resultsof
NORCO
Catalyst
Selection
Before Base Catalyst
May-Oct., 1999
Relative Margin
Relative Feed Rate Change
Catalyst Addition
CCR
Basic Nitrogen
C2<r (incl. H2S)
C3=
C4=
Total LPG
Naphtha (C5-221C)
LCO (221-355C)
HCO (355C+)
Coke
221C Conversion
Riser temperature
FCC Naptha RON Clear
FCC Naptha MON Clear
E-Cat Activity (Grace)
E-Cat Re2O3 (Grace)
$K/day
%
tons/day
%wt
ppm
%wt
%wt
%wt
%wt
%wt
%wt
%wt
%wt
%wt
C
MAT
%
100.0
9.1
0.26
192.3
4.39
5.35
6.34
17.4
45.44
15.86
11.06
5.85
73.08
533
93.65
81.53
67.92
0.56
SHARC Predictions
New Catalyst
14.2
97.9
5.9
0.26
192.3
4.51
5.28
6.24
17.4
46.95
15.19
10.03
5.92
74.78
539
93.95
82.03
Shell Global Solutions
68.0
1.03
16.7
99.2
6.4
0.24
228.4
4.60
5.28
6.44
17.26
46.93
15.96
9.59
5.66
74.45
535
94.1
82.2
68.1
1.03
37
63
62
E-cat activity
61
60
59
58
57
56
Catalyst A
55
Catalyst B
54
5500
6000
6500
7000
7500
8000
38
0.35
0.30
0.25
0.20
0.15
4000
Catalyst B
Catalyst A
4500
5000
5500
6000
Ni+V/4, ppm
39
40
H2 S release
SOx absorption
41
14.0
SOx reduction, %
80%
11.2
R950 in INV, %
60%
8.4
40%
5.6
20%
2.8
0%
0.0
-20%
R950 in INV, %
SOx reduction, %
100%
-2.8
Nov06
Jan07
May07
42
Base
2.8%
Additive
2.6%
2.4%
2.2%
2.0%
1.8%
1.6%
1.4%
1.2%
1.0%
410
415
420
425
430
435
440
445
450
455
460
43
44
New Enabler:
-
Technology is ongoing
R&D in Shell Labs
Shell Global Solutions
45
46
47
1960s-1980s
Expander
protection
1990s
Tightening Emission
Legislation
2005
Meeting <50 mg/m3
Shell Global Solutions
48
This is development
Improving Clean Stack (and reducing SOx/NOx emission)
As we respect our neighbours, and
To keep our license to operate
49
Closing Remarks
Reliability of operation
Quality of products and of environment
Meeting refiners need for wide flexibility on product-slate and feedstock
Shell Global Solutions
50