04_Maximize Benefit from your PRIME-G+ Proceedings.pdf

7/28/2019 04_Maximize Benefit from your PRIME-G+ Proceedings.pdf

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Maximize Benefits from your PRIME-G+

the most advanced technology

for FCC gasoline desulfurization

Annick Pucci


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Agenda

Sulfur regulation

Prime-G+ Commercial Update and Keys for Success

Maximizing Prime-G+ benefits

Quick tuning

Advanced process control

Improving Prime-G+ Performances

Catalytic arrangement

Scheme modification

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Gasoline Sulfur Content in the World

3

Chile: 15ppm

since 2010

EU: 10 ppm

since 2009

Nationwide: 150 ppm

26 big cities at 50 ppm

to be expanded to 50 cities

by 2015

Japan/ S Korea: 10

ppm since 2007

CA: 10 ppm for

CARB 3 since 2008

US: Tier 3 10ppm

by 2016

Source: IFQC, 2013


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Gasoline S Specification Trends

4

EuropeEU 2005 Spec. 50 ppm S

EU 2009 Spec. 10 ppm S

U.S / Canada

Tier 2 (2004-2006) 30 ppm S

CARB 3 (California) 10 ppm S

2016 + Tier 3 10 ppm S

Japan / Korea2007 Spec. 10 ppm S

Worldwide trends towards 10 wppm


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Decrease S in cracked gasoline

while minimizing octane lossand

hydrogen consumption(Minimization ofOlefin Hydrogenation & no AromaticsSaturation & Cycle matching the FCC turnaround)

Industrially proven with Axens Prime-G+ down to

less than 10 ppm sulfur

Prime-G+ the most widely used FCC gasoline HDS

technology

FCC gasoline postreatment challenges

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Agenda

Sulfur regulation

Prime-G+ Commercial Update and Keys for Success

Maximizing Prime-G+ benefits

Quick tuning

Advanced process control

Improving Prime-G+ performances

Catalytic arrangement

Scheme modification

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Splitter

HCN

H2 Make-up

From FCC

Selective

Hydrogenation

Ultra Low S LCN to

Pool, TAME or Alky Unit

Ultra-Low Sulfur

Gasoline

LCN

SHU sectionSplitter section

HDS section

Large majority of Prime-G+ references with a splitter

Prime-G+ typical block flow

Prime-G+

Selective

HDS

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Some Keys for Prime-G+ Success

Performance

Catalytic performances ( activity / selectivity / stability)

Process economics ( low CAPEX & OPEX large revamp experience)

Flexible technology Non regret investment

Reliability

fixed bed reactors familiar to operators

Easy control of product sulfur

Single Source Supplier

R&D, Process Design, Catalyst, Start-up, Service such as..

Training, Advanced Process Control, Users conferences, Catalyst Management

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Catalytic

performances

Keys for Prime-G+ Success

Processeconomics

Process

flexibility

Maximizing

BenefitsImproving

performances9


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Catalytic Performances

Tailored, unrivaled Catalysts for octane retentionand long cycle length SHU Catalyst: Dienes and RSH removal

Lead HDS Catalyst: Bulk HDS / controlled olefin saturation

Polishing HDS Catalyst: Remaining HDS / RSH control / almost no olefinsaturation

Arsenic trapping mass : for HDS catalyst protection against poisoning

Reliability 100 % ofGuarantees Met

Synchronization ofCycle length with FCC turnaround

Catalyst Replacement Market

7competition units went for Axens catalysts

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Mercaptans Removal Doctor Test Negative

Slight Octane Boost

LCN (65C-)S = 10 ppm

RSH < 2 ppm

H2

FRCNS = 2100 ppm

RSH = 100 ppm

Industrial SHU performance

SHU Feed SHU Product

RON 94.0 94.3

MON 82.0 82.2

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Prime-G+ HDS Unit performance

0

100

200

300

400

500

600

700

0 250 500 750 1000 1250 1500 1750

days on stream

0

10

20

30

40

50

60

70

Feed Sulfur, wtppm Product Sulfur, wtppm

5.75 years cycle length at less than 10 ppm S12


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Catalytic

performances


Processeconomics

Process

flexibility

Maximizing

BenefitsImproving

performances13


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Prime-G+ wide Design Range

Licensed Units - Design Range

Unit Capacity: 2,500 - 115,000 BPD

Feed Sulfur: 30 - 4,100 ppm Olefins Content: 9 - 45 vol. %

Feeds: FCC Naphtha, Coker Naphtha,

LSR, Heavy PyGas Product S < 10 ppm

Cycle equivalent to FCC T/A demonstrated

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Very High HDSPG+ 1st Step / 2-Stage HDS

