Takreer_RFCC 1st Day Calss

GS-Caltex RFCC Process Overview June, 2013

Residue Fluidized Catalytic Cracking  Residue Fluidized Catalytic Cracking is a process used to convert residues to gasolines and middle distillates

 Atmospheric Residue (100%)

Cracking Catalyst

• • • • • •

H2, C1 - C2 Gases LPG C5 Cracking Naphtha (LCN) Light Cycle Oil (LCO) RFCC Oil (RO)

 Fluidized means that cracking and coke burning reactions take place with fluidized cracking catalyst

Introduction to RFCC History

Project Proceedings

• 1992. 1

Kick-off Meeting with Stone & Webster

• 1994. 2

Pile Driving for Foundation

• 1994. 7

Erection of Main Fractionator

• 1994. 9

Erection of Reactor & Regenerators

• 1995. 8

CO Boiler Firing

• 1995. 9

Mechanical Completion

• 1995.12

Feed-in

Project Outlines

• Capacity

:

70,000 B/D

• Plot Area – On Site

:

70,000 M2

– Off Site

:

240,000 M2

• Investment Cost

:

US $ 530Million

• Manpower

:

1,110,000 Man-days

RFCC Complex Capacities and Licenses

Unit

Licensor

Detail Eng

Const.

70,000 B/D

S&W

LGEN

DIC

Slurry Filter

8,700 B/D

PALL

PALL

DIC

Sulfur Bed

17,500 B/D

ISG

ISG

DIC

LPG Sweetening

17,500 B/D

Merichem

DEC

LGC

8,500 B/D

UOP

DEC

LGC

LCN Sweetening

19,500 B/D

UOP

DEC

LGC

HCN Sweetening

12,000 B/D

UOP

DEC

LGC

SRU

100 Ton/Day

TPA

DEC

LGC

DeSOx

566,200 NM3/Hr

Haldor Topsoe

DEC

DIC

CD Tech

LGEN

DIC

(CD Tech)

(LGEN)

Delayed

RFCC

C5 Sweetening

Capacity

MTBE

2,500 B/D

(TAME)

(2,800 B/D)

Main Features of GS-Caltex RFCCU •

One of the Largest RFCC Units in the World

•

Most Severe Design Feedstock (CCR: 5~ 7 wt%)

•

Two Stage Stacked Regenerators

•

Two Catalyst Coolers

•

LD2 Separator in Reactor (2009 RSS Separator)

•

Power Recovery Train

•

Two CO-Boilers

•

1st Application of Haldor Topsoe DeSOx Unit to RFCCU

•

Oxygen Enrichment

•

ZSM-5 Injection

•

APC/VPS Utilization

RFCC Improvement History

Improved Items Since Start-up (1)

In 1996

• Conversion Precursor Analysis of Feed Stock • Cat. Cooler Tube Leak Solve (Published on O&GJ) • Radio-tracer Study • Detected 80% Vapor Underflow at the Ramshorn Separator • TPA(Top Pump Around) Injection in Feed Nozzle

Improved Items Since Start-up (2) In 1997

• Slurry Filter Troubleshooting(Published in O&GJ) • Ramshorn Separator Modification • Yield Increase 3 Vol%(Dry Gas, Coke Make Decrease)

• Modified Dust Removal System of 3rd Stage Separator • Improvement DeSOx Unit – Catalyst Screening System – SO2 Converter – Stack Plume

– Mechanical(Fabric Bellows, Acid pump, etc)

Improved Items Since Start-up (3) In 1998

• Improved Fouling of MF Bottom System Through

• HP Steam Generator(152E-201A/B/C/D) Tube Size up • Installed Additional Air Compressor • Integrated Amine System(DGA to DEA) • Catalyst Evaluation – DCR Set up & Test

