RFCC KBR Features

© 2009 KBR. All Rights Reserved.

Residue FCC Designfor Performance

and Reliability

Phil NiccumKBR


You want to put Resid in the Cat Cracker?

♦ Will the resid harm the Cat Cracker?

♦ Do we have the FCC capacity?

♦ What else must be considered?

♦ What are the technology alternatives?


What Cats LikeImportant Feed Characteristics

♦ Large Saturated

Hydrocarbons

♦ Clean

♦ Reliable Supply


What Cats DislikeFCC Feed Characteristics to Avoid

♦ Vanadium Increases catalyst make-up

♦ Carbon Residue Increases coke make Increases required regenerator

size, air rate and catalyst cooler duty

♦ Aromatic Content Negative Impact on conversion

and yield selectivity


Vacuum Distillation: FCC Feed Lost in Vacuum Residue

Direct Feed to FCC: Contaminant Issue (Metals and CCR)

Coking: Addresses Contaminant Issue Hydrogen Deficient Feed to FCC

Hydroprocessing: Addresses Contaminant IssueHigh Cost (TIC, H2, Catalyst)

ROSE: Addresses Contaminant IssueFeed to FCC not Hydrogen Deficient Low Capital and Operating Costs

Residue Upgrading Options for FCC Feed


Residue FCC Processing ChallengesMore than just coke burning capacity

♦ Reaction System Minimize coke production

• Fine feed atomization and low operating pressure

♦ Regeneration System Manage heat generation from coke burning Minimize catalyst deactivation


KBR FCC Rx System Technologies

♦ ATOMAX-2™ FEED NOZZLES Fine atomization,

excellent riser coverage

ATOMAXATOMAX™™


DynaFluxDynaFlux™™


♦ DYNAFLUX™ STRIPPING Better stripping efficiency, even in

high flux strippers



♦ RISER QUENCH TECHNOLOGY Higher mix zone severity,

improves gasoline yieldand octane

Fresh FeedFresh Feed

QuenchQuench



♦ CLOSED CYCLONES 30-40% less dry gas than

unducted riser termination

Closed CyclonesClosed Cyclones


KBR FCC Regenerator Technologies

♦ Countercurrent Regeneration Only one stage needed for residue

processing

♦ Catalyst Cooler Reliably cool regenerator Generate valuable steam


KBR FCC Regenerator Technologies

♦ Countercurrent Regeneration Only one stage needed for residue

processing

♦ Catalyst Cooler Reliably cool regenerator Generate valuable steam

Water In

Water /Steam Out

Catalyst In

FluidizationFluidizationAirAir

Catalyst Out


Partial CO Combustion – Better for Residue

♦ Minimizes catalyst cooler requirements

♦ Reduces size of major equipment Regenerator vessel Regenerator cyclones Air blower

♦ Reduces catalyst makeup by limiting vanadium-induced deactivation

♦ Partial combustion does require CO Boiler or other CO destruction device


V2O5 generated in oxidative environment:4 V + 5 O2 ----> 2 V2O5

Vanadia migrates to other particles via volatile vanadic acid:V2O5 + 3 H2O ----> 2 VO(OH)3

Old Catalyst(lots of vanadium)

New Catalyst(no vanadium)

Old Catalyst "New" Catalyst

BEFORE MIGRATION AFTER MIGRATION

(Vanadium equilibrated between particles)

Vanadium Mobility


Complete Combustion – Better for Gas oils

♦ Simplifies Operation Avoids afterburning even during start-up

♦ Maintains regenerator temperature on HDT VGO

♦ Reduces NOx emissions

♦ Minimizes carbon on regenerated catalyst

♦ Does NOT require CO Boiler or other CO destruction device


KBR Counter-current Regenerator

Spent Catalyst(high carbon)

+ Low O2

Regen Catalyst(low carbon)

+ High O2

DENSEPHASE

BED

cata

lyst

air

Air Distributor

Spent Cat Distributor


Spent Catalyst DistributorOrthoflow™ FCC Installation

Self- Aerated Distributor

Troughs

Spent Cat Standpipe


low O2

high O2


Catalyst(low carbon)

Dense PhaseBed

+

+

cata

lyst

air

Regenerator Design ComparisonsKBR Counter-current Regeneration.

