Shell Global Solutions The Fluidized Catalytic Cracking Process The Fluidized Catalytic Cracking Process 65 years of inspiration for technology development 65 years of inspiration for technology development Mart Nieskens Presentation to KIVI - NIRIA October 4 th 2007
50
Embed
Shell Residue Fluidized Catalytic Cracking Process
Description of Shell Residue Fluidized Catalytic Cracking Process with new developments through the years.
Welcome message from author
This document is posted to help you gain knowledge. Please leave a comment to let me know what you think about it! Share it to your friends and learn new things together.
Transcript
Shell Global Solutions
The Fluidized Catalytic Cracking ProcessThe Fluidized Catalytic Cracking Process65 years of inspiration for technology development65 years of inspiration for technology development
Mart Nieskens
Presentation to KIVI - NIRIA October 4th 2007
2Shell Global Solutions
A 1990 presentation updated with a decade of developments
3Shell Global SolutionsInspection
Troubleshooting/
Design
Implemen
tatio
n
Operatio
nR&
D
Impro
ve
ment
Subject of thispresentation
4Shell Global Solutions
SIMPLIFIED REFINERY FLOW SCHEME
Platformer
HydroDesulph.
Unit
HydroTreater
LPGMogas
KeroGasoil
Fuel Oil
CrudeDistilling
Unit
HYDROSKIMMER
Long Residue (LR)
Naphtha
Crude
LPG
Kero/Gasoil
COMPLEX
HighVacuum
Unit
-
FlashedDistillate
Short Residue (SR)
Gasoil
HydroDesulph.
UnitCatCat CrackerCracker
5Shell Global Solutions
Residue Upgrade (>370 oC) in relation to FCC process ability
6Shell Global Solutions
FLUID CAT. CRACKING UNIT (FCCU)
Flue gas
Air
Air blower
Riser
Fractionator
Flashed Distillate /Long residue
Light cycle oil
Heavy cycle oil
Slurry oil
Steam
Reactor
L
T
P
P
700
525
350
2.0
2.0
Temp., CPres., barg
7Shell Global Solutions
FCC Process
Fresh Feed & Recycles contacted with regenerated catalyst in riser
Catalyst gradually deactivated by formation of coke on surface
Hydrocarbon/steam vapour to Main Fractionator & work-upHydrocarbon/steam vapour to Main Fractionator & work-up
Inter & Intra-stitial hydrocarbons stripped from catalyst using steam
Catalyst flow controlled by
pressure-balance and slide-valves
2-stage cyclone systems keep catalyst inside unit
Spent catalyst flows to regenerator and reactivated by burning off coke
Spent catalyst flows to regenerator and reactivated by burning off coke
Regenerated catalyst flows to bottom of liftpot-riser
Regenerated catalyst flows to bottom of liftpot-riser
Residue FCC: > 25% residue contentOur challenge is to process residueOur challenge is to process residuein a profitable and reliable wayin a profitable and reliable way
15Shell Global Solutions
Development in Shell Cat Cracker Design till 1990
The original….Big inventory , high C/OPoorish cat., Much cokeLowish temp’s CCR<0.3CCR<0.3
• Some Shell advised resid units operate in an excess of 7500 ppm Vanadium !
• Vanadium = poison for E-cat zeolite
• SGSi pilot plant catalyst selection procedure selects the most Vanadium resistant catalysts for the SGSi advised CCUs
Catalyst Vanadium resistance
39Shell Global Solutions
Improved catalyst Nickel resistance
0.15
0.20
0.25
0.30
0.35
0.40
4000 4500 5000 5500 6000
Ni+V/4, ppm
H2, w
t%Catalyst B
Catalyst A
Resid processing -E-cat poisoning with Nickel
• Some Shell advised resid units operate at very high E-cat Nickel levels
• Nickel reacts hydrocarbons to H2+coke
• SGSi catalyst selection methods test catalyst Nickel tolerance in realistic conditions in a pilot plant deactivation unit
Catalyst Nickel resistance
40Shell Global Solutions
Additives to adjust product slate or quality
ZSM-5 and gasoline-S reducers
• SGSi has pilot plant facilities to carry out dedicated pilot plant evaluations for ZSM-5 and Gasoline Sulfur reduction additives
• Several SGSi advised units use these additives continuously (ZSM-5)
41Shell Global Solutions
Additives reduce CCU emissions - SOx
SOx absorption
H2 S release
42Shell Global Solutions
Additives for CCU emissions – SOx and NOx
SGSi gives support for SOx and NOx additive selection and monitoring
Example: SOx additive trial at Reichstett – up to 85% SOx reduction
-20%
0%
20%
40%
60%
80%
100%
SO
x r
ed
ucti
on
, %
-2.8
0.0
2.8
5.6
8.4
11.2
14.0
R950 i
n I
NV
, %
SOx reduction, %
R950 in INV, %
Nov’06 Jan’07 May’07
43Shell Global Solutions
1.0%
1.2%
1.4%
1.6%
1.8%
2.0%
2.2%
2.4%
2.6%
2.8%
3.0%
410 415 420 425 430 435 440 445 450 455 460
SIMDIST Gasoline T95 (°F)
Gaso
lin
e S
ulf
ur/
Feed
Su
lfu
r (%
)
Base
Additive
Additive reduced gasoline Sulfur up to 40% at Constant Gasoline
Cut Point
Effectiveness of Gasoline Sulfur reducing additive- Target < 10 ppm Gasoline Sulfur achieved with feed HT and Additive
44Shell Global Solutions
Latest Shell Developments … Examples
• Process Design Modifications towards maximized flexibility in products like Diesel / Propylene
• Catalyst Circulation Enhancement for increased capacity
• Flue Gas Cleaning towards very low stack emissions
45Shell Global Solutions
Process Design Modifications towards maximized Process Design Modifications towards maximized flexibility in products like Diesel / Propyleneflexibility in products like Diesel / Propylene
Enablers:- In conventional FCCU tuning of operating conditions, like:
- “cat-to-oil ratio”
- Riser temperature- Sharpened design of feedguns, riser-internals, post-riser contact time
- Catalyst formulation and activity- Tuning of ZSM-5 catalyst-additive for propylene
Technology is ongoing R&D in Shell Lab’s
New Enabler:- Equipment addition to conventional FCCU to ‘cleverly’ re-inject gasoline-fractions aiming at superior diesel / propylene yields
Third Stage Separator System (TSS)Third Stage Separator System (TSS)the reliable and costthe reliable and cost--effective solution to reach lowest emissionseffective solution to reach lowest emissions
1. The Flue Gas Cleaning System
2. The Shell Third Stage Separator
48Shell Global Solutions
Evolution of Shell Third-Stage Separator
1960s-1980s
Expander protection 1990s
Tightening Emission Legislation 2005
Meeting <50 mg/m3
49Shell Global Solutions
As we respect our neighbours, andTo keep our license to operate