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  • 7/27/2019 HP Septiembre 2010 New Upgrade Ceramic Feed Distributor Performance Part1

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    REFINING DEVELOPMENTS SPECIAL REPORT

    HYDROCARBON PROCESSINGSEPTEMBER 2010 I 57

    Upgrade FFC performancePart 1New ceramic feed distributor offers ultimate erosion protectionL. M. WOLSCHLAG and K. A. COUCH, UOP LLC, a Honeywell Company, Des Plaines, Illinois

    F luid catalytic cracking (FCC) technology has been a part of the petroleum industry since the 1940s. Despite being a very mature technology, continued development is vital, especially as many refiners move their FCC operations from fuels produc-tion to higher-value products. Advanced diagnostic and designtools are accelerating process developments.

    Through the development and commercialization of world-scale FCC units, technical discoveries have emerged that provideopportunities for improvements across all units, independent of size. Using sophisticated engineering tools, such as computationalfluid dynamic (CFD) modeling combined with radioactive tracerand tomography, will streamline physical inspection reports andcommercial yield analysis. The article highlights advancementsin regenerator technology for higher capacity through existing assets, emissions reduction and feed distribution systems forlarge-diameter risers.

    Dual-radius feed distributors. As refiners look to capital-ize on economies of scale, design throughputs of FCC units havereached record levels. At these scales, opportunities have emerged

    from the background noise of the data to improve FCC technol-ogy. Through pushing multiple constraints to design limits on oneparticular unit, yields and conversion deviated from benchmark performance, with gasoline selectivity lower, conversion lower anddry gas higher than benchmark performance. To get more out of the existing asset, an intensive program was undertaken to achievebenchmark performance.

    The riser for a particular FCC unit has an inner diameter(ID) of 6.6 ft at the point of feed injection, which expands to 9ft immediately above. The feed is injectedinto the riser through a set of circumferen-tially positioned distributors. The combi-nation of low conversion and high dry gasyield seems counter-intuitive, given tradi-tional FCC operations. A hypothesis wasraised that the large riser diameter mightbe preventing the feed from adequately distributing across the full cross-sectionalarea of the riser. To test this hypothesis,a CFD model of the riser was created toanalyze the fluid dynamics of the system.Results of the model supported that raw oilfeed would only penetrate the riser a finitedistance, thus creating a vapor annulus,and that much of the catalyst flowing upthe riser would form a high-density core.Based on CFD results, a tomographic anal-

    ysis (gamma scan) of the riser was completed. The scan resultsconfirmed the CFD model prediction as illustrated in Fig. 1.

    Radioactive tracer work was also completed on the 9-ft IDriser. Irradiated Krypton-79 gas was injected into the riser base.Detectors were positioned along the riser length and reactor tomeasure the tracer as it moved through the system. The resultsindicated that the time of flight of the krypton gas from onedetector to another did not provide a sharp response peak. Anearly peak followed by a secondary peak which was skewed a highdegree is shown in Fig. 2.

    A mathematical evaluation was performed to determine whattype of continuous stir tank reactor (CSTR) response would beneeded to emulate the measured data. To accurately reproduce thefield data plot, a composite plot modeled 100, 40 and 15 CSTR responses (Fig. 2).

    Unit performance, CFD modeling, tracer and tomography tests, and mathematical analysis all indicated the same pathol-ogythe feed was not adequately accessing the full cross-sec-tional area of the riser leading to the presence of a high-density core of catalyst and a low-density annulus, which caused low

    conversion and high dry gas and coke make. One solution tothis problem would be to install two, smaller diameter risers tomatch more conventional FCC sizes. However, installing dualrisers, even with new construction, is substantially more expen-sive. For an FCC unit of 200,000 barrels per stream day (bpsd),the estimated cost difference between a single, large-radius riserand a pair of smaller risers has a cost estimated at $60 million.

    A substantially lower cost solution with an implementation of dual-radius feed distributors was developed (Fig. 3). This design

    CFD prediction and gamma scan of 6.6-ft riser.FIG. 1

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    REFINING DEVELOPMENTSSPECIAL REPORT

    58 I SEPTEMBER 2010 HYDROCARBON PROCESSING

    ensures optimal feed distribution across the entire riser, whileavoiding adjacent spray impact that could cause undesirablespray interference.

    Another CFD model that incorporates the dual-radius feeddistributors was created. Fig. 4 shows catalyst density profiles of an axial slice of the riser, both with and without dual-radius feeddistributors. The riser on the left side without the dual radius feed

    distributors shows the high-density core of the catalyst; the CFDmodel with the dual radius feed distributors indicates that thecatalysts dense core is effectively eliminated.

