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VandenBussche CPACSI2010KeynoteJuly212010Handouts PDF
VandenBussche CPACSI2010KeynoteJuly212010Handouts PDF
CPAC-SI 2010
Overview
Why still worry about crude oil conversion ?
been achieved.
- Evolving energy scene, oil has peaked. - Mature technologies; far up on the learning curve; intrinsic potential has
- Feed characterization
File Number
10,000 8,000 6,000 4,000 2,000 0 1980 1990 2000 2010 2020 2030
Growth Rate Other Renewables 7.3% Biomass 1.4% Hydro 1.8% Nuclear 1.3% Gas 1.5% Oil 0.9% Coal 1.9% WEO- 2008 Total
Mtoe
IEA Reference scenario assumes no changes from current global energy policies
~ 2% fall in energy demand between 2007 10 Renewables fastest growth sector, 10% of supply by 2030
3
40 35 30
Global demand forecast to rise 1.7% in 2010 following two years of decline - Developed economies forecast to be flat in 2010 following 4.4% drop in 2009 Emerging economies will continue to grow
2009 = 2%; 2010 = 3.7%
Source: IEA
2008
2009
2010
2011
2012
2013
2014
Diesel
Million BPD 5
OECD refining margins and utilization remain low (<80%) 1% of refining capacity in OECD idled in 2009, more to come Growth in transportation fuels, primarily diesel
Gasoline
Kerosene /Jet
-1
Source: Purvin & Gertz, 2009 GPMO
Fuel Specifications
10000 1000
Sulfur, Wt%
100 10 1 2007
2010
2015
North America Asia Pacific
2020
2025
Current
2012
2015
2020
Mexico UBA : 15 wppm (Northern frontier and metropolitan areas) Nationwide 500 wppm
5
5,400
Zeolite Catalysts
Amorphous Catalysts
3000 2500 No. Publications 2000 1500 1000 500 0 2000 2001 2002 2003 2004 2005 2006 2007 2008 2009 Publication Year
No. Publications
3000 2500 2000 1500 1000 500 0 2000 2001 2002 2003 2004 2005 2006 2007 2008 2009 Publication Year
File Number
60
Relative Intensity
LESS
IDEAL PT CLUSTERS
36
CRUSHED
ATTENUATION
22 18 3
CURRENT NO HYDRAULIC LIMITATION ISOTHERMAL
CATALYST
Process Geometry
8
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a a
b b
c c
Extremely regular short pores (a) are obtained by anodizing aluminum. These nanostructures are built into regular microchannels (b) and stacked (c).
10
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a a
b b
c c
Extremely regular short pores (a) are obtained by anodizing aluminum. These nanostructures are built into regular microchannels (b) and stacked (c).
11
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a a
b b
c c
Extremely regular short pores (a) are obtained by anodizing aluminum. These nanostructures are built into regular microchannels (b) and stacked (c).