♦ Air travels up

♦ Catalyst travels down

♦ High carbon catalyst contacts low O2 gas minimizes burning rate and particle

temperature

♦ Low carbon catalyst contacts high O2 gas minimizes burning rate and particle

temperature

♦ Dense phase particle contact dissipates heat of combustion Prevents high particle temperatures

♦ Low particle temperature minimizes catalyst deactivation


Regenerator Temperature ControlWhy use a Catalyst Cooler

♦ Provide feedstock and product flexibility Process high carbon residue feedstocks Process VGO feeds at high reaction

temperatures for maximum propylene

♦ Provide Process flexibility Optimize cat/oil ratio Optimize catalyst matrix and zeolite

♦ Minimize catalyst deactivation Reduce catalyst costs

♦ Minimize dry gas make at mix zone

KBR FCCU with Cat Cooler


KBR Dense Phase Catalyst Cooler

SlideValve

CatalystReturn

FluidizationAir

Catalyst In Tubesheet

Tubesheet

InnerTube

Scabbard --Outer Tube

Water In

Water &Steam Out


Dense Phase Catalyst Cooler TechnologyFlexibility for Cracking Heavy Feedstocks


Key Features of Catalyst Cooler

♦ High Heat Transfer Coefficient♦ Flow-Through Design Provides

Heat Removal Flexibility♦ No Fluidization Impingement

on Tubes♦ 16 Coolers Operating Since 1990

with No Erosion Related Shut-downs

Water In

Water /Steam Out

Catalyst In

FluidizationFluidizationAirAir

Catalyst Out


Key Features of Catalyst Cooler

♦ High Heat Transfer Coefficient♦ Flow-Through Design Provides

Heat Removal Flexibility♦ No Fluidization Impingement

on Tubes♦ 16 Coolers Operating Since 1990

with No Erosion Related Shut-downs


Easy To Remove Tube Sheet

Easy Removalof Tube Bundle

From Top

Cooler Tube Bundle Lift at KPI


Performance of Dense Phase Catalyst CoolerHeat Removal Duty vs. Catalyst Circulation Rate

50

60

70

80

90

100

110

120

130

0 20 40 60 80 100 120 140

Catalyst Circulation Rate Through Cooler (% of Design)

Cat

alys

t C

oo

ler

Du

ty (

% o

f D

esig

n)


Regenerator Temperature ControlCat Cooler can adjust automatically to feed changes

712

716

720

724

728

Time (hours)

0

10

20

30

40

50

60

70

80

90

100

0 5 10 15 20 25

Cat Cooler Duty Cat Cooler Duty Regen Temp Regen Temp

Cat

alys

t Coo

l er

Dut

y (%

of d

esig

n)

Reg

ener

ator

Tem

pera

ture

(°C

)


Example of Increasing Feed CCR and Metals

♦ 70,000 BPSD atmospheric resid direct to FCC

♦ Catalyst cost at $2,000/ton

♦ Va/Ni ratio is 1/1


Dealing With Regenerator Bed Temperature

0

2

4

6

8

10

12

0 2 4 6 8

ConCarbon, wt%

Co

ke Y

ield

, wt%

Total BurnPartial Burn

Catalyst Cooling200 MMBtu/hr 400 MMBtu/hr


Catalyst Makeup Costs

0

0.5

1

1.5

2

2.5

0 10 20 30 40 50 60

Total Metals, wppm

Cat

alys

t C

ost

, $/

bb

l Va/Ni=1 Va/Ni=4

Typically consider alternatives at 20 ppm total metals


Other Advantages of Countercurrent

Regeneration


Regenerator ComparisonsSide Entry vs. Center Entry with Catalyst Distributor

Side Entry Regenerator Center Entry with Spent Catalyst Distributor


Catalyst(high carbon)

low O2

high O2

Spent Catalyst(low carbon)

Dilute PhaseBed

+

+

cata

lyst

air

Regenerator Design ComparisonsCo-current Regeneration

♦ Highest carbon catalyst contacts fresh air with 21% O2

♦ Rapid O2 transfer produces high burning rate

♦ Heat transfer to fluid bed is not rapid enough to prevent high particle temperatures

