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10/12/2016
1
UOP 7200-0© 2015 UOP LLC. A Honeywell Company All rights reserved.
UOP Technology Advancements
ARPEL FCC Best Practices WorkshopLuis Bougrat
UOP Technology Services
October 5th, 2016 Bio Bio, Chile
Agenda
• Honeywell UOP Overview
• Reactor-Regenerator Technology Advancements
- Feed Distributors
- Reactor Disengaging Devices
- Spent Catalyst Strippers
- RxCatTM Technology
- Modern Regenerators
• Q&A
10/12/2016
2
UOP Overview
Upstream Midstream Downstream
Exploring, drilling and producing crude oil
and natural gas
Processing, storage and transportation
Refining oil, gas, and biomass into
fuels and chemicals
UOP Positioning in Energy Supply Chain
Participate Only When Gas Processing Close to Wellhead Processing
Technology and Materials for Natural Gas Processing and Production of Petchem Feeds
Process Technology, Equipment, Materials, Services
10/12/2016
3
UOP Creates Knowledge for the Oil and Gas Industry
Honeywell Confidential
Better Economics Continuous Innovation Reliability Expertise
800+R&D employees
3,000+ Active patents
2,500
200 with PhDs
Engineers and scientists
31out of 36refining technologies
in use today were developed by
UOP
• Process Technology
• Catalysts
• Adsorbents
• Equipment
• Services
UOP technology makes more than 60% of the world’s gasoline, 70% of its polyester
and 90% of biodegradable detergents, and processes more than 40% of its LNG
Petrochemicals Natural GasRefining Renewables
UOP technologies offer
a high return on
investment
Continuous technology
improvement allows
customer operations to
remain cutting edge
UOP technologies are
among the most widely
proven in the world
UOP has a century-long
record leading technology
development for the oil and
gas industry
Largestprocess licensing
organization
in the
world
North America
Des Plaines, IL
Houston, TX
Tulsa, OK
Europe
Antwerp, Belgium
Guildford, UK
Bucharest, Romania
Asia
Delhi, India
Kuala Lumpur
Shanghai, China
North America
Anaheim, CA
Baton Rouge, LA
Beggs, OK
Catoosa, OK
McCook, IL
Mobile, AL
Shreveport, LA
Tonawanda, NY
Tulsa, OK
Europe
Brimsdown, UK
Reggio de
Calabria, Italy
Asia
Shanghai, China
Zhangjiagang, China
Penang, Malaysia
Hiratsuka, Japan
Yokkaichi, Japan
North America
Des Plaines, IL
Houston, TX
Mt Laurel, NJ
Tulsa, OK
South America
Rio de Janeiro, Brazil
Europe/Russia
Antwerp, Belgium
Erkrath, Germany
Guildford, UK
Milan, Italy
Moscow, Russia
Rolle, Switzerland
Asia/Middle East
Delhi, India
Bangkok, Thailand
Singapore
Seoul, South Korea
Tokyo, Japan
Beijing, China
Shanghai, China
Kuala Lumpur, Malaysia
Jakarta, Indonesia
Baghdad, Iraq
Dubai, UAE
North America
Anaheim, CA
Des Plaines, IL
Mobile, AL
Riverside, IL
Shreveport, LA
Middle East
Dhahran, KSA
Asia
Delhi, India
Shanghai, China
Hiratsuka, Japan
Research & Development
Manufacturing
Engineering Centers
Sales & Service Offices
Honeywell UOP Global Locations
10/12/2016
4
Rx-Rg Technology Advancements
Throughput
Stack Emissions
Onstream Availability
Low Sulfur Fuels
Profitability
Continuing Demand for FCC Technology Innovation
Market Pressures
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5
FCC Technological Advancements - Industry
What other advancements have you observed?
