(R)FCC Product Flexibility

with FlexEneTM
Christian Dupraz

Agenda

Propylene & Regional Fuels Market

Product Flexibility
(R)FCC Options for High Propylene Yield
Integrated FlexEne Configuration
Selectivity of Propylene Production
Additional Product Flexibility Opportunity
Conclusion

GTF ARTC 2012 - Bangkok

Global Trend for Propylene

Production Forecast by Source
2010 Production
~ 75 Million tons (Mt)

2010-2015: Additional Propylene

Production by Source
20 Mt/y
18
16
14
12
10
8
6
4
2 Basis
0
2010 2011

12%

52%
36%

From Refineries
(DCC/RFCC/FCC)
From Steam crackers
On purpose production*

2012

2013

2014

2015

Average Annual Growth Rate ~ 4.5%

Additional propylene production
from refineries > 4 Mt/y

* Metathesis, Olefins cracking, MeOH to propylene,

C3 dehydrogenation
GTF ARTC 2012 - Bangkok

Source: Axens (2011)

Regional Trend for Fuels:

Asia Pacific Growth in Motor Fuels
Market Structure
2010 vs. 2020
11.7%

AAGR %/yr

10.2%

9.2%

3.3%

14.8%

15.6%

19.9%

21.3%

3.7%
13.1%

4.7%
14.6%

15.6%

14.0%

40%
20%
0%

11.0%

9.7%

2010
27.4
Mbdoe

2020
35.4
Mbdoe

1.5

3.6%

3.2%

1.0
4.9%

0.5

2010-2020
AAGR
2.6%

Other* = Kerosene ( Jet Kerosene), Refinery Gas, Petroleum Coke,

NGL, Lubricants, Bitumen, Paraffin Wax, Refinery Losses,
GTF ARTC 2012 - Bangkok

2.0

0.0

G Je
as t
o
N lin
ap e
ht
ha

60%

Other*
LPG
Naphtha
Motor Gasoline
Jet Kerosene
On-road diesel
Off-road diesel
Fuel Oil

80%

2.5
10.9%

D
ie
se

100%

Mbdoe

Incremental Demand
2010-2020

Source: Axens & other sources (2010)

4

Refinery FCC Options for

Higher Propylene Production

High Severity, Specific Design &

ZSM-5 Catalyst Addition
Very selective

Recycle of Light Naphtha (LN) or

C4 Cut
Higher severity, 2nd Riser

GTF ARTC 2012 - Bangkok

Simplicity of recycle appears

attractive

Are there alternatives which are

more selective & flexible?
5

High Severity Plus High ZSM5 Addition

Is There More Propylene Potential?
Propylene & C5-160C LN vs Conversion & ZSM5*
16

50
C3= with ZSM5
LN with ZSM5
LN without ZSM5

12
Propylene, wt%

48

C3= witout ZSM5

46

10

44

42

40

38

36

LN, wt%

14

*Basis: HDT VGO, Low RE catalyst with high ZSM5 content

34
76

GTF ARTC 2012 - Bangkok

78

80
82
Conversion, wt%

84

86
6

LN Recycle Cracking For Max Propylene

Limited Potential
25

50

Molar profile
Feed=100

Aromatics
C5=

Ci mol, feed base 100

20

40
C3=

15

30

10

20

C6=
C4=

10
C7=

0
0

50

100
150
Increasing
Conversion

200

0
250

Over 60 w% of olefins converted become aromatics!

Low conversion, high gas yield & limited ultimate
propylene potential when recycled to extinction
GTF ARTC 2012 - Bangkok

Other Options:
C4 Cut Direct Recycle Cracking

Full C4 cut is recycled (about 40% non-reactive paraffin)

Conversion of C4 olefin via C8+ oligomer intermediates
Severe conditions required: high gas yield & aromatics
C5+ Composition

18
14
12

Olefin
Paraffin

50

Aromatics
40

10

Wt%

Wt%

60

Gas
Propylene
Gasoline

16

30

20

10

20
40
60
Butene Conversion, %

80

20

40
60
Butene Conversion, %

80

* HDT VGO, Low RE catalyst with high ZSM5 content

GTF ARTC 2012 - Bangkok

Another Way: FlexEneTM

Flexible
AlkEne Oligomerization & Recycle
Flex

FlexEne Light Olefin Processing Route

STEP 1

C4 olefins are transformed into C8 & C12 olefins

(oligomers) in a PolyNaphtha (oligomerization)
Unit
STEP 2

Oligomers are highly reactive and crack

selectively toward propylene in FCC

GTF ARTC 2012 - Bangkok

FlexEne: Integration of Proven

Technology: Polynaphtha & FCC
Product
Recovery
C4 cut

C4 Raffinate

Gasoline

Gasoline
Recycle

FCC Feed:
VGO/Resid
GTF ARTC 2012 - Bangkok

Distillate

Fuel Gas
Propylene
LPG
Gasoline
Distillate
Fuel Oil

TM
PolyNaphthaTM

Oligomerization

Recycle Selected
Oligomers to FCC Riser
to Maximize Propylene

Distillate

Motor
Fuels

Recover Oligomers as
or Gasoline or
or Distillate
Distillate to
to
optimize G/D
G/D ratio
ratio
10

FlexEne Provides Highest Selectivity for

Light Olefins to Propylene
Propylene / Wet Gas (mol/mol)

