driving fcc units into maximum propylene to increase profitability · 2018-02-13 · driving fcc...

1 © 2016 W. R. Grace & Co. | Confidential Driving FCC Units into Maximum Propylene | Nov, 2016

Driving FCC Units into Maximum Propylene to Increase Profitability

Maria Luisa Sargenti – Marketing Manager EMEA GPS | Lisbon | Nov 14-16, 2016


How does Grace support refiners?

Planning Operation Blending/Pump

Profitability Reliability Right product mix

*2016: early switch from summer to winter „brew“

Extensive technology screening

tailored solution

Manufacturing and technology focus with strong technical sales and service component

Six Sigma, Laboratory support, optimum

product mix

C4=

(Alky, ETBE) Propylene

Gasoline/LCO Min. Bottoms

Octane*

Presenter

Presentation Notes

Unit Health Check; Troubleshoot; Specialty Tech Service; Technology


Gasoline/C4= Demand

The demand for gasoline continues to grow globally • 2016 growth is predicted to be 1.1% globally. • C4= as well as iC4 are valuable precursors to low sulfur high RON gasoline

blending components

Gasoline demand drives C4= demand

Downstream ProcessingFCC Cracking Overcracking

Feed

VGO/ResidCracking

Naphtha Olefins

Naphtha Paraffins

O

Gasoline

Pool

Blending

Hydrogen transfer

ETBE

Alkylate


The Catalyst Approach

For refiners targeting more C4= and Octane, • Conventional ZSM-5 additive is designed to crack gasoline olefins down to C5= to

maximize C3= • ACHIEVE® 400 and GBA™ deliver superior selectivity of C4= / C3= by preferentially

cracking gasoline olefins at C7 and above and promoting reactions that favor C4= production

Grace offers both catalyst and additive solutions: ACHIEVE® 400 and GBA™

C6=

C7=

C8= 2 C4= 44% C3= + C5= 56%

C3= + C4= 95% C2= + C5= 2%

2 C3= 83% C2= + C4= 16%

Selectivity C3=/C4=

0.64

1.0

11

Reactant

ACHI

EVE®

400

G

BA™

Relative Reactivity

100

12

1.5 Con

vent

iona

l ZSM

-5 A

dditi

ve

Buchanan et al., J. Catal., 158, 279 (1996)


Higher Diffusivity Matrices

Flexible Hydrogen Transfer

Higher Activity

Advanced Metals

Tolerance

Dual Zeolite Technology

Boosting Octane with ACHIEVE® 400

ACHIEVE® 400 increased C3= and C4= Selectivity favoring C4= Objective: • Increase LPG olefinicity • Preferentially C4= for alkylation

unit Unit Information: • UOP Side-By-Side design • 100 kbd • VGO and ATB blend Operating Constraint: • Maintain total LPG make

provided an estimated $12MM/yr benefit or $0.43/BBL net of OPEX

Feedstock properties: 24.0 - 24.5 API - 0.25 – 0.5 wt% S - 1.35 – 1.6 wt% MCR, Economics are calculated as incremental yields at constant crude prices.

ACHIEVE® 400

Base

ACHIEVE® 400

ACHIEVE® 400 ACHIEVE® 400

Base

Base Base

Catalagram, No. 117 | Fall 2015


GBA ™ Technology

GBA™ is Grace’s newest additive designed to crack gasoline olefins more selectively to C4= and boost octane via isomerization activity

• GBA™ provides a flexible additive approach to boost C4= even further while maintaining superior C4=/C3= selectivity