12
File Number
Evolution in Micro Engineering of catalysts leads to more precise control of reaction conditions, opening up new pathways in chemistry
File Number
14
File Number
s 4+ ring aromatic
3 ring aromatics
2 ring aromatics
tics a m o nes r a e g h n t i 1r ph a n and s n lefi o , fins f a r pa int o p g boilin
File Number
polarity
15
c arbon # n-paraffins BP is oparaffins 5 0.0000 N C4to5 6 0.0000 N C5to6 7 0.0037 N C6to7 8 0.0000 N C7to8 9 0.0000 N C8to9 0.0000 10 0.0138 NC 9to10 0.0000 11 0.0695 NC 10to11 0.0253 12 0.2379 NC 11to12 0.1337 13 0.2132 NC 12to13 0.1728 14 0.1048 NC 13to14 0.1244 15 0.0784 NC 14to15 0.0509 16 0.0989 NC 15to16 0.0250 17 0.1779 NC 16to17 0.0599 18 0.2345 NC 17to18 0.0654 19 0.2401 NC 18to19 0.0889 20 0.3276 NC 19to20 0.1048 21 0.4029 NC 20to21 0.2054 22 0.5382 NC 21to22 0.2895 23 0.7439 NC 22to23 0.3576 24 1.0435 NC 23to24 0.5220 25 1.2980 NC 24to25 0.7038 26 1.5800 NC 25to26 1.0406 27 2.0178 NC 26to27 1.1057 28 2.1506 NC 27to28 1.4096 29 1.7958 NC 28to29 1.4000 30 2.1534 NC 29to30 1.2583 31 2.1274 NC 30to31 0.3877 32 1.4528 NC 31to32 0.6016 33 1.4158 NC 32to33 0.4819 34 1.4829 NC 33to34 0.7331 35 1.0510 NC 34to35 0.0000 36 0.8090 NC 35to36 0.2623 37 0.7761 NC 36to37 0.2468 38 0.2002 NC 37to38 0.1781 39 0.4446 NC 38to39 0.0000 40 0.3127 NC 39to40 0.1039 41 0.2814 NC 40to41 0.0844 42 0.1920 NC 41to42 0.0000 43 0.0947 NC 42to43 0.0707 44 0.1493 NC 43to44 0.0321 45 0.0557 NC 44to45 0.0000 46 0.0551 NC 45to46 0.0000 47 0.0307 NC 46to47 0.0082 48 0.0288 NC 47to48 0.0000 total 26.4845 12.3345
0.0000 0.0000 0.0361 0.0486 0.0729 0.0216 0.0103 0.0373 0.0404 0.0656 0.0890 0.1164 0.0983 0.1413 0.1840 0.2283 0.2603 0.2291 0.0000 0.0000 0.0000 0.4351 0.5832 0.4163 0.3501 0.3301 0.4544 0.2853 0.2207 0.5958 0.1020 0.0858 0.0000 0.0000 0.0000 0.0205 0.0000 0.0000
0.0000 0.0027 0.0298 0.0046 0.0080 0.0152 0.0145 0.0000 0.0000 0.0000 0.0000 0.0000 0.0054 0.0000 0.0000 0.0000 0.0445 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000
0.0061 0.0000 0.0000 0.0027 0.0314 0.1492 0.1229 0.0879 0.0242 0.0200 0.0322 0.0356 0.0929 0.1209 0.1479 0.2226 0.2791 0.5101 0.3687 0.5076 0.6995 0.7238 0.9944 1.1411 0.6577 1.1627 0.3184 1.5501 0.0628 0.8804 2.7261 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000
0.0265 0.0829 0.0203 0.0076 0.0000 0.0033 0.0155 0.0351 0.0456 0.0441 0.1008 0.1165 0.1360 0.3098 0.3690 0.2721 1.1734 0.4474 0.9070 0.6116 0.4266 0.0000 0.2608 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000
0.0132 0.0307 0.0393 0.0151 0.0487 0.0575 0.0404 0.0492 0.0651 0.1170 0.1767 0.1527 0.2724 0.7128 0.5654 0.5595 0.7924 1.3992 1.3876 1.3810 1.1196 1.1224 1.6154 0.3151 2.4801 0.9831 0.2476 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000
0.0000 0.0140 0.0085 0.0231 0.0013 0.0144 0.0314 0.0563 0.1057 0.1393 0.1072 0.1151 0.0682 0.0395 0.0574 0.0000 0.2989 0.0753 0.0827 0.0906 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000
