axens flexene artc_2012_cd-english

(R)FCC Product Flexibility with FlexEneTM

Christian Dupraz

2GTF ARTC 2012 - Bangkok

Agenda

• Propylene & Regional Fuels Market• Product Flexibility• (R)FCC Options for High Propylene Yield• Integrated FlexEne™ Configuration• Selectivity of Propylene Production• Additional Product Flexibility Opportunity• Conclusion

3GTF ARTC 2012 - BangkokSource: Axens (2011)

2010 Production~ 75 Million tons (Mt)

On purpose production*

From Refineries (DCC/RFCC/FCC)From Steam crackers

52%36%

12%

02468

101214161820

2010 2011 2012 2013 2014 2015

• Average Annual Growth Rate ~ 4.5%•• Additional propylene production Additional propylene production

from refineries > 4 Mt/yfrom refineries > 4 Mt/y

2010-2015: Additional Propylene Production by Source

Mt/y

Basis

Global Trend for Propylene Production Forecast by Source

* Metathesis, Olefins cracking, MeOH to propylene, C3 dehydrogenation


Source: Axens & other sources (2010)

Market Structure2010 vs. 2020

Regional Trend for Fuels:Asia Pacific Growth in Motor Fuels

Other* = Kerosene (≠ Jet Kerosene), Refinery Gas, Petroleum Coke, NGL, Lubricants, Bitumen, Paraffin Wax, Refinery Losses, …

0.0

0.5

1.0

1.5

2.0

2.5Mbdoe

Incremental Demand 2010-2020

11.0%

15.6%

13.1%3.7%

19.9%

14.8%

10.2%

11.7%

9.7%

14.0%

14.6%4.7%

21.3%

15.6%

9.2%10.9%

0%

20%

40%

60%

80%

100%

2010 202027.4

Mbdoe35.4

Mbdoe

2010-2020 AAGR2.6%

3.3%

3.6%

4.9%

3.2%

AAGR %/yr

Diesel Je

tGas

oline

Naphtha

Jet KeroseneOn-road dieselOff-road diesel

Fuel Oil

Motor GasolineNaphtha

LPGOther*

Jet KeroseneOn-road dieselOff-road diesel

Fuel Oil

Motor GasolineNaphtha

LPGOther*


Refinery FCC Options for Higher Propylene Production

• High Severity, Specific Design & ZSM-5 Catalyst Addition

• Very selective

• Recycle of Light Naphtha (LN) or C4 Cut

• Higher severity, 2nd Riser

• Simplicity of recycle appears attractive

• Are there alternatives which are more selective & flexible?


High Severity Plus High ZSM5 AdditionIs There More Propylene Potential?

0

2

4

6

8

10

12

14

16

76 78 80 82 84 86Conversion, wt%

Prop

ylen

e, w

t%

34

36

38

40

42

44

46

48

50

LN, w

t%

C3= with ZSM5 C3= witout ZSM5 LN with ZSM5 LN without ZSM5

Propylene & C5-160°C LN vs Conversion & ZSM5*

*Basis: HDT VGO, Low RE catalyst with high ZSM5 content


LN Recycle Cracking For Max PropyleneLimited Potential

• Over 60 w% of olefins converted become aromatics!

Increasing Conversion

Molar profile Feed=100

0

5

10

15

20

25

0 50 100 150 200 250

Ci m

ol, f

eed

base

100

0

10

20

30

40

50

C3=

C4=

C5=

C6=

C7=

Aromatics

• Low conversion, high gas yield & limited ultimate propylene potential when recycled to extinction


02468

1012141618

0 20 40 60 80Butene Conversion, %

Wt%

GasPropyleneGasoline

• Full C4 cut is recycled (about 40% non-reactive paraffin) • Conversion of C4 olefin via C8+ oligomer intermediates• Severe conditions required: high gas yield & aromatics

* HDT VGO, Low RE catalyst with high ZSM5 content

C5+ Composition

0

10

20

30

40

50

60

0 20 40 60 80Butene Conversion, %

Wt%

OlefinParaffinAromatics

Other Options:C4 Cut Direct Recycle Cracking


Another Way: FlexEneFlexEneTMTM

FlexFlexible AlkEneEne Oligomerization & Recycle

STEP 1

• C4 olefins are transformed into C8 & C12 olefins (oligomers) in a PolyNaphtha (oligomerization) Unit