PG+ 1stStep = Prime-G+ Selective Hydro genation Unit (SHU) + Splitter

FCC

FRN

HDT

1&2

SHU LSG

LN

Prime-G+ Processing Schemes

FCC

FRNHDTSHU

LSG

Low / Moderate HDS1-Stage HDS

Moderate / High HDSPG+ 1st Step / 1-Stage HDS

2-Stage HDS

FCC

FRN

HDT

SHU LSG

LN

FCC

FRN

HDT1&2

SHU

LSG


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Catalytic

performances


Processeconomics

Process

flexibility

Maximizing

BenefitsImproving

performances16


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Process Economics

Low CAPEX

Simple scheme & fixed bed reactors

Low OPEX

Low hydrogen consumption

Large revamping experience

Reuse ofexisting idle equipment (Gasolinesplitter, HDT reactors)

Retrofit of idle units (NHDT , DHDT, Isomerizationunits, Semi-reg reformers)

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Catalytic

performances


Processeconomics

Process

flexibility

Maximizing

BenefitsImproving

performances18


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Maximize benefit by quick tuning

After start-up Operating feed is often different from design Feed properties are fluctuating a lot Product S specification often needs to be modified based

on market demand or gasoline pool optimization

Prime-G+ can accommodateMajor parameters to be optimized

For Performances adjustment

SHU & HDS Catalysts Temperature

LCN yield For energy minimization

Splitter Reflux Ratio minimization HDS Quench & Heater optimization

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Operational Fine Tuning: Splitter Reflux Ratio Minimization

From

SHU

HCNTo HDS

section

LCN

Splitter reflux is fixed at basicengineering phase as a result of

LCN/HCN separation quality

Design feed

sulfur in LCN

Depending on actual processedfeed and gasoline pool constraints,reflux and LCN draw may be slightlyadjusted

S

Main benefits On-spec LCN thus resulting in minimum

octane loss in downstream HDS

HP Steam / fuel gas savings in reboiler

Electricity / cooling water savings inoverhead condensers

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Advantages of APC

Fine tuning is neglected too often! To secure pool in case of high fluctuation of feed

quality or product spec

Over-quality S is systematically targetedMore octane loss

APC only capable to control gasoline Pool Swithout S over-quality in Prime-G+

As Licensor, Axens is in a unique position to boostyour Prime-G+ performance by using proprietarymodels for APC

APC benefits are quickly quantifiable

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Sulfur Distribution with & without APC

Product Sulfur Content

+ 1.2

ppmAveragewithoutAPC

TargetValue

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Splitter

HCN

H2 Make-up

From FCC

Selective

Hydrogenation

LCN

APC Strategy

Prime-G+

Selective

HDS

Blend

ControlledDiolefin

HydrogenationCut-point

optimization

and internal

reflux control

Sulfur

Control

Maximization

of Octane

Retention

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0 7 14 21 28

APC Startup Industrial Plant

Hours

APC OFF TUNING APC ON

MON Loss: -20%MON

Loss

Product

Sulfur

On Spec +/- 0.5ppm

H2

Make-up

HDS Temp

H2 Make-up

-20%

WABT -3C

Minimize

OPEX

MaximizeRun-length

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Prime-G+ APC : Why Work With Axens ?

Prime-G+ is not a simple HDS process

APC is not only Sulfur Control, but also

Octane Loss minimization

Run Length maximization Energy Consumption minimization.