0.0066 0.0238 0.0635 0.2127 0.3164 0.2837 0.4375 0.5200 0.4675 0.3913 0.3207 0.5572 0.5727 0.7693 0.8746 0.4893 0.5352 1.0661 0.1761 0.1068 0.0605 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000
0.0023 0.0379 0.1119 0.1791 0.5134 0.7101 0.9780 0.9434 1.2566 0.5246 0.8354 0.7015 0.5826 0.5731 0.7459 0.8545 0.6046 0.6218 0.0000 0.2232 0.0316 0.0357 0.0000 0.0000 0.0000 0.0000
5.5589
0.1247
13.6789
5.4119
15.7589
1.3289
8.2515
11.0672
total 0.0000 0.0000 0.0099 0.0000 0.0000 0.0165 0.1650 0.6389 0.7141 0.4149 0.2247 0.2458 0.3922 0.5122 0.7149 1.0988 1.4736 1.9033 2.4983 3.4796 4.6737 5.4949 5.9533 8.0492 7.9415 8.6590 7.5492 6.3705 4.8065 7.6116 2.8052 5.6786 5.6179 1.8436 0.5465 0.7256 0.3973 0.2277 0.1654 0.2019 0.0557 0.0551 0.0389 0.0288 100.0000
16
File Number
APPI
ESI
MALDI
Biomass, Resids
Typical Performance
Mass Resolution Mass Accuracy Max Mass Range Sensitivity 1,000,000 .0001 amu >3,000 amu <1 PPM
200
Resid
300 400 500 700 900 1000 1100
600
800
File Number
Distillate
Pyrolysis Oil
18
File Number
Active Sites
XPS XAFS Gas Adsorption - Temp. Prog. Desorption - Temp. Prog. Reduction FTIR Raman Moessbauer ESR X-Ray Fluorescence
Reactivity/Adsorption
Calorimetery - High Temperature - Liquids Diffusion - ZLC Reactivity Testing - Microreactors - TAP - TSR - SSITKA - Pulse Microreactor - TEOM - Isotopic Labeling
20
"The information lost by not using in situ methods would be similar to studying life having access to only pre-natal and post-mortem information"
File Number
Details of mesopores clearly visible Able to correlate performance with meso-porosity and diffusion path
21
UOP 5222I-11 File Number
Reduction
10 Pt cluster 8-10 Pt cluster Pt dimer
Pt-atom dimers
2 nm
2 nm
Morphology of Metal Clusters on the Atomic Scale Degree of Metal Support Interaction
22
File Number
6 C5+ RONC Improvement over Zeolite 4 2 0 -2 -4 -6 -8 -10 100 150 200 DABT. C 250 300
Vapor equilibrium
Tm/Pt/SZ
Pt/SZ
Liquid equilibrium
Zeolite
23
File Number
At RT only the monoclinic structure of ZrO2 is stable. Tetragonal phase can be stabilized at RT by addition of cationic dopants.
24
File Number
Comparison of Tm and Zr
Real part of Fourier transform Magnitude of Fourier transform
Tm-SZ Tetragonal Model
21 18 15 12 0 2 4 6 8
12 10 8 6
Tm Zr
R ()
18 15 12 9 6 0 2 4 R () 6 8
R ()
24
18
12
Tetragonal ZrO2 Neighbor Zr-O Zr-O Zr-Zr Zr-Zr Zr-O Zr-O Zr-O Number 4 4 4 8 4 8 8 R () 2.1 2.4 3.6 3.6 4.1 4.2 4.3
Selected Paths from Model R () 2.10 0.01 2.31 0.01 3.63 0.01 3.67 0.01 3.93 0.08 4.06 0.08 4.27 0.06 2 (2) 0.005 0.001 0.013 0.001 0.005 0.002 0.013 0.002 0.030 0.004 0.009 0.002 0.015 0.003
6 0 2 4 R () 6 8
Zr structure is consistent with tetragonal ZrO2 Tm and Zr Spectra are similar but also different, particularly in the first shell signal
25
File Number
R ()
16 14 12 10 8 0 2 4 R () 6 8
Extreme distortion forcing unit cell to be cubic-like It is not possible for the tetragonal phase to be so distorted, as the Zr EXAFS spectra is consistent with a normal tetragonal unit cell Try cubic ZrO2 structure instead!
