Stripping Efficiency ImprovementAfter Catalyst Stripper Packing Installation

in RFCC Unit

2007.12

Location Of ONSAN Complex

JAPAN

CHINA

O

S Seoul

UlsanOnsanPusan

Seoul ↔ Ulsan : 400 Km

Pusan ↔ Ulsan : 50 Km

Ulsan ↔ Onsan: 15 Km

S-OiL

Refinery Overview

SPM

BTX/P-X

CDU

R2RR2RHYC/HVL

R&D Center

CDU CDU

MHC

#2CDU

MHC

#1HVL

#3CDU

#2VDU

RFCC

HYC

MTBE

H2Crude

Atm. Residue

VGO

Vac. Residue

HydrotreatedResidue

Hydrotreated Residue

Lube Base Oil

LPGNaphthaKeroseneDiesel

Propylene

Gasoline

MTBE

Slurry

LPG

LCO

NaphDSL

NaphDSL

KeroDSL

LPG

NaphKeroDSL

LPG

#1CDU Lube

Plant

Lube Base Oil / Wax

BTXBenzene

TolueneXylene

H2

H2

C9 Aro.

H2

Naph

Atm. Residue Para Xylene

Benzene

X-C#1

VDU

Asphalt

MDO

HDO

DAO

SDASDA

#1HMP#2HMP#3HMP

#2HVL

R2R

Overall Process Flow Scheme

RFCC

ㆍ RFCC (Residue Fluidized Catalytic Cracking) Unit

The purpose of RFCC unit is to convert heavy feedstockssuch as AR or VR into lighter valuable products mainlyGasoline,C3=,LPG and Light Cycle Oil.

Besides the valuable products, the catalytic reactions produces dry gas,slurry oil and coke.

The cracked gaseous products are treated in the fractionatorand downstream units.

The coke ,deposited on the catalyst in the reaction zone,is burnt in the regeneration zone.

RFCC Process(R2R)

ㆍDesign : 40,000 BPD

ㆍCurrent: 73,000 BPD

.New Air blower

.New Catalyst cooler

.New Feed injector/Stripper Packing

.New Tower internal

ㆍLicensor : Axens(IFP,France)

ㆍFeed : Treated (VR + VGO)

ㆍ1 Reactor / 2 Regenerators(R2R)

ㆍMain Products

. Propylene (10 vol%)

. Gasoline (55 vol%)

ㆍConversion : 80 vol%

Catalyst Stripper(1)

ㆍ Catalyst Stripper in FCC Unit

The FCC process is using small particles of catalyst whichbehave as a fluid when aerated with gas.

The catalyst is continuously circulated from the reaction zone to the regeneration zone.

The Catalyst Stripper located in Reactor bottom section whichrecovers volatile hydrocarbon contained in the catalystparticles before the catalyst enters regenerators.

Catalyst Stripper(2)

ㆍ Catalyst Stripper in FCC Unit

The internals in the Catalyst Stripper improve

hydrocarbon recovery by prompting intimate contact of

the stripping steam and catalyst,

however R2R Unit doesn’t have the internals and

this is known to cause the increase of coke yield and

stripping steam consumption.

R2R Reactor & RegeneratorsR2R Reactor & Regenerators

SLURRY

LCO

HVY GASOLINE

GAS RECOVERYSECTION

FUEL GAS

PROPYLENE

PROPANE

C4

LT. GASOLINE

FEED

Fractionator

Disengager / Stripper

RISER

2nd Regenerator

1st Regenerator

CatalystCooler

R2 FLUE GASR1 FLUE GAS

740 ℃1.15 KSCG

660 ℃1.90 KSCG

526 ℃1.25 KSCG

Combustion Air

Packing nstallation Backgrounds

ㆍ H2 on Coke level in R2R Unit was around 7~8 wt%.(While, well-designed catalyst stripper internals could achieve below 6 wt% )

ㆍ Under the bottleneck of Air Blower.

ㆍ Frequent Catalyst Cooler isolation by tube leak Charge down.

ㆍ 2 Licensors was competitors.( Axens (manufactured by Koch-Glitsch), ABB Lummus )

ㆍ Commercial experiences was key reason for selection.( Axens (20 units, as of 2005), Lummus (No, as of 2005))

Before Packing Installation

- Stripping Steam Ring.. Upper steam ring. Main steam ring. Lower steam ring. Half moon steam ring

- Steam Flow :10.7 T/H

- H2 on Coke : 7~8 wt%

Stripping Steam

Hydrocarbon

Reactor

Stripper

After Packing Installation

- Stripper Steam Ring(Upper ring removed)

- 8 Layers Structured Packing

- Stripping Steam : 8.0 T/H(Steam Reduction : 2.7 T/H)

- H2 on Coke : 5~6 wt%Stripping Steam

Hydrocarbon

Reactor

Stripper

Packing

Stripper Packing (8 Layers)

Structured Packing Picture (S-OiL)

Installed Packing Picture (S-OiL)

RISER

SHELL

Packing

Stripping Efficiency Improvement

Before After- CCR (Ton/min.) 36.0 39.0- Steam (Ton/h) 10.8 8.0- Steam/CCR (kg/Ton) 5.0 3.4- H2 on Coke (wt%) 7~8 5~6

o In spite of higher CCR and lower Stripping Steam rate, Stripping Efficiency was improved. (H2 on Coke can be decreased)

H2 on Coke After Packing Installation

H2 on Coke / Stripping Steam

0.0

2.0

4.0

6.0

8.0

10.0

12.0

2005-03-01 2005-03-31 2005-04-30 2005-05-30 2005-06-29 2005-07-29 2005-08-28 2005-09-27 2005-10-27

Date

H2 o

n C

oke,w

t%

0

2000

4000

6000

8000

10000

12000

Strip

pin

g s

team

,

kg/h

H2 on Coke Stripping steam

Economics Analysis

- Total Investment Cost : 1 billion won

(including installation cost)

- Steam (MP) reduction : 2.8 Ton/h

* CO2 emission reduction : 5,000 Ton/Year

- Payout periods (IRR) : About 2 years (40%)

(excluding Charge increase)

Reference (By Axens)

Reference (By Axens)

Reference (By Axens)

Reference (By Axens)

Reference (By Axens)

Reference (By Lummus)

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