Post on 03-Apr-2018
7/28/2019 04_Maximize Benefit from your PRIME-G+ Proceedings.pdf
1/40
Maximize Benefits from your PRIME-G+
the most advanced technology
for FCC gasoline desulfurization
Annick Pucci
7/28/2019 04_Maximize Benefit from your PRIME-G+ Proceedings.pdf
2/40
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
2
7/28/2019 04_Maximize Benefit from your PRIME-G+ Proceedings.pdf
3/40
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
7/28/2019 04_Maximize Benefit from your PRIME-G+ Proceedings.pdf
4/40
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
7/28/2019 04_Maximize Benefit from your PRIME-G+ Proceedings.pdf
5/40
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
5
7/28/2019 04_Maximize Benefit from your PRIME-G+ Proceedings.pdf
6/40
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
6
7/28/2019 04_Maximize Benefit from your PRIME-G+ Proceedings.pdf
7/40
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
7
7/28/2019 04_Maximize Benefit from your PRIME-G+ Proceedings.pdf
8/40
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
8
7/28/2019 04_Maximize Benefit from your PRIME-G+ Proceedings.pdf
9/40
Catalytic
performances
Keys for Prime-G+ Success
Processeconomics
Process
flexibility
Maximizing
BenefitsImproving
performances9
7/28/2019 04_Maximize Benefit from your PRIME-G+ Proceedings.pdf
10/40
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
10
7/28/2019 04_Maximize Benefit from your PRIME-G+ Proceedings.pdf
11/40
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
11
7/28/2019 04_Maximize Benefit from your PRIME-G+ Proceedings.pdf
12/40
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
7/28/2019 04_Maximize Benefit from your PRIME-G+ Proceedings.pdf
13/40
Catalytic
performances
Keys for Prime-G+ Success
Processeconomics
Process
flexibility
Maximizing
BenefitsImproving
performances13
7/28/2019 04_Maximize Benefit from your PRIME-G+ Proceedings.pdf
14/40
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
14
7/28/2019 04_Maximize Benefit from your PRIME-G+ Proceedings.pdf
15/40
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
7/28/2019 04_Maximize Benefit from your PRIME-G+ Proceedings.pdf
16/40
Catalytic
performances
Keys for Prime-G+ Success
Processeconomics
Process
flexibility
Maximizing
BenefitsImproving
performances16
7/28/2019 04_Maximize Benefit from your PRIME-G+ Proceedings.pdf
17/40
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)
17
7/28/2019 04_Maximize Benefit from your PRIME-G+ Proceedings.pdf
18/40
Catalytic
performances
Keys for Prime-G+ Success
Processeconomics
Process
flexibility
Maximizing
BenefitsImproving
performances18
7/28/2019 04_Maximize Benefit from your PRIME-G+ Proceedings.pdf
19/40
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
19
7/28/2019 04_Maximize Benefit from your PRIME-G+ Proceedings.pdf
20/40
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
20
7/28/2019 04_Maximize Benefit from your PRIME-G+ Proceedings.pdf
21/40
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
21
7/28/2019 04_Maximize Benefit from your PRIME-G+ Proceedings.pdf
22/40
Sulfur Distribution with & without APC
Product Sulfur Content
+ 1.2
ppmAveragewithoutAPC
TargetValue
22
7/28/2019 04_Maximize Benefit from your PRIME-G+ Proceedings.pdf
23/40
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
23
7/28/2019 04_Maximize Benefit from your PRIME-G+ Proceedings.pdf
24/40
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
24
7/28/2019 04_Maximize Benefit from your PRIME-G+ Proceedings.pdf
25/40
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
7/28/2019 04_Maximize Benefit from your PRIME-G+ Proceedings.pdf
26/40
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
7/28/2019 04_Maximize Benefit from your PRIME-G+ Proceedings.pdf
27/40
Catalytic
performances
Keys for Prime-G+ Success
Processeconomics
Process
flexibility
Maximizing
BenefitsImproving
performances27
7/28/2019 04_Maximize Benefit from your PRIME-G+ Proceedings.pdf
28/40
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
7/28/2019 04_Maximize Benefit from your PRIME-G+ Proceedings.pdf
29/40
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
7/28/2019 04_Maximize Benefit from your PRIME-G+ Proceedings.pdf
30/40
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
30
7/28/2019 04_Maximize Benefit from your PRIME-G+ Proceedings.pdf
31/40
Axens R&D strategy
Catalyst formulationLab scale screening
Industrial processReactor internals
Process development
Operating conditions
Axens is
committed tocontinuously
improve its
existing products31
7/28/2019 04_Maximize Benefit from your PRIME-G+ Proceedings.pdf
32/40
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
7/28/2019 04_Maximize Benefit from your PRIME-G+ Proceedings.pdf
33/40
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
33
7/28/2019 04_Maximize Benefit from your PRIME-G+ Proceedings.pdf
34/40
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
34
7/28/2019 04_Maximize Benefit from your PRIME-G+ Proceedings.pdf
35/40
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
35
7/28/2019 04_Maximize Benefit from your PRIME-G+ Proceedings.pdf
36/40
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
36
7/28/2019 04_Maximize Benefit from your PRIME-G+ Proceedings.pdf
37/40
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
7/28/2019 04_Maximize Benefit from your PRIME-G+ Proceedings.pdf
38/40
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
38
7/28/2019 04_Maximize Benefit from your PRIME-G+ Proceedings.pdf
39/40
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
7/28/2019 04_Maximize Benefit from your PRIME-G+ Proceedings.pdf
40/40
Conclusion (2/2)
Revamp scenario ranking
Skills(Technology Licensor + Catalyst Supplier)
Catalyst management
Best strategy for APC
Ensure the success / Improve your performance
40