– High Conversion, Less Coke Make Catalyst Selection

Improved Items Since Start-up (4) In 1999

•

Installed O2 Enrichment(100% O2 Injection) System

•

LPG Capacity Increase Through Common LPG Unit

•

Recovered Flaring LPG From Sulfur Bed

•

Modified ESP Ash Handling System

•

Operation optimization – Operation Guide Set-up Through Test Run – Dry Training For Emergency S/D Case – Troubleshooting History Keeping & Training – Knowledge Sharing Network Establish(Homepage)

•

Recorded Max Feed of 83,700 BPSD in Dec 12, 1999

Improved Items Since Start-up (5) In 2000

• Expander Service • Cat. Cooler Steam Let-down System Service

• Held 3rd RFCC Peer Review • Injected ZSM-5

• R2 Partial Burning Mode Operation • Recorded Max Feed of 84,500 BPSD on March 30, 2000 • Recorded Conversion Max (77.5%)

Improved Items Since Start-up (6) In 2001

• Expander Modification 2 Stage to Single • Modified Air Blower Filter to Dual Bag Filter System • Increased O2 Injection Capacity by 12,000 Nm3/Hr • Installed 4th Cyclone at Downstream of 3rd Stage Separator • Installed LPG Vaporizer for RFCC

• Replaced Stripper Reboiler and Modified Column Internal • Modified DeC3 Column Internal

Improved Items Since Start-up (7)

In 2005



Modified Feed Nozzle to Micro-Jet Type (ABB-Lummus)



Introduced Selective Hydrogenation Unit (SHU)



Replaced Main-Fractionator Tray



Replaced Stripper Tray



Replaced Column Trays (DeC5, DeC4, DeC3, Splitter)



Replaced Primary & Secondary Absorber Trays



Improved Cooling, Pumping & Hydraulic Systems of the Downstream Units

Improved Items Since Start-up (8)

In 2009



Reactor RSS



Stripper Packing Install



Cyclone Replacement



DeSOx GGH Replace



DeC4 Auxilary Rebolier Install

Improved Items Since Start-up (9)

In 2012



RSS Improvement



ESP Modification



WSA Condenser Glass Tube Modification



SO2 Converter Burner Replace

RFCC Catalyst Employment Daily Usage, ton

Feed Rate, BD

Price, USD/MT

Start Up Catalyst Recommended by Licensor (SWEC)

26

64,000

1,900

Grace Davison Orion II

Optimize Catalyst Activity

28

67,000

1,900

1997 ∼ 2000

BASF Ultrium I

Improve Catalyst Activity (Less Bottom)

21

72,000

1,800

2000 ∼ 2003

BASF Ultrium II

Improve Bottom Cracking & Activity Retention (Less Bottom)

25

78,000

1,800

2003 ∼ 2008

BASF Ultrium III

Improve Coke Selectivity & Metal Tolerance (Higher Feed & Less Cat Addition)

27

90,000

1,900

2008 ∼ Now

JGC C&C CVZ I

Improve Metal Tolerance (Less Cat Addition)

20

92,000

2,700

Year

Catalyst Brand

Catalyst Feature

1995 ∼ 1996

Grace Davison Orion I

1996 ∼ 1997

RFCC Operation & Monitoring

Key Parameters Dry Gas (27,000 Nm3/Hr) C3 (11%) Converter R/C (80,000 B/D)

(Rx-Regen) Catalytic Cracking

C4 (16%) C5 (15%) LCN (30%) HCN (7%) LCO (15%) RO (9%) Coke (8~9 wt%)

Feed

Catalyst

Operation

Quality

Properties

Variables

Feed Properties • Physical Property – API Gravity

: 19~22 (API = 141.5/Sp.Gr. - 131.5 )

– Distillation Temp 50%

: 480~520 ‘C

– Aniline Point

: 90~100 ‘C

– Viscosity

: 150~200 cSt @ 50’C

• MCR(Micro Carbon Residue) : 4.5~6 wt% • Sulfur : 1.6 ~ 2.1 wt% • Nitrogen : 1300~1600 ppm • Metal (Ni:5~12 ppm/V: 5~20/Fe: 2~4), Na (