To minimize Octane Loss, it is mandatory to use HDS

inference based on Kinetic model

Axens is in a unique position to offer you the best

APC strategy

R.O.I. typically below 6 months25


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Prime G+ Users Conference

Technical Conference Exclusively reserved for licensees

Forum of Exchange

Best practices and operational issues

Good Feedback from Past Conferences

7 conferences already organized.

the 8th conference

is scheduled in 201426


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Catalytic

performances


Processeconomics

Process

flexibility

Maximizing

BenefitsImproving

performances27


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Client Needs After 1st start-up

Market demand is evolving, more frequent needs Capacity increase

Processing of higher end boiling point gasoline

Co-processing of more refractory / alternativefeeds

Progressive implementation of tighter sulfurspecifications in gasoline pool

Requirement for increased octane retention

increased cycle length reduced utility consumption

With minimum investment cost28


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Improved Performances After 1st Start-Up

Low Cost Options Use latest generation catalyst

Use new reactor internals

Rearrangement of catalytic volume

Medium/High CAPEX options Scheme modifications

Adding a gasoline splitter

Adding additional reactors

Adding a second HDS stage Energy efficiency : Heat integration

Rearrangement of HX train

Maximum reuse of existing equipment29


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Improved Performances : Low cost solutions

Increased octane retention

Higher selectivity catalyst

Increased cycle length

Higher activity/stability catalyst

Unrivalled tailored Prime-G+ catalysts

HR 845 HR 841HR 806

PG+ SHU PG+ Main HDS PG+ Polishing

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Axens R&D strategy

Catalyst formulationLab scale screening

Industrial processReactor internals

Process development

Operating conditions

Axens is

committed tocontinuously

improve its

existing products31


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Prime-G+ Catalyst Management

Perform analysis of spent catalyst forRecovery ofmaximum value from spentcatalyst (regenerability diagnostics vslevel of contaminants)

Optimization of the catalyst loading forachievement of required performance

at minimum refill cost

Access to the Pool ofAxens

Regenerated Catalysts

New internals

Regenerated

(Axens)

Regenerated

(Client)

Fresh

(Axens)

OptimizedLoadingDiagram

Optimize customer revenue through catalyst life cycle

Simplify & ease catalyst change out activities 32


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0%

10%

20%

30%

40%

50%

60%

70%

80%

90%

100%

0 200 400 600 800 1000

Days

DT

progression

TC1-1 % TC1-2 % TC1-3 % TC1-4 % TC1-5 % TC00 % TC2-1 % TC2-2 % TC2-3 % TC2-4 %

Case Study : Hy Mix Improved Distribution

Conventional Distributor

Abnormal DT progression

Hy-Mix Tray + Dense Loading

Smoother operation

After Hy-Mix: Ideal profile maximize catalyst activity & stability

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Easy to implement & moderate capital expenditureSingle stage HDS section with SHU

Low Sulfur

Gasoline to Mogas

Mild HDS

Prime-G+ Scheme Modifications

H2 Make-up

FRCN

HDSSHU

STARTING SITUATION

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Low Sulfur

Gasoline to Mogas

Intermediate HDS

H2 Make-up

FRCN

HDS

Add a Splitter

Prime-G+ 1

st

Step

HCN

65C+

ULS LCN to Pool, TAME or Alky

Unit

Splitter

SHU Polishing

HDS

Add a Polishing HDS reactor

Moderate revamp cost for :Tighter S ,Longer cycle ,Lower octane loss

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HCN

65C+

FRCN

Splitter

SHU HDS

H2 Make-up

2nd Stage

HDS

ULS Gasoline

to Mogas

H2S

ULS LCN to Pool, TAME or Alky Unit

1st Stage

HDS

Minimum product sulfurOptimize cycle, minimize octane loss & H2 cons.

2-stage Prime G+

High HDS

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Splitter

H2 Make-

up

FRCN

Prime-G+

SHU

Ultra Low S

FRCN

High

PurityEther

MeOH

Regain octane with Prime-G+ & TAME

37

25% Olefin reduction & 0.1 bar RVP reduction

Prime-G+

HDS

TAME


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Process Scheme Modifications: Energy Efficiency

Process scheme selection is not only based onperformances but more frequently on environmental

and utility criteria

Improvement of the unit by thermal integration byaddition of exchangers

AXENS can provide expected CO2 footprint of theinstalled scheme by estimating emissions

associated to each utility Axens can propose key modifications of your

Prime-G+ in order in order to reduce CO2 emissions

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Conclusion (1/2)

PRIME-G+ leading technology For selective HDS ofFCC gasoline

214 references /148 running units: 100% guarantees met

Benefits of

Flexible and reliable technology large revamping experience

Long run length at


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Conclusion (2/2)

Revamp scenario ranking

Skills(Technology Licensor + Catalyst Supplier)

Catalyst management

Best strategy for APC

Ensure the success / Improve your performance

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Documents

04_Maximize Benefit from your PRIME-G+ Proceedings.pdf