301-final-a shackleford solutions for maximizing value ... · solutions for maximizing value with...
TRANSCRIPT
Solutions for Maximizing Value with
FCC Feeds from Opportunity Crudes
Alexis Shackleford
RefComm GalvestonMay 4-8 2015
BASF Refining Catalysts
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What is Tight Oil?
� Tight Oil: oil produced from low permeability (e.g. tight) shale,
sandstone and carbonate rock formations
� Game-changer for North American refining industry
Sources: EIA (US Energy Information Administration)
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Tight Oil Quality Variability from One Field Source Baker Hughes
Bitumen Recovery from Oil Sands: Properties will Differ Based on Upgrading
Shovel & Truck
Extraction /
Flotation
SAGD*
Diluted
Bitumen
(DilBit)
Oil Sand Synthetic
Crude Oil
(SCO)30% In-Situ
70% Mining
UP
GR
AD
ER
*Steam Assisted Gravity Drainage
FCC Feed VGO Cut Properties
� Tight Oil
� Highly paraffinic
� Very low Sulfur
� Low Ni and V
� Low coke producing feed
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VGO Cut Property TX Shale
BakkenCore WTI
Maya Blend Wabasca
Cold Lake
API Gravity 31.9 24.5 26.3 21 13.4 14.9
Sulfur wt% 0.18 0.27 0.46 2.05 4.31 3.56
Nickel ppm 0.09 0.47 0 0.64 3.79 1.8
Vanadium ppm 0.08 0.14 0 4.48 5.1 5.18
Con Carbon wt% 0.03 0.68 0.01 0.47 1.41 1.69
Source: KBC. Coking and CatCracking Conference by The Refining Community, Galveston TX. May
6-10 2013
� Oils Sands
� Aromatic feeds
� High Sulfur
� High Ni and V
� High Con Carbon
FCC Operation with Tight Oil
� Less VGO available
� Wet gas handling limit
� Heat balance concerns
� Max Feed Preheat, feed resid and/or use heavy recycle
� Low gasoline pool octane
� Low REO catalyst and/or use ZSM-5
� Low Sulfur, Nickel and Vanadium
� Higher alkali and iron contaminant
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FCC Operation with Oil Sands
� Operations depends on how much upgrading was done before
� Lower conversion
� Ensure proper feed vaporization
� Higher cat deactivation: change cat make-up strategy
� Higher delta coke
� Requires higher air rate – Don’t exceed cyclone superficial velocity resulting in high cat
losses!
� Manage high regenerator temperature
� High Sulfur and nitrogen: manage gasoline specifications and emissions
� High Nickel and Vanadium – change catalyst technology
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Feedstock CharacterizationThree Hydrotreated Bitumen vs. reference VGO
� Even after severe hydrotreating bitumen derived feeds maintain high aromatic content
� High percentage of mono and di aromatics indicate high conversion possible
Feeds Reference A B C
API 22.5 21.5 22.5 25.4
Sulfur 0.8 0.2 0.2 0.1
Hydrocarbon Type by SARA & GC-MS
Saturates 73 44 43 60
Aromatics:
Mono 7 32 33 25
Di 4 10 10 7
Tri+ / Polars 16 14 14 8
Most Severe Hydrotreating (Feed C) is required to match VGO feed reactivity
BASF ACE at 990 deg-F RxT
Base Catalyst
69
70
71
72
73
74
75
76
77
78
3 5 7 9 11
43
0 F
Co
nve
rsio
n,
wt%
Cat/Oil Ratio
Reference: API 22.5
Feed A: API 21.5
Feed B: API 22.5
Feed C: API 25.5
Iron in Feed
� High Iron in feed results in:
� Mild dehydrogenation catalyst that increases coke and hydrogen yields
� Mild CO promotion
� Plugging of catalyst pores by “iron nodules” at very high Fe content
10ECat from a unit processing Tight Oil, Fe = 1.5 wt%
“Iron Nodules”
High Iron on ECat
� High porosity
catalyst such as
BASF’s DMS
and Prox-SMZ
have very high
tolerance to iron
pore mouth
plugging
� One unit
successfully ran
above 2 wt%
����
Other Suppliers
BASF Users
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� Many FCCs already process “dumbbell” type feeds via blending
hydrocracker bottoms with VGO or resid
� Feed compatibility needs to be considered due to asphaltene precipitation
mainly in the feed system
� Number of methods available for feed compatibility testing
� Main concern is with modeling these feeds, need to model them as separate
feeds vs. average properties
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Dumbbell Feeds
Adapting to the Changing Market Place: Impact on FCC Operations and Catalysts 13
BASF Customer Not Processing Either
BASF Customer Processing Tight Oil
BASF Customer Processing Oil Sands
Opportunity Crudes heavily changing
North America
75%0%
62%77%
61%0%
67% 33%13%
13%
CANADA
http://religionanddiversity.ca
0%86%
Case #1: VGO FCC Processing Tight Oil
� Gulf Coast unit running 100% Eagle Ford
� Catalyst: NaphthaMax®
� API gravity increased from 22 to 28
� The lower feed N reduced NOxemissions
Case #1: VGO FCC Processing Tight Oil
� Ni and V
decreased
� Na and Fe
increased
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Case #1: VGO FCC Processing Tight Oil
� To maintain regenerator bed temp, slurry recycle was increased to 15%
� No issue with catalyst circulation limit
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� Conversion increased from 75 vol% to 86 vol% going to 100% tight oil
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Case #1: VGO FCC Processing Tight Oil
Case #1: VGO FCC Processing Tight Oil
� Gasoline increases, then enters into the overcracking regime
� The gasoline RON decreases as the feed is more paraffinic
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Case #1: VGO FCC Processing Tight Oil
