Generating value in the FCC

New catalyst technologies and technical service support helped a refiner

overcome difficulties with VGO conversion

Dicho Stratiev Ivan Chavdarov And Alexandr Ivanov Neftochim Burgas Jsc
Aleksey Popov and Rafael González W. R. Grace & Co.

L
ukoil Neftochim Burgas
Impact of feedstock properties on commercial FCC unit conversion levels
Refinery JSC (Neftochim)
commissioned an H-Oil
Parameter Increasing H-Oil VGO %
vacuum residue ebullating bed Base Scenario 1 Scenario 2 Scenario 3
hydrocracker in 2015 that led to Density, kg/m3 0.9090 0.9145 0.9156 0.9200
a significant deterioration of the Conradson carbon, wt%
KUOP
0.30
12.11
0.31
11.96
0.26
11.93
0.45
11.70
FCC unit’s vacuum gasoil (VGO) Hydrogen content, wt% 12.45 12.28 12.24 12.10
feedstock quality. Consequently, Number of aromatic rings 1.06 1.13 1.15 1.30
Total number of cyclic structures 2.21 2.27 2.30 2.31
a significant drop in conversion Conversion level, wt% FF Base -1.4 -3.6 -6.4
was observed that negatively
affected FCC unit profitabil- Table 1
ity. Grace and Neftochim went
through the challenge successfully by means of institute side-by-side design with a feedstock
a collaboration that included implementation of processing capacity of 250 t/h. Several major
state of the art catalyst technology together with revamps to the unit have been conducted
a variety of tailored services, resulting in a gain through the years, including air distribution, feed
of +1.6 wt% conversion and 0.86 wt% gasoline nozzles, riser termination device, and cyclones,
in the more challenging scenario. In this article, and ancillary equipment in the FCC complex has
Neftochim and Grace explain how a strong tech- also been upgraded/debottlenecked, including
nology partnership can deliver value far beyond the wet gas compressor, steam production sys-
simply the supply of FCC products. tem, and depropaniser unit. The FCC complex
Located on the Balkan Peninsula at 15km from also has a VGO hydrodesulphurisation unit for
Burgas in Bulgaria, Lukoil Neftochim is the larg- feedstock pretreatment.
est oil refinery in the Balkans and the largest
industrial enterprise in Bulgaria. It started oper- The H-Oil VGO challenge
ations in 1963 and became part of the Lukoil The Neftochim FCC unit typically processed des-
group in 1999. With a refining capacity of 7 mil- ulphurised VGO as its main feedstock contribu-
lion t/y, Neftochim refinery produces a wide tor. The FCC unit’s objectives are typically:
range of products that include LPG, gasoline, • Maximise FCC unit conversion.
diesel, jet fuel, and polymers. Neftochim refinery • Maximise gasoline yields and gasoline octane
has a Nelson complexity index of 13 with a crude • Optimise C3= and C4 cut
conversion rate of 87%. • Increase FCC feed throughput.
The FCC is a primary conversion unit that Feedstock properties are the dominating factor
plays a crucial role in the Neftochim refinery determining FCC conversion levels and yields of
profitability. It uses heat and catalyst to convert high margin key products like naphtha, C3=, C4
a low cost, high molecular weight feed type like cut or light cycle oil (LCO). In 2015, Neftochim
VGO into lighter, more valuable products such commissioned an H-Oil vacuum residue ebul-
as gasoline, LPG and fuel oil. Commissioned lating bed hydrocracker and, since then, the
in 1982, Neftochim FCC is a Groznii Project Neftochim FCC unit has processed an approx-