    The dual-radius feed distributors were installed on a FCC unitdesigned with an 8-ft-diameter riser at the point of feed injection.The unit was commissioned in May 2009. Results indicate that dry gas yield and conversion and gasoline selectivity were within expec-tations. The risers gamma scans indicate that the catalysts highdensity core was effectively eliminated. The catalyst density profileof the riser at approximately 1 pipe diameter above the point of dual radius feed injection, indicates that core annular flow has beenachieved with an evenly distributed catalyst density profile (Fig. 5).

    Additional tomography scans were completed at varying feed ratiosto optimize distribution of oil and steam across the riser.

    Erosion of the inner feed distributors was a client concern.This was mitigated by using ceramic feed distributors. Ceramic

    offers the ultimate in erosion protection, and feed distributors with ceramic tips can withstand highly erosive environments withzero discernable erosion.

    CERAMIC FEED DISTRIBUTORS

    Development. FCC feed distributor tips are subjected to a

    high-temperature, high-velocity erosive environment. To func-tion in this harsh environment, FCC feed distributors have his-torically been fabricated from various erosion-resistant materials.

    While these materials are proven effective at reducing rates of erosion, most erosion-resistant materials are, by their nature,generally hard and brittle and can be susceptible to brittle frac-ture. Erosion and brittle fracture have been an industry-wideissue, and can be induced mechanically or by thermal shock.This must be considered in the design of FCC feed distributorsas erosion and brittle fracture can occur when relatively cold oiland/or steam are rapidly introduced to the system in which thetips are hot from circulating catalyst.

    These issues were addressed in many ways with a distributionsystem. Following proper operating procedures will avoid thermalshock and brittle fracture. However, erosion is more a function of operating environment as opposed to improper operation.

    Designs. Advanced design feed distributors include three pri-mary designs: standard, weld overlay and ceramic. The standarddesignthe new distributor for most FCC applicationsbal-ances the erosion issue and the possibility of cracking due to ther-mal shock. The tip incorporates a more erosion-resistant metalalloy, changing the geometry and reducing stress concentrations.Incorporating orifice extensions extends the flashing hydrocarbonfeed further away from the metal tip. Additional protection canbe provided by applying a very hard diffusion coating over thecobalt-based (Co-based) alloy.

    The weld overlay design is applied to resolve chronic problems with wet steam and installations that have a high risk of thermalshock. The erosion-resistant weld overlay is applied to a softer,more ductile base metal for superior thermal shock resistance.To further combat erosion, this tip incorporates orifice exten-sions to move the flashing hydrocarbon feed further away from

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    Schematic of dual-radius feed distributors.FIG. 3CFD models of the riser catalystprofiles with and without dual-radius feed distributors.

    FIG. 4

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    REFINING DEVELOPMENTSSPECIAL REPORT

    60 I SEPTEMBER 2010 HYDROCARBON PROCESSING

    the distributor tip. While a very hard diffusion coating is usedto provide additional protection against erosion, the primary design goal is resistance to thermal shock, and, therefore, it isrecommended only for FCC operations that have proven to beparticularly susceptible to thermal shock.

    Finally, the ceramic design represents a step-change improve-ment for superior erosion resistance. Determining the erosion

    potential of FCC feed distributors is based on the physical prop-erties of the feedstock. The ceramic design is used in applications where erosion is forecast to be higher than normal or in units thathave previously exhibited high erosion rates. Even though theceramic material is very hard, quench testing in the laboratory

    and commercial application have indicated that new ceramic tipsare no more susceptible to thermal shock than traditional fabrica-tions with co-based alloys. Fig. 6 shows three new tip designs, as

    well as older versions.

    Ceramic tipsdesign challenges. Ceramic materials are widely accepted and proven to be more resistant to erosion than

    metallic materials. The characteristics that impart erosion resis-tance also tend to make these materials more brittle. Successfulapplication of ceramics in FCC feed injection required that twotechnical challenges be overcome: 1) selecting a suitable ceramicmaterial that can be fabricated into the required geometry and2) developing a means to connect the ceramic tip to the metallicbase assembly of the distributor.