STEP 2

• Oligomers are highly reactive and crack selectively toward propylene in FCC

FlexEne™ Light Olefin Processing Route


FlexEne: Integration of Proven Technology: Polynaphtha & FCC

FCC Feed:VGO/Resid

PolyNaphthaTM

OligomerizationPolyNaphthaTM

Oligomerization

C4 cut

Gasoline

DistillateMotorFuels

Recover Oligomers as Gasoline or Distillate to optimize G/D ratio

Recover Oligomers as Gasoline or Distillate to optimize G/D ratio

or

Fuel GasPropylene

LPGGasolineDistillateFuel Oil

C4 Raffinate

Recycle Distillate

Gasoline

Recycle Selected Oligomers to FCC Riser to Maximize Propylene

Recycle Selected Oligomers to FCC Riser to Maximize Propylene

Product RecoveryProduct Product RecoveryRecovery


FlexEne Provides Highest Selectivity for Light Olefins to Propylene

• Oligomer cracking is more selective with lower impact on Wet Gas Compressor (WGC)

• Less gas & aromatics formation for higher ultimate propylene yield when recycled to extinction

Relative Propylene Selectivity v Recycle

0.0

0.5

1.0

1.5

2.0

2.5

Direct C4 LCN C4 Oligomers

Prop

ylen

e / W

et G

as (m

ol/m

ol)


0%

10%

20%

30%

40%

50%

60%

70%

80%

90%

100%

Max Gasoline

FCC alone

Dry gasLPG w/o C3=C3=GasolineDistillateDCO Coke

Flexibility Example:FlexEne Applied to C4 or C3/C4 Cut


Product Flexibility - Gasoline Case

FCC C4 cut

Propylene

Distillate Gasoline

Motor Fuel

Motor Fuel

FCCGasoline Mode

PolyNaphthaGasoline Mode

Prod

ucts

Prod

ucts Propylene for

Max Gasoline


0%

10%

20%

30%

40%

50%

60%

70%

80%

90%

100%

Max Gasoline

FCC alone

Max Gasoline

FCC + FlexEne



Recycle of oligomerized C4 or C3/C4 Cut


Product Flexibility - Distillate Case

Propylene

DistillateGasoline

Motor Fuel

Motor Fuel

FCCDistillate Mode

PolyNaphthaDistillate Mode

Prod

ucts

Prod

ucts

FCC C4 cut

Propylene for Max Distillate


0%

10%

20%

30%

40%

50%

60%

70%

80%

90%

100%

Max Gasoline

FCC alone

Max Gasoline

FCC + FlexEne

Max Distillate

FCC + FlexEne





Product Flexibility - Propylene Case

FCC C4 cut

Propylene

Gasoline&

Distillate Motor Fuel

Motor Fuel

FCCPropylene Mode

PolyNaphthaConversion Mode

Prod

ucts

Prod

ucts


0%

10%

20%

30%

40%

50%

60%

70%

80%

90%

100%

Max Gasoline

FCC alone

Max Gasoline

FCC + FlexEne

Max Distillate

FCC + FlexEne

Max Propylene

FCC + FlexEne


0.0

1.0

2.0

3.0

4.0

5.0

G/D

G/D




PolyNaphtha Puts the Flex(ibility) in FlexEne

• Flexibility to vary Gasoline vs Distillate ratio:• Gasoline Mode: 100% Gasoline• Distillate Mode: 70% Jet-Diesel / 30% Gasoline

• Option to recover oligomers or recycle crack• Simple fixed bed process with fully regenerable

Si-Al catalyst• Low cost alternative to alkylation• Can be extended to C3-C9 olefinic streams

A separate PolyNaphtha Oligomerization unit provides superior yields and greater flexibility


FlexEne Advantages

• Combination of 2 widely proven processes• FlexEne adds ~ 3%wt absolute to C3= yield• FlexEne effect is cumulative over and above the

effect of temperature & ZSM-5• FlexEne can target increased C3= or Motor

Fuels (G or D) via selection of recycle cut• Flexibility to change product target.• May be extended to C3-C9 cuts depending on

market demand (G/D, C3=/G, etc.)


Resid Application: Soukhna Refinery & Petrochemical Complex

• R2P (Resid to Propylene) Technology• 68,000 bpsd• R2R technology, >10 wt% Propylene• FlexEneTM, Gasoline & Propylene mode• Feed: API=23, CCR=3, S = 1.6 wt%

Location: Soukhna, EgyptSource: Google Earth


VGO Application:PETRON Bataan Refinery

• High Propylene FCC (HP FCC)• 35,900 bpsd• 250 000 ktpa of Propylene• FlexEneTM, Gasoline & Propylene mode• Feed: VGO + Hydrotreated Coker Gasoil

Location: Bataan, Philippines Source:Petron


Conclusion

• Strong demand for Propylene & regional demand for all fuels - product flexibility desired

• LN & C4 recycle to FCC is not selective for added propylene and no impact on distillate

• FlexEne combines proven FCC & PolyNaphthatechnology to optimize production of propylene, gasoline, jet or diesel = Flexibility

• FlexEne has been applied in 7 projects over the last 3 yrs

(R)FCC Product Flexibility with FlexEneTM

axens flexene artc_2012_cd-english

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