R ()
18
12
4 R ()
26
File Number
EXAFS Results
Cubic Tm
Intensity 10000 8000 6000
Modeling of XRD
Tetragonal Only
Observed Calculated
10000
8000
4000
Intensity
' 15a_tet_obs' ' 15a_tet_calc'
6000
4000
2000
2000
'15a_cubtet_obs' '15a_cubtet_calc'
Number of Zr neighbors
24 20 16 12 8 4 0 24 20 16 12 8 4 0
cubic ZrO2
Zr Distribution
0 35 36 37 38 Degrees 2 theta 39
0 35 36 37 38 Degrees 2 theta
40
39
40
tetragonal ZrO2
R (Angstroms)
Tm has cubic structure within the tetragonal ZrO2.- related to similarity in cation distribution between the cubic and tetragonal ZrO2. This leads to unique structure of the zirconia - resulting in enhanced activity by modifying acidity of surface sulfate group.
27
File Number
1 - 10 g TSR
TEOM
Process Model
Diffusion Adsorption Heat of Ads. Capacity
IR Thermography
Rxn Mechanism
Isotopic Labeling
ZLC
Characterization
28
File Number
29
File Number
62 C
1. Temperature ?
250 C 215 C
250C
2. Mass Transfer?
Internal : unlikely at 50-200 microns External : unlikely in Fluidised Beds
File Number
30
31
File Number
Oscillating Reactor
- Frequency related
to mass
m = K o
1 1 1 2 2 f1 f0
32
File Number
Operations reports and data CFD evaluation of existing equipment Tracer and tomography evaluation of existing equipment Update CFD to incorporate learnings from the field and use code for revamps. Tomography for the modified equipment Incorporate final finetuned learnings into CFD design tool.
33
24
0 -0.1 -0.2 -0.3 -0.4 -0.5 -0.6 -0.7 -0.8 -0.9 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 -0.9 -0.8 -0.7 -0.6 -0.5 -0.4 -0.3 -0.2 -0.1 0.9
lb/ft3
Penetration Problems Likely for any FCC Riser over 48 Inches in Diameter
34
UOP 5201C-05 File Number
Tips at identical elevation Positioned to avoid adjacent spray impact that could lead to erosion
35
lb/ft3
36
Single Stage UOP UnicrackingTM Unit Reactor Section- Process Analyser Map
NH3 0-100 ppm Catalyst activity
H2S 100 ppm-3wt% Catalyst activity H2 (in presence of H2S) 80-97% process control Current TCD drifts
Make-up Hydrogen
Wash Water
H2 (in presence of H2S) 80-97% process control Current TCD drifts
Cold Separator
Flash Gas
Organic N/Total N
500-2000ppm Rx1 5-50ppm Rx2 Catalyst activity
Hot Separator
Flash Drum
to Fractionator Sour Water to Treating
Total S <10 ppm - 50ppm Main spec Distallation temp Main spec
Fresh Feed
Viscosity Index Temp 100F 2ndary spec
to Fractionator
Refinery Process Management and Models need integrated sensor Measurement and Control for Optimization and Value
37
File Number
Conclusions
Advances in Crude Oil Conversion Technologies Critical to Energy Growth, Now and in the Foreseeable Future. Significant Potential for Technology Improvement; Step Changes still occur. Understanding Feed Composition & Catalyst Functionality, Measuring Field Performance are Key to Continued Technology Improvement. Fundamentals and Analytics strongly impact this Technology Area from the Nano- to the Macro-scale.
38
File Number
Acknowledgements
Stimulating discussions and contributions by the following colleagues are gratefully acknowledged :
M. Stine G. Venimadhavan J. Donner S. Bare D. Galloway A. Ringwelski M. Caracotsios C. Stevens C. Gosling P. Sechrist B. Ellis S. Philoon C. Romatier
G. Towler G. Funk R. Rosin D. VandenHoff M. Cohn D. Adams P. Adams S. Kelly B. Arena W. Rathbun
The opinions and observations expressed in this presentation are those of the authors and do not necessarily represent those of UOP LLC or Honeywell International Inc.
39
File Number