♦ High particle temperatures accelerate catalyst deactivation


Catalyst Interior Particle Temperature Rise

Com

bust

ion

Rat

e

Time

Lowest O2, high coke, controlledheat release,

little diffusional resistance

Highest O2, high coke,rapidheat release,

little diffusion resistance

♦ Concurrent Regeneration Rapid burning results in rapid temperature increase inside the particle Burning rates remain relatively high during the first 25-30% of combustion Temperature spike inside the particle Temperature rise- water- metals all combine to deactivate catalytic sites

♦ Countercurrent Regeneration Much lower burning rates mitigates interior temperature rise Burning rates remain well below cocurrent for most of the combustion Lower burning rates allow the heat to be dissipated to flue gas

ΔT

empe

ratu

re

Cocurrent

CountercurrentAdditional

Deactivation

Temperaturespike


Commercial Catalyst ActivityImprovement From Counter-Current Regeneration

BASE CASECo-Current

REVAMPCounter-current Delta

Catalyst Data:

Surface Area, m²/g 143 162 +18

Avg. bulk density, g/cc 0.90 0.88 -0.02

Pore volume, cc/g 0.34 0.39 +0.05

MicroActivity, wt% 68.5 73 +4.5


low O2

high O2


Regen Catalyst(low carbon)

DensePhaseBed

+

+

cata

lyst

air

Mechanism of KBR FCC NOx Reduction

When spent catalyst distributedacross top of regenerator bed...

NO produced in bottom of bedcontacts carbon near top of bed

2 C + 2 NO ----> 2 CO + Nitrogen

Less than 10% of nitrogen in cokeburns to NOx in Counter-CurrentRegeneration


Two Stage Units Add Complexity

♦ Higher Investment (up to 20%)

♦ Operations More Complicated


Major Equipment Summary

10 (for full burn)

1 (for partial burn)CO Boiler

21Orifice Chambers

10Catalyst Transfer Line Expansion Joints

42Catalyst Transfer Lines

21Flue Gas Slide Valves

32Catalyst Slide Valves

32Major Reaction Vessels

Two Stage RegeneratorKBR Orthoflow


Total Installed Costs

120.4 %--Delta Cost

1401011640Total $(000)

13701140Bulk Materials

300250Catalyst Storage Drum

23701300Flue Gas System

41203900Air Blower

58505050Converter



Percent of Total Installed Cost

120.4100.0Total (%)

11.79.8Bulk Materials

2.62.1Catalyst Storage Drum

20.411.2Flue Gas System

35.433.5Air Blower

50.343.4Converter



Orthoflow™ FCC ConverterMaximum Operating Flexibility

FCC Type VGO Resid Complete Partial

R2-R X X

High Efficiency X X X

KBR Orthoflow™ X X X X

FEEDSTOCK COMBUSTION

♦ CONCLUSION: The Orthoflow™ regenerator handles VGO’s or Resid’s in complete or partial combustion without compromise


Regenmax Technology


Orthoflow™ RegenMax™

Spent Catalyst

Regen Catalyst Air

Flue Gas

CatalystBed

Spent Catalyst

Regen Catalyst Air

Flue Gas

CatalystBackmixingAirCatalyst

UpperBed

LowerBed

Regenmax™ TechnologyBaffle Provides Staging In Single Vessel

UpperBed

LowerBed

Baffle


Regenmax™ Technology

RegenMax™ ModelRegenMax™ Baffle


Photo of Regenmax™ Baffle


Regenmax™ Benefits

♦ Burns catalyst clean in partial CO combustion Without requiring an increase in catalyst inventory or unit size

♦ Achieves this in a single, simple regenerator vessel Less costly than building

two-stage regenerators

♦ Feedstock operatingflexibility Can switch to complete

combustion when desired


Reliability of Regenmax™

♦ Baffle does not interferewith catalyst flow fromupper bed to lower bed High percentage of

open area Unique design limits

backmixing

♦ No change in densityprofile in bed

♦ No flooding or otherflow problems


KBR Orthoflow Advantages for Residue Processing

♦ Reaction Features Low Pressure – Short Contact Time Minimizes gas and coke

♦ Regeneration Features

Ultimate regenerator operating flexibility accommodates the reactor heat demand

• Full or partial CO combustion• Dense phase catalyst cooler

Economy of design and operation• Single stage regeneration• Minimize catalyst deactivation• Low NOx emissions Mobil Altona


Thank you very much…

Questions?

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