    The geometry used for the ceramic distributor tip was thesame as the traditional elliptical-feed distributor. The same prin-ciples and considerations applied to reducing mechanical stressesand improving thermal shock resistance in metallic tips wereapplied to address the brittle nature of ceramics. The ceramictips were subjected to laboratory quench testing to simulate theunique temperature profiles in the feed-injection system. Quenchtesting was used to help select the proper ceramic material, and itconfirmed that the final material was no more susceptible to brit-tle fracture than previous FCC feed distributor metallic tips.

    The large differences in thermal expansion coefficientsbetween the materials provided the next challengea meansof attaching the ceramic tip to the metallic base assembly.The attachment should provide a liquid-tight seal at designpressure drop across the distributor, while accommodating a wide range of feed and steam temperatures experiencedacross startup, normal operation and FCC unit shutdown.Creative engineering, stress modeling, full-scale prototyping and therma-cycle testing were all used to develop a proprietary mechanical connection. With an acceptable ceramic identi-

    fied and a means of connecting the ceramic to the metal baseassembly, the next step was to demonstrate new distributorsin a commercial application.

    Ceramic tipsa commercial experience. As the designdetails for the new ceramic tip and connection were finalized,an opportunity presented itself in which two ceramic tips couldbe installed in the same reactor riser at the same time as metal-lic tips, providing an ideal side-by-side commercial test.1 Thesubject FCC had a history of aggressive feed distributor tip ero-sion, and a trial installation of the ceramic tips was welcomed.Final design details regarding tip connection were addressed. In

    Gamma scan of 8-ft ID riser with dual-radius feed

    distributors.

    FIG. 5

    FCC feed distributor tip designs.FIG. 6 Metallic and ceramic feed distributor tips after 18 monthsin operation.

    FIG. 7

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    REFINING DEVELOPMENTSSPECIAL REPORT

    62 I SEPTEMBER 2010 HYDROCARBON PROCESSING

    April 2007, ceramic tips were commissioned in a commercialFCC reactor riser.

    After 18 months of operation, the ceramic tips were inspectedand were free of erosion and cracking, while the adjacent metal-lic tips exhibited signs of erosion. In Fig. 7, the metallic tipshows significant erosion, while the ceramic tip shows zerodiscernable erosion.

    The viability and benefit of using ceramic tips for the feeddistributor were confirmed. The expected life of the distributorsin this application was revolutionized, from imminent failure(with an average run life of 23 years), to potentially a life withperpetual success.

    Since January 2010, FCC ceramic feed distributors have beendelivered to three refiners in addition to the trial installation. Thesecond installation was placed into service on May 17, 2009, andit continues to perform well with two additional project ship-ments pending. Ceramic distributors are currently recommendedand supplied as the premiere offering to improve reliability ininstallations with aggressive distributor tip erosion.

    Elephant trunk arm combustor riser disengager.The market drive to maximize returns through economies of scale can present technical challenges with respect to scale-up. A phenomenon occurred on a large combustor style FCC regenera-

    tor in which flue-gas catalyst losses appeared to increase at thehigher end of superficial velocities that are typically stable forsmaller designs. In this case, the refiner was interested in achiev-ing a higher capacity through an existing asset.

    The inside of the upper regenerator has two major pieces of equipment: cyclones and a combustor disengager. The combus-tor disengager provides the first-stage inertial separation of cata-

    lyst from the combustion products, and the cyclones provide thefinal separation. Layout of this particular regenerator is uniquein that the cyclone pairs are configured on two different radii(Fig. 8). While this has been a common plan view layout forbubbling-bed regenerators, this was the first time it was appliedto a combustor-style unit.

    To start the evaluation, a CFD model of the regenerator wascreated to study the unit-specific gas flow paths in the upperregenerator. The model demonstrated that the gas flow exiting the standard tee disengaging arms was in the range of 49 m/s(Fig. 11). This velocity range is between 50%100% higher ata 15% lower superficial velocity compared to the next largestcombustor-style regenerator. The model also indicated that the

    jet length projected from the disengaging arm was long enoughthat the high-velocity gas stream moved horizontally in the area of the dipleg termination. This resulted in fines re-entrainment

    with preferential flow to the inner-radius cyclone pair, at a ratethat exceeded the catalyst discharge capacity of the cyclones. Thisresult was initially difficult to believe, as the primary cycloneinlets on the two different radii were only 18 in. apart. However,the preferential flow was readily apparent upon internal unitinspections at the turnaround six years after commissioning. A slight change to the base design had a profound impact on theequipment performance.