www.digitalrefining.com/article/1002290 Catalysis 2019 1


Figure 1 Overview of FCC conversion through FCC catalyst technologies
imately 20-30% range of a blend of HVGO and
LVGO from the H-Oil unit. As this VGO feed-
stock is already cracked, its nature is very aro-
matic and heavy – it can exhibit densities as high
as 973 kg/m3. Its introduction into Neftochim’s
FCC feedstock blend had a huge impact on feed
crackability, as shown in Table 1.
Given the expected negative impact of pro-
cessing H-Oil VGO, with losses of conversion
between 2-6 wt% FF, the Neftochim refinery
asked Grace to provide technology solutions to
cope with this new, very challenging scenario. To
provide the highest increase in unit profitability
to Neftochim, Grace proposed to engage both
parties in a collaboration to find the optimum
catalyst technology and services, with a focus on
the following value generators:
• Continuous state-of-the-art FCC catalyst and
additives technologies implementation
• FCC unit operations optimisation and
debottlenecking
• FCC unit reliability monitoring and
improvement.
Nadius 4G technology platform
In the current challenging and ever changing
refining market, it is vital to build long term
strategies to maintain the highest levels of com-
petitiveness. Neftochim and Grace have been col-
laborating closely over the last decade to achieve
increases in FCC unit performance throughout
the period. Indeed, continuous implementation
of newly developed catalyst technologies has
delivered consistent unit conversion growth and
additional value to FCC operations (see Figure 1).
Grace has been continuously delivering value
through different technologies to the site since
2012. Due to rare earth hyperinflation in 2011,
Grace introduced its rare earth-free REsolution
2 Catalysis 2019
Figure 2 Nadius 4G catalyst
technology’s main performance
functionalities
technology to help Neftochim alleviate its oper-
ating costs with no debit in catalyst performance.
Indeed, Grace’s Z-21 rare earth-free zeolite
stabilisation delivered a 1 wt% FF conversion
increase compared to the incumbent competi-
tor catalyst at the time. Once this price inflation
period ended, Grace introduced the Nadius 4G
Technology Platform with Nadius 545, which
provided further benefits in unit conversion by
additional 1 wt% FF conversion.
Nadius 4G catalyst technology is the latest
generation of Grace’s Nadius catalyst family
for hydrotreated and straight-run VGO feed
applications. Nadius 4G incorporates new tech-
nologies that were developed during the R&D
programme that was initiated as a result of the
tight oil boom in North America and the new
challenges faced by European refineries. This
R&D programme resulted in advances to key cat-
alytic functionalities; Nadius 4G features higher
zeolitic activity with a tailored hydrogen transfer
specific for this particular application (see Figure
2).
The new catalyst technologies resulted in
successive improvements in FCC unit oper-
ating profitability, as expected. Nevertheless,
Neftochim challenged the status quo and tri-
alled an alternative FCC catalyst supplier in
2015 together with the commissioning of the
H-Oil unit. The resulting conversion levels were
about 2 wt% FF lower than the base level of 2011.
This massive drop of conversion was at the time
partly attributed to the change in FCC feedstock
quality due to its lower crackability.
Meanwhile, Neftochim encouraged Grace to
find new technology solutions to maximise con-
version in the new scenario. Grace conducted
extensive research to develop Nadius 865 ZP
catalyst technology. Subsequent ACE pilot plant
www.digitalrefining.com/article/1002290
 Feedstock properties for ACE
catalyst selection
New feedstock
Density, 15°C, g/cm³ 0.928
Refractive Index, 60°C 1.509
Sulphur, wt% 0.50
Conradson Carbon, wt% 0.15
UOPK Factor 11.69
Nadius 865 performance with 25% H-Oil VGO feedstock blend
Parameter Base Case 1 – H-Oil VGO Case 2 - Nadius 865 ZP Delta
Hydrotreated VGO, wt% 100 75 75 -
H-Oil VGO, wt.% 0 25 25 -
Conversion, wt% FF Base -3.1 -1.5 +1.6
Gasoline yield, wt% FF Base -1.8 -0.95 +0.9

Table 2 Table 3

testing with representative feed-

stock for the new scenario (see

Standard conversion, wt% FF

Nadius 865 ZP
Table 2) against the base catalyst
Base
Nadius 983 catalyst confirmed
the performance according to
Neftochim’s objectives (see
Figures 3-5).
Following the promising per-
formance benefits identified in
the ACE pilot plant for Nadius
865 ZP, Neftochim conducted
a commercial FCC unit trial
employing the technology. FCC 3 4 5 6 7 8
unit results shown in Table 3 Catalyst to oil
revealed that Nadius 865 ZP
provided superior performance, Figure 3 Nadius 865 ZP ACE activity vs base
achieving +1.6 wt% FF conver-
sion and 0.86 wt% FF gasoline at
25 wt% H-Oil VGO level versus
the base case.
Standard gasoline (C5,

Ecat testing results

A change of FCC catalyst rep-
221ºC), wt% FF

resents a significant step for

refiners. Grace provides a risk
mitigation plan and performs
a range of activities to support Nadius 865 ZP

refineries, both before and dur- Base

ing the catalyst change-out, with 3 4 5 6 7 8

the express purpose of minimis- Catalyst to oil
ing those risks and ensuring
a smooth and successful tran- Figure 4 Nadius 865 ZP ACE gasoline vs base
sition. A key part of this rein-
forced technical support is the close monitoring stock are constant, the ACE unit allows a selec-
of the circulating inventory change-out coupled tivity assessment without the influence of the
with an ACE pilot plant Ecat performance eval- ever changing operating variables of the FCC
uation using Ecat samples received on a weekly commercial unit.
basis. It is generally accepted that most of the Results from ACE Ecat testing revealed that
impact on yield shifts from a new catalyst can Nadius 865 ZP provided higher gasoline yields at
be observed when circulating inventory reaches constant conversion while preserving LPG selec-
≥60% change-out level of the new catalyst. As tivity (see Figures 6 and 7).
ACE pilot plant operating conditions and feed- A common issue when searching for improved

www.digitalrefining.com/article/1002290 Catalysis 2019 3

 of bottoms upgrading perfor-
mance at constant conversion
Nadius 865 ZP
Base
is occurring. As Figures 8 and 9
show, Nadius 865 ZP catalyst
technology maintains superior
bottoms cracking selectivity at
Bottoms, wt% FF

constant conversion, while Figure

10 shows improved FCC bot-
toms destruction at constant gas-
oline production.

