kmg rompetrol & grace: increase fcc profitability …...•kmg rompetrol is among the 5 highest...
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1 © 2018 W. R. Grace & Co. | ConfidentialIncrease FCC profitability by Operating in Propylene Maximization Mode | October 2-4, 2018
KMG Rompetrol & Grace: Increase FCC Profitability by
Operating in Propylene Maximization Mode
Rafael González Sánchez | Regional Technical Sales Manager
RefComm Conference | Valencia, 2nd – 4th October 2018
2 © 2018 W. R. Grace & Co. | ConfidentialIncrease FCC profitability by Operating in Propylene Maximization Mode | October 2-4, 2018
Poll Question
• European refineries which are integrated with
petrochemical facilities will be better positioned for the
future market challenges.
a) True
b) False
c) It depends
3 © 2018 W. R. Grace & Co. | ConfidentialIncrease FCC profitability by Operating in Propylene Maximization Mode | October 2-4, 2018
KMG Rompetrol
Refining and petrochemicals is one of the main
business units of KMG International
• It has two Production facilities: Petromida
consisting of a Refinery and Petrochemical
Complex and Vega Refinery.
• The refinery operates integrated petrochemical
production facilities, making propylene a key
product for the refinery
• The fluid catalytic cracking (FCC) unit is the main
contributor to the refinery’s production of light
olefins, especially propylene.
Nelson Complexity Index 10.5
Unit design UOP SBS
Unit capacity, bbl/day 24100
FCCU unit process 100 % hydrotreated feed
Crude processed are typically URAL with blend to other
opportunity crudes like Kirkuk, Azeri, Siberian, CPC
4 © 2018 W. R. Grace & Co. | ConfidentialIncrease FCC profitability by Operating in Propylene Maximization Mode | October 2-4, 2018
KMG Rompetrol
Refining and petrochemicals is one of the main
business units of KMG International.
• It has three production units – Petromidia
refinery (in Navodari), Vega refinery (in Ploiesti)
and the Petrochemicals division.
• Petromidia is the most efficient refinery in
Romania and the 9th out of 250 refineries in
Europe and Africa.
• The refinery operates integrated
petrochemical production facilities, making
propylene a key product for the refinery
• The fluid catalytic cracking (FCC) unit is the
main contributor to the refinery’s production of
light olefins, especially propylene.-
Annual Refining Capacity
(MTmn)
Nelson Complexity Index 9.7
FCCU process hydrotreated
feed100%
Unit design UOP SBS
Typical feed process
URAL/CPC/Kirkuk76%/6%/20-30%
5 © 2018 W. R. Grace & Co. | ConfidentialIncrease FCC profitability by Operating in Propylene Maximization Mode | October 2-4, 2018
Global Cumulative Growth in Petchem
Demand
• 2016 - Petchem make up 12% of crude oil market.
• 2035 - Petchem will make up almost 50% demand of crude oil growth
6 © 2018 W. R. Grace & Co. | ConfidentialIncrease FCC profitability by Operating in Propylene Maximization Mode | October 2-4, 2018
FCCU Propylene Yields
• Yields of over 12 wt% have been achieved with Grace’s latest generation
of propylene maximization technology.
• KMG Rompetrol is among the 5 highest FCCU propylene yields in EMEA
Refineries in EMEA are utilising Grace solutions
to achieve excellent propylene yields
9.4
7.7
2
4
6
8
10
12
14
50 55 60 65 70 75 80 85
C3
= yi
eld
s, w
t%
Conversion, wt%
Ecat ACE Global Benchmark ACHIEVE vs. Base Case Catalysts
Base Case ACHIEVE
7 © 2018 W. R. Grace & Co. | ConfidentialIncrease FCC profitability by Operating in Propylene Maximization Mode | October 2-4, 2018
ACHIEVE® – Five steps to success
Continuous analysis of ACHIEVE is being conducted to validate the
increased profitability of the KMG Rompetrol FCCU.