Relative Propylene Selectivity v Recycle

2.5
2.0
1.5
1.0
0.5
0.0
Direct C4

LCN

C4 Oligomers

Oligomer cracking is more selective with lower

impact on Wet Gas Compressor (WGC)
Less gas & aromatics formation for higher ultimate
propylene yield when recycled to extinction
GTF ARTC 2012 - Bangkok

11

Flexibility Example:
FlexEne Applied to C4 or C3/C4 Cut
100%
90%
80%
70%
Dry gas

60%

LPG w/o C3=

C3=

50%

Gasoline

40%

Distillate
DCO

30%

Coke

20%
10%
0%
Max Gasoline
FCC alone
GTF ARTC 2012 - Bangkok

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Product Flexibility - Gasoline Case

FCC
Gasoline Mode
Products

Propylene

PolyNaphtha
Gasoline Mode

Propylene for
Max Gasoline

FCC C4 cut

Distillate
GTF ARTC 2012 - Bangkok

Gasoline

Motor
Fuel
13

Flexibility Example:
FlexEne Applied to C4 or C3/C4 Cut
100%
90%
80%
70%
Dry gas

60%

LPG w/o C3=

C3=

50%

Gasoline

40%

Distillate
DCO

30%

Coke

20%
10%
0%
Max Gasoline

Max Gasoline

FCC alone

FCC + FlexEne

Recycle of oligomerized C4 or C3/C4 Cut

GTF ARTC 2012 - Bangkok

14

Product Flexibility - Distillate Case

FCC
Distillate Mode
Products

Propylene
Propylene for
Max Distillate

FCC C4 cut

Gasoline
GTF ARTC 2012 - Bangkok

PolyNaphtha
Distillate Mode

Distillate

Motor
Fuel
15

Flexibility Example:
FlexEne Applied to C4 or C3/C4 Cut
100%
90%
80%
70%
Dry gas

60%

LPG w/o C3=

C3=

50%

Gasoline

40%

Distillate
DCO

30%

Coke

20%
10%
0%
Max Gasoline
FCC alone

Max Gasoline

Max Distillate

FCC + FlexEne FCC + FlexEne

Recycle of oligomerized C4 or C3/C4 Cut

GTF ARTC 2012 - Bangkok

16

Product Flexibility - Propylene Case

FCC
Propylene Mode
Products

Propylene

FCC C4 cut

Gasoline
&
Distillate

GTF ARTC 2012 - Bangkok

PolyNaphtha
Conversion Mode

Motor
Fuel
17

Flexibility Example:
FlexEne Applied to C4 or C3/C4 Cut
100%

5.0

90%
80%

4.0

70%
Dry gas

60%

G/D

3.0

50%
40%

2.0

LPG w/o C3=

C3=
Gasoline
Distillate
DCO

30%

Coke

20%

1.0

G/D

10%
0%

0.0
Max Gasoline
FCC alone

Max Gasoline

Max Distillate

Max Propylene

FCC + FlexEne FCC + FlexEne

FCC + FlexEne

Recycle of oligomerized C4 or C3/C4 Cut

GTF ARTC 2012 - Bangkok

18

PolyNaphtha Puts the Flex(ibility)

in FlexEne
A separate PolyNaphtha Oligomerization unit
provides superior yields and greater flexibility

Flexibility to vary Gasoline vs Distillate ratio:

Gasoline Mode: 100% Gasoline

Distillate Mode: 70% Jet-Diesel / 30% Gasoline

Option to recover oligomers or recycle crack

Low cost alternative to alkylation

Simple fixed bed process with fully regenerable

Si-Al catalyst
Can be extended to C3-C9 olefinic streams

GTF ARTC 2012 - Bangkok

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FlexEne Advantages

Combination of 2 widely proven processes

FlexEne can target increased C3= or Motor

Fuels (G or D) via selection of recycle cut

Flexibility to change product target.

FlexEne adds ~ 3%wt absolute to C3= yield

FlexEne effect is cumulative over and above the
effect of temperature & ZSM-5

May be extended to C3-C9 cuts depending on

market demand (G/D, C3=/G, etc.)

GTF ARTC 2012 - Bangkok

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Resid Application: Soukhna Refinery &

Petrochemical Complex

Location: Soukhna, Egypt

Source: Google Earth

R2P (Resid to Propylene) Technology

68,000 bpsd
R2R technology, >10 wt% Propylene
FlexEneTM, Gasoline & Propylene mode
Feed: API=23, CCR=3, S = 1.6 wt%

GTF ARTC 2012 - Bangkok

21

VGO Application:
PETRON Bataan Refinery

Location: Bataan, Philippines

Source:Petron

High Propylene FCC (HP FCC)

35,900 bpsd
250 000 ktpa of Propylene
FlexEneTM, Gasoline & Propylene mode
Feed: VGO + Hydrotreated Coker Gasoil

GTF ARTC 2012 - Bangkok

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Conclusion

Strong demand for Propylene & regional

demand for all fuels - product flexibility desired

LN & C4 recycle to FCC is not selective for

added propylene and no impact on distillate

FlexEne combines proven FCC & PolyNaphtha

technology to optimize production of
propylene, gasoline, jet or diesel = Flexibility

FlexEne has been applied in 7 projects over the

last 3 yrs

GTF ARTC 2012 - Bangkok

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(R)FCC Product Flexibility

with FlexEneTM