UOP FCC Innovations Developed Using Sophisticated Engineering Tools

Transcription

1 UOP FCC Innovations Developed Using Sophisticated Engineering Tools Robert Mehlberg, Lisa Wolschlag & Keith Couch UOP LLC, A Honeywell Company XVI Foro de Avances de la Industria de la Refinación June 30 - July 1, 2010 Mexico City 2010 UOP LLC. All rights reserved. UOP

2 Improved FCC Riser Design Feed Distributors UOP 5381D-02

3 New Diagnostic Tools Provide New Opportunities World Scale FCC 200 kbsd 9 foot ID riser tonne/min catalyst circulation Deviations From Benchmark Performance Gasoline Selectivity: Conversion: Dry Gas: How to Achieve Benchmark Performance in the Most Economical Way? UOP 5381D-03

4 Tracer Data Shows 3 Regimes Mar 2007 Gas Injection Response, counts Early Peak Low Conversion Late Peak Riser Ex Top Avg Channeling Normal Wall Flow Composite High Coke and Gas Time, seconds Mathematical Composite of Pathologies Matches Tracer Data and Observed Yield Problems UOP 5381D-04

5 Scale-Up Challenges Riser Hydraulics Riser 9 ft lb/ft 3 CFD Prediction Dense Core 2500mm Above Feed Vapor Annulus Actual Riser Gamma Scan Dense Core Regenerated Catalyst Standpipe Vapor Annulus UOP 5381D-05

6 Dual Radius Feed Distributors 6 inner distributors Tips at identical elevation Positioned to avoid adjacent spray What did the CFD Model Indicate? UOP 5381D-06

7 CFD Predicts Dense Core Elimination Density lb/ft 3 Dense Core impacts yields of big riser Dual Radius Feed Distribution Eliminates Dense Core Looks like we have a solution but will it work? High slip and asymmetry impact yields of any size riser UOP 5381D-07

8 Gamma Scan Confirms Core Elimination More symmetrical density profile Catalyst density variation reduced by 50% Unit performance met design targets Successful solution to conversion problem improved confidence in CFD as a design tool UOP 5381D-08

9 Optimix Feed Distributor Development UOP 5381D-09

10 Optimix Feed Distributor Development Weld Overlay Previous Optimix Tip New Standard Optimix (ER) Tip Ceramic Tip New Standard Previous Tip Optimix (ER) Weld Overlay Tip Optimix (ER) - Ceramic Tip UOP 5381D-10

11 Ceramic Tips Prove to be Successful Metallic Tip Ceramic Tip 18 Months of Operation Prove Superior Performance of Ceramic Distributor Tips UOP 5381D-11

12 Regenerator Scale-Up Creates Challenges Combustor Disengaging Arms Outer Radius Inner Radius Cyclone Pairs Cyclone Pairs Changes to Base Engineering Design First dual radius cyclone installation in a combustor style regenerator Normal Losses 0.04 lb/bbl 0.07 at higher velocity (caught by TSS) Uneven secondary cyclone wear after 6 years UOP 5381D-12

13 Tee Disengager Development Gas Velocity m/s Base Case 0.95 m/s Cyclone Inlets Disengager Dipleg Outlets 4-9 m/s High Gas Velocities Re-entrained Catalyst and Overloaded Inner Cyclones UOP 5381D-13

14 Elephant Trunk Improves Performance Elephant Trunk 1.05 m/s Cyclone Inlets Disengager Dipleg Outlets 1-3 m/s Velocities at the Dipleg Outlets Reduced 70-90% Solution applies to All Combustor Sizes UOP 5381D-14

15 Elephant Trunk Improves Combustion Kinetics % Vapor Entering Cyclones Elephant Trunk Disengager Tee Disengager Time (secs) More plug flow Less short circuiting No dead zones Residence time increased 26% Reduced afterburn Dense bed 1198 F Afterburn: 8 F Lower excess O 2 = lower NOx Elephant Trunk Disengager has Benefits for All Sized Combustors UOP 5381D-15

16 T Bubbling Bed Regenerator Layout 100 F Spent Catalyst Dense Phase Spent Catalyst Riser Gull Wing Slots Air Grid Main Air Regenerated Catalyst Regen Catalyst Standpipe UOP 5381D-16

17 Tracer Analysis to Quantify Actual Performance Cyclone 9 Cyclone 8 Cyclone 10 14% 12% 10% 8% 6% 4% 2% 0% Cyclone 1 Cyclone 2 Ideal Distribution Actual Distribution Cyclone F Cyclone 6 Gull Wing Cyclone 5 Cyclone 3 Cyclone 4 Gull Wing Design Caused Catalyst and Air Maldistribution UOP 5381D-17

18 Distributor Development Gull Wing Distributor Piped Spent Catalyst Distributor Piped Distributor Provides Better Distribution with the Same Lift Air Requirement UOP 5381D-18

19 CFD Predicted Catalyst Density Profiles Gull Wing Piped Distributor Piped Distributor Improves Catalyst/Air Mixing UOP 5381D-19

20 Tracer Results Validate Piped Distributor Cyclone 7 Cyclone 8 Cyclone 9 14% 12% 10% 8% 6% 4% 2% 0% Cyclone 1 Dilute phase ΔT: F Excess O 2 : 2% 1% Cyclone 6 Cyclone 5 Cyclone 4 Cyclone 3 Ideal Distribution Actual Distribution Piped Spent Catalyst Distributor Provides Homogeneous Flow Distribution UOP 5381D-20

21 The Coke Challenge RxCat Wants Higher throughput Higher conversion Less dry gas Also Wants Retain existing equipment Lower coke yield Improved regenerator performance UOP 5381D-21

22 RxCat Solution for Low Delta Coke Lower Emissions More Selective Yields 6) Excess O 2 requirement reduces 5) CO promoter requirement reduces 4) Regenerator temperature increases 1) Heat balance neutral recycle 2) Catalyst and oil contact temp decreases 3) Riser C/O and Delta Coke increase UOP 5381D-22

23 Effect of RxCat on Unit Performance Regenerator Dense Bed, F Base Elevated Premix (0) (4) Regen Temp Cat/Oil (1) Elevated Optimix (2) + AF Stripper (3) + VSS RTD Regen S. P. Cat/Oil + RxCat Riser Cat/Oil RxCat Technology Offers Both Increased Throughput and Product Yields UOP 5381D-23

24 RxCat Technology Commercialization Refiner #1 - Americas: Apr 05 Regenerator temp control Refiner #2 Asia: Mar 08 Regenerator temp control Refiner #3 Asia: Feb 08 Propylene Production Refiner #4 Asia: Apr 09 Propylene Production 6 More RxCat Systems in Construction UOP 5381D-24

25 MxR Chamber Elimination Regen Catalyst Spent Catalyst Challenges Revamp hydraulics and schedule Catalyst inventory Capital cost MxR Chamber UOP 5381D-25

26 MxR Chamber Elimination Regen Catalyst Spent Catalyst Spent Catalyst Regen Catalyst Low DP Internals MxR Chamber New Mixing Riser Available 4Q 2010 UOP 5381D-26

27 Concluding Remarks These 5 innovations are commercially proven and cost effective FCC is key refinery infrastructure so continued development is vital Advanced diagnostic and design tools are accelerating process developments and innovations UOP is delivering technological innovations confidently, quickly and with reduced risk UOP 5381D-27

28 UOP 5381D-28