Internal screening by Grace before offering ACHIEVE - screening study using the ACE® pilot
plant to identify most suitable formulation – July 2015
New technology proposed – September 2015
Grace Management of Change presented and discussed – September/December 2015
First delivery of new catalyst to KMG Rompetrolrefinery – July 2016
ACHIEVE results are showing the expected benefits in propylene yield and C4’s selectivity – test run
January 2017
8 © 2018 W. R. Grace & Co. | ConfidentialIncrease FCC profitability by Operating in Propylene Maximization Mode | October 2-4, 2018
ACHIEVE – ACE results
Key Unit Objectives
• Maximum Propylene Yield
(min.10 wt% of FF)
• Maximum Iso-Butylene Yield
• Maximize LCO
• High RON
• Higher dcoke
• Minimize dry gas
Improved performance with selected FCC catalyst tested by
Grace’s pilot plant
-1.5 -1 -0.5 0 0.5 1 1.5
C/O
Coke
dcoke
Dry Gas
LPG
Gasoline
LCO
HCO
C3=
iC4=
total C4
iC4=/total C4
iC4=/LPG
ACE Performance Deltas
Key objectives
wt %
9 © 2018 W. R. Grace & Co. | ConfidentialIncrease FCC profitability by Operating in Propylene Maximization Mode | October 2-4, 2018
Ecat comparison BASE vs. ACHIEVE
ACE Ecat results confirm improved olefins yields
1.500
1.700
1.900
2.100
2.300
2.500
2.700
2.900
3.100
3.300
71.0 72.0 73.0 74.0 75.0 76.0
IC4
=, w
t%
Conversion, wt%
ECAT Iso-butylene, wt%6.00
6.50
7.00
7.50
8.00
8.50
9.00
9.50
10.00
10.50
11.00
71.0 72.0 73.0 74.0 75.0 76.0
Pro
pyle
ne
ye
ild
, w
t%
Conversion, wt%
ECAT Propylene Yields (wt%) ACHIEVE Base catalyst
10 © 2018 W. R. Grace & Co. | ConfidentialIncrease FCC profitability by Operating in Propylene Maximization Mode | October 2-4, 2018
ACHIEVE – Unit Performance
ACHIEVE catalyst formulation provides significant bottoms
upgrading
42
46
50
54
80.0 85.0 90.0 95.0
Ga
so
lin
e, w
t%
Conversion, wt%
0
2
4
6
8
10
80.0 85.0 90.0 95.0
Slu
rry,
wt%
Conversion, wt%
0
4
8
12
80.0 85.0 90.0 95.0
LC
O,
wt%
Conversion, wt%
0.0
1.0
2.0
3.0
4.0
5.0
80.0 85.0 90.0 95.0
Dry
Ga
s, w
t%
Conversion, wt%
ACHIEVE Base catalyst
11 © 2018 W. R. Grace & Co. | ConfidentialIncrease FCC profitability by Operating in Propylene Maximization Mode | October 2-4, 2018
ACHIEVE – Unit Performance
Key refinery objectives of increased propylene and
isobutylene yields have been achieved
6
8
10
12
80 82 84 86 88 90 92 94
Pro
pyle
ne
, w
t%
Conversion, wt%
0.0
1.0
2.0
3.0
4.0
80 82 84 86 88 90 92 94
Iso
-Bu
tyle
ne
, w
t%
Conversion, wt%
20
24
28
32
80 82 84 86 88 90 92 94
LP
G,
wt%
Conversion, wt%
0
0.1
0.2
0.3
0.4
0.5
80 82 84 86 88 90 92 94
iC4
= / C
4=
e, w
t%
Conversion, wt%
ACHIEVE Base catalyst
12 © 2018 W. R. Grace & Co. | ConfidentialIncrease FCC profitability by Operating in Propylene Maximization Mode | October 2-4, 2018
ACHIEVE – Unit Performance
Compared to the Base catalyst system,
the ACHIEVE catalyst:
• provided higher iso-butylene and propylene yields as expected.
• 11.0 wt% propylene yield is achieved
ACHIEVE test run results at maximum unit throughput and max.
severity demonstrate higher refinery profitability for 2.3 M$/y
ECAT Properties: Activity, wt% 73.5 -75.0 UCS, Å 24.26 SA, m2/g 182 - 192
Operating conditions:
Unit throughput, t/h 142
ROT, o C 541
FPH temperature, o C 215
Specific Gravity 0.885
ZSM- Additive (OlefinsUltra HZ), % 7
Operation Mode Full Burn
Performance ACHIEVE vs. Base
Dry Gas, wt% 0.29
C3=, wt% 1.26
iC4= , wt% 1.05
LPG, wt% 1.68
Total Naphta, wt% -1.77
LCO, wt% 2.03
Slurry, wt% -2.10
Coke, wt% -0.13
13 © 2018 W. R. Grace & Co. | ConfidentialIncrease FCC profitability by Operating in Propylene Maximization Mode | October 2-4, 2018
Outlook
• The most profitable refineries are the ones that leverage their
flexibility to capture market opportunities.
• Increased profit of 2.3M $/y is calculated using refinery PIMS
model.
• Rompetrol could even further optimize performance and
improve profitability through additions of Grace’s latest
generation ZSM-5 additive, OlefinsUltra® XZ.
• Refinery plan is to increase downstream petrochemical unit
capacity for additional 15-20% to further increase LPG
production.
14 © 2018 W. R. Grace & Co. | ConfidentialIncrease FCC profitability by Operating in Propylene Maximization Mode | October 2-4, 2018
Rafael González Sánchez | Regional Technical Sales Manager
Refining Technologies - [email protected]
www.grace.com
Valentin Nilca | Senior Process Engineer Ljubica Simic | Technical Sales Manager
KMG Rompetrol Rafinare Refining Technologies - [email protected] [email protected]
www.rompetrol.com www.grace.com