Delivering value
3 4 5 6 7 8 A value proposal that delivers
Catalyst to oil maximum benefits and eco-
nomic profit requires a profound
Figure 5 Nadius 865 ZP ACE bottoms vs base understanding of needs and
value drivers. Establishment of
a long term partnership with
52
Nadius 865 ZP
the Neftochim refinery ena-
51 Base bled Grace to identify the value
opportunities for Neftochim
50
Gasoline, wt%FF

operations and objectives, and

49 to build a tailored proposal for
technical services to fit the refin-
48
er’s needs. Some of the success-
47 ful outcomes include:
46 • Improved energy efficiency:
69 70 71 72 73 74 75 76 77 Grace and Neftochim managed
Conversion, wt% FF to increase annual profitability
in excess of €1.3 million using
Figure 6 Ecat gasoline selectivity FCC simulation modelling to
optimise steam injection into the
unit.
21 • Feedstock optimisation and
Nadius 865 ZP
20 Base
prediction: Grace supports
Neftochim using simulation and
19
statistical models coupled with
18 ACE pilot plant tests to monitor
LPG, wt%FF

LPG make in the new propylene

17
strategy as well as helping with
16 estimates to Neftochim refin-
ery’s crude selection strategy.
15
46 47 48 49 50 51 52 • Troubleshooting and unit
Gasoline, wt%FF inspection services: Grace pro-
vided support to identify the
Figure 7 Ecat LPG selectivity at constant gasoline yield root cause of a particle loss epi-
sode and its solution. Grace also
gasoline selectivity is the potential bottoms crack- provided Neftochim with a complete FCC unit
ing selectivity debit when catalyst design does not inspection service with a technical report.
have the optimum balance between required high
intrinsic activity and balanced hydrogen transfer. Conclusion
Therefore, it is vital to check that no deterioration By means of the latest Nadius 865 ZP technology,

4 Catalysis 2019 www.digitalrefining.com/article/1002290

Neftochim was able to increase
significantly FCC unit conver- 10.5
sion and gasoline yield by 1.6 10.0 Nadius 865 ZP
wt% FF and 0.9 wt% FF, respec- 9.5
Base
tively, after introducing the
9.0
heavy, poorly crackable H-Oil

Bottoms, wt%FF
8.5
VGO into the feedstock blend.
8.0
Although challenged with a com-
7.5
petitive technology trial, Nadius
4G demonstrated its performance 7.0
in VGO maximum conversion 6.5
applications. Additionally, a 6.0
69 70 71 72 73 74 75 76 77
technical support team delivered
a list of opportunities for value Conversion, wt% FF
creation, including unit opera-
tions and feedstock optimisation, Figure 8 Ecat bottoms selectivity
FCC simulation models, turna-
round and revamp inspection, 21
or specific logistical services that 20
Nadius 865 ZP
Base
helped Neftochim to extract fur-
ther profitability from their FCC 19
unit. 18
To stay competitive in the
LCO, wt%FF

current increasingly challeng- 17

ing refining market, it is vital to 16

both utilise highest performance
catalyst and additives in the 15
69 70 71 72 73 74 75 76 77
market as well as continuously Conversion, wt% FF
identify value opportunities
from the FCC operations. Lukoil Figure 9 Ecat LCO selectivity
Neftochim Burgas JSC refinery
and Grace demonstrated that, 10.5
Nadius 865 ZP
through a strong, long term 10.0
Base
partnership far beyond the sup- 9.5
ply of FCC products, it is possi- 9.0
Bottoms, wt%FF

ble to create an environment of 8.5

collaboration to maximise profits 8.0
in the FCC unit.
7.5
NADIUS is branded as AURORA in the 7.0
Americas and Asia.
6.5
Dicho Stratiev is Chief Process Engineer 46 47 48 49 50 51 52
with LUKOIL Neftochim Burgas JSC. Gasoline, wt% FF
Ivan Chavdarov is Deputy Project
Manager of FCC Revamping Project with Figure 10 Ecat bottoms yields vs gasoline production
LUKOIL Neftochim Burgas JSC.
Alexandr Ivanov is Chief Engineer/First Deputy of Chairman of
Management Board with LUKOIL Neftochim Burgas JSC.
Aleksey Popov is Technical Sales Manager with W. R. Grace &
More articles from: W. R. Grace & Co.
Co.
Rafael González is Regional Marketing Manager EMEA with W. More articles from the following categories:
R. Grace & Co. Catalysts and Additives
Fluid Catalytic Cracking

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