FCC Propylene Production

Transcription

1 FCC Propylene Production Closing the Market Gap by Leveraging Existing Assets Keith A. Couch UOP LLC 105th NPRA Annual Meeting March 18-20, UOP LLC. All rights reserved. UOP 4706A-01

2 Higher Severity Propylene Design Operating Flexibility Envelope Gasoline Higher Throughput If Higher Propylene Production is Attractive, There Are Revamp Options to Get You There UOP 4706A-02

3 FCC Unit Design & Operating Envelopes Propylene Yield, wt-% FF Maximum Gasoline f (Rx T, P P, C/O, P T ) Gasoline Propylene + + LPG Aromatics Gasoline Yield, wt-% FF What is the Optimal Propylene Yield? UOP 4706A-06

4 FCC Propylene Production Targets C 3 = Wt-% Yield on Fresh Feed Unit A E J P R S T Average Initial RFQ Final Design Selected UOP 4706A-12

5 Process Variables Response Study Existing Reactor Constrained on Cyclone Inlet Percent, or Pressure (psig), or Temperature (T-1000 o F) Hydrotreated Feed, kbsd C 3 = Production, tonnes/day Reactor Pressure Reactor Temp (T F) C 3 = wt-% % FF C 3 = Production Tonnes/day UOP 4706A-08

6 Process Variables Response Study Existing Reactor Constrained on Cyclone Inlet Percent, or Pressure (psig), or Temperature (T-1000 o F) Hydrotreated Feed, kbsd C 3 = Production, tonnes/day Maximum Severity Costs About 50% Capacity UOP 4706A-09

7 FCC Operating Modes C 2 = C 3 = C 4 = Wt-% % Yield on Fresh Feed Gasoline Gasoline + LPG Propylene +Aromatics Gasoline UOP 4706A-10

8 FCC Operating Modes Wt-% % Yield on Fresh Feed Gasoline Gasoline + LPG Propylene +Aromatics Total Delta Aromatics % Benzene % Optimizing the Overall Complex LP is Critical to Defining the Optimum FCC Operating Envelope UOP 4706A-11

9 FCC Propylene Production Targets C 3 = Wt-% Yield on Fresh Feed Unit A E J P R S T Average Initial RFQ Final Design Selected UOP 4706A-12

10 Product Recovery System Design Review Which Type of Recovery System is Best? Compression Based Cold Box,, or Absorption Based Gas Concentration UOP 4706A-13

11 Product Recovery System Designs Compression Based Cold Box C 1 / C 2 / C 3 Main Column C 4 / C 5 Absorption Based C 1 / C 2 Main Column Absorber/ Stripper C 3 / C 4 / C 5 UOP 4706A-14

12 Product Recovery System Design Review Product Recovery System Case Study Feed Rate: 50,000 BPSD Ethylene yield: Propylene yield: Gasoline yield: Propylene recovery: Ethylene recovery: 9 wt-% FF 23 wt-% FF 19 wt-% FF 98 wt-% FF 98 wt-% FF UOP 4706A-15

13 Recovery System Costs EEC (MM$) Capital Costs Gas Con Cold Box Gas Con Utility Costs Cold Box US Dollars per Hour Product Recovery Refrigeration Main Column BF Water HP Steam MP Steam LP Steam Cooling Water Shaft Work UOP 4706A-16

14 Propylene Recovery in the Primary Absorber Propylene Recovery (%) % C 3 = Recovery in Primary Absorber Debutanizer Bottoms Recycle (1000 BBL/day) High Absorber Efficiency Beats the Cost of Compression UOP 4706A-17

15 Utilities and Annualized Capital Costs Costs (MM $/yr) Utility Annualized Capital 0 Gas Con Cold Box Gas Con Cold Box Natural Gas Price: CMAI $5.9 / MM Btu July 2006 $10.7 / MM Btu September 2005 UOP 4706A-19

16 Utilities and Annualized Capital Costs Costs (MM $/yr) Utility Annualized Capital $5.9 / MM Btu $10.7 / MM Btu 0 Gas Con Cold Box Gas Con Cold Box Higher Absorption Efficiency Beats Compression Costs Across a Wide Range of Utility Values UOP 4706A-20

17 U.S. Propylene Focus 100% 80% C 3 = TPA 60% 40% 20% 0% US Gulf Coast %C 3 = to Polymer CMAI Data wt-% FF US East Coast US West Coast Rest of US %C 3 = to LPG or Alkylation UOP 4706A-21

18 Propylene and Natural Gas Values $/Tonne Polymer Grade C 3 = Refinery Grade C 3 = Natural Gas $215 $ C 3 = Slippage to Fuel Gas has Become Costly UOP 4706A-20

19 Propylene Product Downgrade C 3 + in Dry Gas (mol-%) C 3 = Loss to Dry Gas (tonne/day) C 3 = Value Lost ($/day) 3% 7% $0 5% 17.4 $6,480 $900 / tonne: Product Downgrade = $4,600,000 / yr Current Economics do Justify Recovery Projects UOP 4706A-26

20 Gas Con Recovery Constraints Fractionator & Absorber Capacities - High capacity trays or packing - Additional in-line or parallel absorber Lean Oil Circulation & Cooling Temperature - Additional lean oil circulation - Chilled water system HP Condenser Duty -Stripper overhead routed directly to primary absorber bottoms Off-loads the high pressure condenser Better feed conditioning to primary absorber UOP 4706A-27

21 Gas Con Capacity Constraints Wet Gas Compressor Capacity - Increased reactor pressure (possible re-rate) rate) Higher suction head to off-set lower MW Lower ACFM to accommodate cyclone velocity constraints - Re-rate the compressor Heat Integration with the FCC Main Fractionator - Alternative heat integration configurations But Can the Same Gas Con Handle a Step- Change in Operating Severity? UOP 4706A-27

22 Absorption Based Gas Con Flexibiliity Operating Mode Gasoline: C 3 = + Aromatics: Wild Naphtha 0.8 X 0.2 X Stabilized Naphtha 0.2 X 0.8 X Absorber/ Stripper C 1 / C 2 Main Column X Same Equipment Capacity for Both Modes! Same Equipment C / 3 C / C 4 5 Capacity for Both Modes! UOP 4706A-18

23 C 3= Alkylate & Regular Gasoline Values $/Tonne C 3= to Alkylate Regular Gasoline $ The Value Gap Between C 3 = to Alkylate and Gasoline is One Incentive to Increase FCC Severity UOP 4706A-19

24 Revamp Constraint Commercial Example Alleviated Constraints Feed Rate: +58 % Propylene Yield: 9.9 wt-% FF Propylene Rec.: 97 wt-% FF C 3 + in Fuel Gas: < 3.0 mol-% FF UOP has Revamped Over 500 k-bpsd k of Existing FCC Capacity for C 3= in the 7 to 10 wt-% FF FF UOP 4706A-29

25 Summary: There are current economic drivers for FCC s s to produce more propylene. Economics analyses suggest that optimal propylene production is well below what the technology is capable of producing. New unit constructions support that 10 to 11 wt-% propylene production is an economic optimum for most. UOP can help move existing refiners move higher on the propylene production curve within major capital equipment constraints. UOP 4706A-30

26 UOP 4706A-31