Catalytic
• Catalyst improvements
• Yield additive
• Gasoline Sulfur Reduction Additives
• Emission additives
• Hydrotreated feed
Hardware
• Feed Distributors
• Riser Termination Devices
• RxCat Technology
• Spent Catalyst Stripper Internals
• Packed Strippers
• Regenerator Design
Controls
• Emergency Interlock Systems (EIS)
• Operations Simulator
• Advanced Process Controls (APC)
• Connected Performance Systems (CPS)
Feed Distributors
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6
OptimixTM Feed Distributors
OptimixTM Feed Distributors
Mechanical
Improvement
– DUR O LOK couplings
– Tip design
– Custom Sizes: 3” - 8"
Conversion increase:
1 - 4 lv-%
Gasoline yield increase:
1 - 3 lv-%
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7
Reactor Disengaging Devices
Reactor Riser Disengaging Devices
10/12/2016
8
Bed Cracking
DateCommercialized: 1942
HC Containment: 0%
Vented Riser DCC SCSSStandard Tee
1971
0%
1983
70-80%
1993
~ 94-97%
1988
~ 94-97%
Open
( Pcyclone <Prx )
Closed
( Pcyclone >Prx )
Open
Reactor Riser Disengaging Devices
Reactor Riser Disengaging Devices
10/12/2016
9
Vortex Separation Technology
• Single stage of cyclones
- Highest throughput capability per reactor diameter
• Highest hydrocarbon containment of any RTD
- VDS/VSS 99.7+%
- Effective pre-stripping
- No primary dipleg under-flow
VSSInternal Riser
VDSExternal
Riser
Modern Reactor Riser Disengaging Devices
UOP Confidential
10/12/2016
10
Primary VSS/VDS Revamp Objectives
Maximize C5+ Gasoline
Yields
Boost Gasoline Octane
Reduce Dry Gas (C2-)
Yield
Boost LPG Yields
Lower Delta Coke
Hydrocarbon Processing | September 2010
Revamp Effects Example – UOP Literature
10/12/2016
11
Penalty of Dipleg Under-Flow
Higher Containment Higher Product Selectivity
YieldsCyclone Outlet
Reactor Vessel
C2-, wt-% 2.7 15.6
LPG, lv-% 23.8 37.6
Gasoline, lv-% 54.2 46.6
LCO, lv-% 20.9 10.0
Slurry, lv-% 8.1 5.8
Spent Catalyst Stripper
10/12/2016
12
Spent Catalyst Stripper Challenges
Catalytic & Hardware Advancements Led to Lower Coke
Lower regenerator temperature
Higher catalyst circulation rate
Higher stripper flux
Lower efficiency
Higher steam consumption
Higher air demand
Hydraulic limitsReduced benefits of previous technology
upgrades
UOP 4285B-12
Modern Stripper Internals – UOP AFTM Technology
10/12/2016
13
AFTM Stripper Technology
Typical Benefits:
Coke reduction
– 0.04 Wt-%
Increased conversion
– 1 – 2 lv%
Flux capacity
– Operating up to 125,000 lb/ft2/hr
Baffle to Packing Revamp:
– Substantial steam reduction
– 15% H2 in Coke reduction
Trays
Grids
Packing
AFTM Packing’s Exceptional Performance has Led to its Exclusivity as the Standard Stripper Internal
Key Benefits of Improved Delta Coke?
• Open Discussion
10/12/2016
14
RxCatTM
Technology
RxCat™ Technology Improves Control
of Catalyst/Oil Ratio• If conventional FCC Unit catalyst
circulation is constrained
• RxCat Technology can remove this
constraint
RxCat Technology Further
Optimizes Catalyst Circulation Rate
Cat/OilRiser =Coke Yield ΔH Regeneration
CpCat (TRegen – TReactor)
10/12/2016
15
RxCatTM
“Also Wants”
Retain existing
equipment
Lower coke yield
Improved
regenerator
performance
The Coke Challenge
“Wants”
Higher throughput
Higher conversion
Less dry gas
UOP 4285B-16
The RxCatTM Solution
1)Heat balance
neutral recycle
2) Cat & Oil contact
temp decreases
3) Riser C/O
increases
4) Regenerated
catalyst temp
increases
5) Regen cat circ
decreases
6) Eliminate CO
promoter
7) Lower excess
O2 requirement
No
Conversion
Debit
Lower
Emissions
10/12/2016
16
Emissions with RxCatTM Technology
Regenerator Design
10/12/2016
17
Modern FCC Reactor and Regenerator
Modern Catalyst Coolers
10/12/2016
18
Commercialization of Recent UOP Developments
• OptimixTM Feed Distributors
- 114 locations (>500 distributors)
• Vortex Riser Termination Devices
- 85 commissioned
• AF™ (Advanced Fluidization) Stripper
technology
- 89 commissioned
- 14 AF Packing
• Two-Stage Regenerators
- 12 commissioned
• Catalyst Coolers
- 67 commissioned
• UOP Third Stage Separator
- 8 operating
• RxCat Technology
- 9 operating