0.5

1.0

1.5

2.0

2.5

3.0

3.5

4.0

1 2 3 4 5 6 76.0

6.5

7.0

7.5

8.0

8.5

9.0

4.5 5.0 5.5 6.0 6.5 7.0 7.5 8.0

C3=, wt%FF

C4=

, wt%

FF

OlefinsUltra® HZ GBA™

ΔLPG, wt%FF

ΔRON

OlefinsUltra® HZ GBA™


Higher Profitability with GBA™

For a 50 kBD FCCU,

GBA™ may provide $2–5MM/yr additional uplift over conventional LO additives

$5M $3M

$2M

Conventional ZSM-5

Higher C4= Selectivity Higher Octane Total Value

Estim

ated

FC

C p

rofit

abili

ty, $

M


Light Olefins Additives Portfolio

OlefinsUltra® for applications where moderate-to-high propylene production is required

OlefinsUltra® HZ for propylene focused operations

OlefinsUltra® MZ is Grace’s newest additive

designed specifically for very high propylene applications

GBA™ is Grace’s newest additive designed to crack gasoline olefins more selectively to C4= and boost octane via isomerization activity

Performance

Light Olefins

OlefinsUltra®

OlefinsUltra® HZ

OlefinsUltra® MZ

GBA ™


Global Propylene Market Supply - 2030

• Most propylene is produced by steam crackers as a by-product of ethylene.

• It is foreseen that other on-purpose propylene supplies will contribute 27% of global propylene supplies in the form of propane dehydrogenation (PDH), methanol-to-olefins (MTO), and metathesis.

• Refinery FCC units also contribute (will continue) to a significant portion of global propylene supplies

Steam Cracker

48%

Refinery

25%

Other "On Purpose"

27%

Source: WoodMackenzie

Presenter

Presentation Notes

Historically, propylene was readily available, either as a co-product of heavy liquids cracking or from refinery sources. Growth in demand for propylene derivatives has outpaced that for ethylene derivatives for several years. The higher propylene demand has largely absorbed readily available sources of propylene to yield, until now, a fairly balanced global market in terms of propylene supply and demand.


FCC Operating Conditions and Propylene Yield

FCC units • Have been historically geared for maximising gasoline yield

• Low yields of propylene are typically obtained in such max gasoline modes

• However propylene yields can be increased by adjusting the following operating conditions:

• high riser outlet temperature

• high catalyst-to-oil ratio

• high e-cat activity

• low reactor pressure


Global FCC Propylene Yields Based on ECat Pilot Plant Testing

Highest FCCU propylene producers are in Asia Pacific and EMEA

Average = 5.3 wt.% Max = 8.0 wt.%




Heavy feeds processing

Grace catalysts are the top class for nickel tolerance (EMEA ecat benchmarking)

Grace supplies 63% of the resid segment with NEKTOR technology

1000080006000400020000

0.6

0.5

0.4

0.3

0.2

0.1

0.0

Ni Equivalents (Ni+V/4+0.4/0.33*Sb) [mg/kg]

Ecat

ACE

Hyd

roge

n Yi

eld

[wt .%

F F]

AB

NEKTOROther Grace

Catalyst family

Average Ecat Data per Customer EMEA - Q1 2016

N = 74

0

20

40

60

Past 2003 2007 2015

Nr.o

f Uni

ts

FCCU Feed Trends(Europe / Middle east / Africa)

HT VGO SR VGO RESID

SR VGO processing is declining, in contrast, Resid processing is increasing.

HT/VGO27%

Grace63%

Competitors37%

RESID73%

EMEA Market Segmentation 2016


Optimising catalyst for resid to propylene

• High zeolite stability and metals tolerance to meet resid feedstock requirements.

• State of the art Vanadium trapping functionality

• Balanced mesoporosity to achieve the optimum level of coke-selective bottoms cracking

• Appropriate level of H-transfer activity to increase LPG olefins.

• Additional use of the OlefinsUltra® family additive

• Industry leading attrition resistance for minimum losses.

Metals tolerance Coke Selectivity

Bottoms cracking activity

Propylene selectivity

Physical properties

FCC Catalyst key features

Presenter

Presentation Notes

A key objective for the refinery is to process resid feedstock in the FCCU while achieving the highest propylene yield, which requires the use of different catalyst functionalities


Catalyst System for Maximum Propylene

ProtAgon™ 4G • is the latest generation of Grace’s

propylene maximization technology. Yields of over 12wt% have been achieved with this catalyst technology.