    Solution. The solution developed was a variation on whatis called the elephant trunk disengager (Fig. 12). While basic

    elephant trunk disengagers were used in FCC reactor riser disen-gagers in the late 70s and early 80s, the regenerator applicationrequired substantial engineering work to ensure that the propergas flow paths and catalyst separation efficiencies were achievedThe disengager arm was curved to lower the impact transition,reduce catalyst attrition and improve lining reliability. The shroud

    was extended to direct the catalyst more into the catalyst bed, but was limited in length so as not to provide excessive separationDual-radius cyclone system in regenerator.FIG. 8

    Tee and elephant trunk arm disengage.FIG. 9 CFD model of the gas profiles in the upper regeneratorwith tee and elephant trunk arm disengagers.

    FIG. 10

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    efficiency that would lead to increased afterburn and high dilutephase temperatures. The outlet area was optimized to ensure thatthe combustion gases bleed off horizontally with minimal cross-

    wind at cyclone dipleg terminations (Fig. 9).The CFD model of the final design indicated that at a super-

    ficial velocity of 1.05 m/s, slightly higher than the base casemodel, the gas velocities exiting the arms of the elephant trunk

    disengager were significantly lower than the gas velocities for thetee disengager, with peak gas velocities reduced by 25% and thehorizontal gas velocities at the dipleg outlets reduced to nearly zero (Fig. 10).

    With the original design, 10 out of 11 inner cyclones holedthrough after six years of operation. With the elephant trunk disengage installation, the fines entrained to the inner-cycloneset were reduced sufficiently to reasonably expect a 10-year ser-vice life. This enables the refiner to either significantly reducemaintenance costs and realize greater onstream reliability, or topush the system harder for greater operating margin.

    CFD model validation. CFD models have historically met with substantial skepticism in mixed-phase fluidized bedsystems. To validate the CFD modeling efforts, multiple oper-ating regenerators were modeled, and the results compared

    with turnaround field inspection reports. The CFD modeling has proven to be predictive with respect to erosion of both thecyclones and the external support braces when compared withfield inspection reports.

    To further evaluate the accuracy of the CFD modeling anddetermine the proper boundary conditions for the models, mul-tiple radioactive tracer tests were completed on regenerators withthe tee disengager and elephant trunk disengager. The downwardgas flow predicted with the tee disengager was validated, and theresidence time of the flue gas within the upper regenerator was

    within 6% of the CFD model. Tracer studies of the elephant

    trunk disengager confirmed a greater amount of gas dispersion,eliminating regions of high gas velocity, and effectively using regenerator volume.

    The first commercial combustor riser elephant trunk disen-gager was commissioned in 2009. Initial results have been very promising. Catalyst containment is very good and continues

    to be closely monitored. The flue gas residence time in theupper regenerator increased by as much as 26%substantially improving regenerator performance. The unit design and opera-tion resulted in extremely low delta coke operation and a regen-erator average dense-bed temperature as low as 1,198F. Even

    with this low regenerator temperature operating at maximumthroughput, the average afterburn is only 8F. This is a step-

    change advancement in regenerator combustion performanceand it supports that the modeled increase in flue-gas residencetime was achieved.2

    The elephant trunk disengager was developed to improve theperformance of a very large combustor. CFD modeling, tracer

    work, unit inspection and operational data collectively contrib-uted to its creation, proof of principle and commercialization.However, by using these sophisticated tools, other benefits were

    Cyclone 1

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    FIG. 11

    Gull-wing and piped spent-catalyst distributor.FIG. 12

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    64

    REFINING DEVELOPMENTS

    discovered that are applicable to all sized units. Eliminating thehigh-velocity regions reduces erosion to internals and associatedcatalyst attrition. The increased residence time improves the burn-ing capacity of the regenerator, enables lower excess oxygen opera-tion and directionally reduces NOx emissions. Now, the elephanttrunk arm disengager has become the standard design for all new combustor-style regenerators, with several revamp and new unit

    designs in progress.SPENT CATALYST DISTRIBUTOR

    Problem. Engineering tools and associated skills used to solvethe previously discussed problems for very large FCC units can beused on FCC units of all sizes and types, to support operating andreliability needs of individual refiners. In one example, an 80,000-bpsd FCC unit with a bubbling bed regenerator exhibited a regen-erator cyclone outlet temperature differential of 100F from oneside of the regenerator to the other. This afterburn differentialresulted in a localized hot spot that limited the throughput of theunit against a main air-blower constraint. The regenerator wasan older design that used a gull-wing spent-catalyst distributordesign. Catalyst maldistribution in the regenerator causes fuel-richareas in the dense phase, with localized hot spots directly abovein the dilute phase. Hot spots can be completely invisible withina unit depending on where instrumentation is placed in relationto the spent-catalyst inlet.