� Total LPG increased from 24 vol% to 30 vol%
� This large increase in LPG may constrain the gas plant
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Case #2:HT VGO FCC Processing Tight Oil
� This refinery process VGO, ~70%
of which is hydrotreated
� Went to 80% Eagle Ford
� Using BASF’s NaphthaMax® II
catalyst
� Since it is hydrotreated, properties
are similar
� No major unit operating
changes
� Limited by minimum regen
temperature
Operation Base Change
Feed Gravity API 26.6 +0.7
Feed Sulfur wt% 0.5 +0.1
Feed Nitrogen ppmw 960 -90
Feed Concarbon wt% 0.16 -
Preheat Temperature °F Base +43
Reactor Temperature °F Base +3
Dense Temperature °F Base +3
Catalyst Addition tons/day Base -
ZSM-5 Additions Yes (5%) No
Equilibrium Catalyst
ECat FACT wt% 77 -
Ni + V ppm 1500 +50
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Case #2:HT VGO FCC Processing Tight Oil
� Conversion increased
� Lower dry gas and coke
� Despite ZSM-5 being removed,
the C3= make and total LPG is
higher
� Higher total liquid yield
� Unit is operating very well with
NaphthaMax® II catalyst with no
need to make a catalyst change
Normalized Yields Base Change
Conversion vol% 80 +2.0
Dry Gas wt% 1.8 -0.1
C3= vol% 8.4 +0.4
LPG vol% 27.7 +0.9
Gasoline vol% 63.6 +1.9
LCO vol% 15.3 -1.7
Slurry vol% 4.8 -0.3
Coke wt% 4.10 -0.05
Total Liquid Yield vol% 111.3 +0.9
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Case #3:Mild Resid FCC Processing Tight Oil
� Prior to the introduction of Bakken, the
FCC ran VGO
� Due to the lack of VGO in Bakken, the
unit started processing reside for
improved economics
� Changed catalyst from BASFs
NaphthaMax® to Fortress™ for excellent
metals tolerance
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Case #3:Mild Resid FCC Processing Tight Oil
� All contaminant
levels have
increased
� Conversion
dropped due to
heavier
feedstock
� The excellent
metal tolerance
of Fortress™
enabled a high
resid run
0
1000
2000
3000
4000N
i, V
(ppm
)
ECat Nickel and Vanadium
Ni V
0
0.2
0.4
0.6
0.8
Na (
wt%
)
ECat Sodium
0.55
0.65
0.75
0.85
0.95
1.05
1.15
Fe (
wt%
)
ECat Iron
0
1000
2000
3000
4000
Ca (
ppm
)
ECat Calcium
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� FCC transitioned to process 25%
Syn Crude that is highly upgraded
� Use NaphthaMax II catalyst
� 90% of the feed is hydrotreated
� API Gravity increased 5.7 numbers
� Yet conversion only increased 3
numbers, with the majority of the
conversion coming from LCO
� Gasoline sulfur increased
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Case #4HT VGO FCC Processing Oil Sands
Operation Base Change
Feed Gravity API 26.7 +5.7
Feed Sulfur wt% 0.09 +.04
Reactor Temperature °F 970 +17
Regen Bed Temp °F 1290 -
Slurry Recycle %FF 27% +7%
Equilibrium Catalyst
Activity % 75 -
Nickel + Vanadium ppm 1100 -
Normalized Yields
Conversion vol% 76.5 +3.0
LCO vol% 16.5 -2.2
Slurry vol% 7 -0.8
Product Properties
Hvy Gasoline Sulfur ppm 60 +40
Benchmarking Operations
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55
60
65
70
75
80
85
90
95
17 19 21 23 25 27 29 31 33 35
Co
nvers
ion
, vo
l%
Feed Gravity, API
Conversion vs. Feed Gravity
Case 1: LTO VGOCase 2: LTO HT VGOCase 3: LTO Mild ResidCase 4: Oil Sands HT VGO
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Wide Variety of Catalysts Used for Tight Oil & Oil Sands Operation
Gas Oil Max Conversion
- NaphthaMax®
- NaphthaMax® II
- NaphthaMax® III
- PetroMax™
- BituPro™
Gasoil Max Distillate Units
- HDXtra™
Resid Max Conversion Units
- Endurance®
- Flex-Tec®
- Fortress™
Resid Max Distillate Units
- Stamina™
Optimizing Value
Assuming Tight Oil feed and typical Gulf Coast Economics
� Maximize Conversion over LCO
� Maximize LPG= selectivity
� Increase Gasoline Octane
� Maximize Preheat
� Catalyst Management: More proactive catalyst management due to the
variability of the feed
� Contaminants Management
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Summary
� Advantaged crude production will continue to
rise
� FCC catalyst technology and service must be
flexible to meet the changing feed quality and
operating conditions associated with the
crude
� There is no universal catalyst solution
� BASF is the market leader for tight oil FCC
applications providing catalyst solutions to
meet the unique challenges
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Trademarks
Aegis, BituPro, Defender, Flex-Tec, Fortress, HDUltra, HDXtra, NaphthaMax and Stamina are
trademarks of BASF.
Although all statements and information in this publication are believed to be accurate and
reliable, they are presented gratis and for guidance only, and risks and liability for results
obtained by use of the products or application of the suggestions described are assumed by the
user. NO WARRANTIES OF ANY KIND, EITHER EXPRESS OR IMPLIED, INCLUDING
WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE, ARE
MADE REGARDING PRODUCTS DESCRIBED OR DESIGNS, DATA OR INFORMATION SET
FORTH. Statements or suggestions concerning possible use of the products are made without
representation or warranty that any such use is free of patent infringement and are not
recommendations to infringe any patent. The user should not assume that toxicity data and
safety measures are indicated or that other measures may not be required.
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