    To validate the temperature data, catalyst tracer work wascompleted on the regenerator to evaluate the flow distributionin the unit. With ideal distribution, a radar plot of the detectorsignals would show perfect symmetry. The actual unit data showedthat the catalyst was heavily skewed to one side, which was not a surprise (Fig. 11).

    Solution. The typical spent catalyst distributor installed in a

    bubbling-bed regenerator of this vintage was the gull wing design with an external lift riser. Fig. 12 is a schematic of the distributor. Air maldistribution in this type of regenerator design results fromtwo sources. First, the external riser lift air discharges vertically outof the disengager, resulting in an oxygen-rich environment in thedilute phase. Second, high localized catalyst density and resultant

    CFD model of the catalyst densities in a regenerator withgull-wing and piped spent-catalyst distributors.

    FIG. 13

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    REFINING DEVELOPMENTS SPECIAL REPORT

    65

    hydraulic head caused a preferential flow of combustion air to theopposite side of the regenerator.

    To achieve a more even catalyst density and uniform cokedistribution, the piped spent catalyst distributor was developed(Fig. 12). The piped distributor was designed to radially dis-tribute both the lift air and spent catalyst across the regeneratorbed through a set of side arms. The size and orientation of the

    distributor arms were designed in an iterative process with CFDmodeling to ensure as much even catalyst and air distributionas possible within the back-pressure limitations of the existing lift air blower.

    CFD models of the gull-wing distributor and the piped spentcatalyst distributor were created to predict the catalyst distribu-tion, gas flow paths and bed-density profiles in the bubbling-bedregenerator. With the gull wing distributor, the catalyst wasconcentrated in the bed center. With the piped spent catalystdistributor, the catalyst distribution was much more uniformthroughout the bed (Fig. 13).

    Results. The piped spent-catalyst distributor was commis-sioned in December 2006. Post-revamp tracer tests were con-ducted on the regenerator. The actual catalyst distribution isvery close to the ideal distribution as illustrated in Fig. 14.

    Operational data also indicate a significant improvementin the regenerator performance. The dilute phase temperaturedifferential was reduced from 100F pre-revamp to about 15Ffollowing the implementation of the piped spent-catalyst dis-tributor. As a result, the refiner was able to lower the excess oxy-gen level in the flue gas from a pre revamp minimum of 2 mol%to a post-revamp 1 mol%, enabling a higher capacity throughexisting assets and saving on utility consumption.HP

    Part 2 of this article can be viewed online at HPs Website in the September 2010 issue. The article will

    discuss improvements in FCC technology that achieve lower

    coke yield, optimum coke combustion while retaining existing equipment.

    ACKNOWLEDGEMEN TS

    The authors thank the following individuals for their assistance in providing data and/or support that made this article a realityPeter J. Van Opdorp, UOP,

    who provided the yield estimate comparisons between the design case and outermaximum case; Reza Mostofi-Ashtiani, Mechanical Engineering and MaterialsEngineering Center, for providing his assistance and expertise with the CFDmodels; and Dave Ferguson, Justin Tippit, Benjamin Chang, Pannatat Trikasem,Brian Octavianus and Nurudin Sidik, at Tracerco, for their dedication and effortthat contributed to a successful project.

    LITERATURE CITED

    1 Mitchell, T. P. and K. A. Couch, Optimix (ER) CommercializationCeramic Tips, July 2009.

    2 Couch, K. A., K. D. Seibert and P. J. Van Opdorp, Controlling FCC Yieldsand Emissions, NPRA Annual Meeting, March 2004.

    Lisa Wolschlag is senior manager of the FCC, alkylation and treating develop-ment department for Honeywells UOP business located in Des Plaines, Illinois. Shehas 18 years of experience working in various areas of UOP including research anddevelopment, field operating service, technical service and process development. Ms.Wolschlag received a BS degree in chemical engineering from the University of Illinoisand an MBA from the University of Chicago.

    Keith Couch is senior business leader of BTX/aromatic derivatives for HoneywellsUOP business located in Des Plaines, Illinois. He has worked for UOP for 18 years inmanufacturing, research and development, field operating service, technical service,sales support and process development. Mr. Couch received a BS degree in chemicalengineering from Louisiana Tech University and is pursuing an MBA from the Univer-sity of ChicagoBooth School of Business.

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