• is manufactured using the Grace EnhanceR™ Technology Platform, and is an extension of the ProtAgon catalyst family, which is the market leader in the EMEA region

Refineries in EMEA are utilising the ProtAgon™ 4G catalyst to achieve excellent propylene yields


Case Study | Best in class C3=

OMV Schwechat | FCC Unit data

• OMV Schwechat refinery is one of the largest and most technologically

advanced inland refineries in Europe. • The refinery operates integrated petrochemical production facilities, and

supplies plastics manufacturer Borealis with petrochemical precursor products, making propylene a key product for the Schwechat refinery.

Timeline of propylene maximisation and catalyst optimisation in OMV Schwechat FCC unit

Presenter

Presentation Notes

OMV Schwechat refinery is one of the largest and most technologically advanced inland refineries in Europe. The refinery operates integrated petrochemical production facilities, and supplies plastics manufacturer Borealis with petrochemical precursor products, making propylene a key product for the Schwechat refinery.


V Case Study | Best in class C3=

DCR Pilot Plant testing* Testing: • Ecat samples from both trial periods • Actual feed samples from OMV • Same riser outlet temperature (ROT)

as the Schwechat FCC unit • Grace catalyst system exhibited

significantly higher propylene selectivity at constant conversion, as well as higher propylene yield at constant coke

*DCR testing is widely accepted as the most accurate methodology for replicating real-life FCC unit conditions



The unit objectives • are closely linked to market

demand for refined petroleum products.

• maximum propylene and minimum slurry being the primary targets

• C2= and iC4= are highly desired for petrochemical use and a ETBE etherification unit.

• C2= produced by the FCC unit supplements ethylene generated by the steam cracker and is beneficial to OMV.



FCC Unit data / simulation model The FCC unit’s profitability has been

improved due to: • Higher propylene and isobutylene

selectivity • Improved dry gas selectivity at higher C2=

selectivity • Improved bottoms upgrading • Excellent attrition resistance • Lower catalyst usage. • Improved FCC operational flexibility

Profitability increase of ca $3/MT FF from catalyst (based on propylene increase only)

PTQ, 2Q 2016 : “Maximizing Propylene Yields in FCC Units - A Case Study at OMV Schwechat Refinery”; Ignacio Beltran , OMV ; Matthias Scherer, GRACE RT ; et al .


Maximise profitability from resid to C3=

GRACE customised catalyst technology with controlled zeolite acidity at highest intrinsic activity & combined with state-of-

the art alumina sol matrix plus tuned ZSM-5 activity.

Grace’s catalyst delivered improved profitability for CEPSA’s FCC unit

Performance Base catalyst ProgREss-26 Conversion, wt% Base +1.0

C3=, wt% Base +0.6

C4=, wt% Base +0.9

LPG, wt% Base +2.1

LPG olefins, vol% Base +2.2

Total Naphtha, wt% Base -0.46

LCO, wt% Base +0.44

Slurry, wt% Base -1.55

Coke, wt% Base -0.10

Unit profitability, M€/yr Base + 4.0

Cepsa’s Gibraltar - San Roque Refinery: A Case Study for Boosting Unit Profitability through FCC Catalyst Selection for Propylene Maximisation

PTQ Q4/2016


Pool Question

What are key FCC Catalyst features for resid to propylene? a. Propylene selectivity, physical properties, low price b. Metals tolerance, bottoms upgrading, propylene selectivity, physical

properties, maximise FCC profitability c. High e-cat activity, high riser outlet temperature, high catalyst-to-oil

ratio, low reactor pressure d. All of them


Final remarks

GRACE best available technologies to provide industry standard: Residue

• GRACE will further strengthen its position in the important residue upgrading segment by the newly launched EnhanceR™ and MIDAS® platform based technologies.

• In order to max. profitability both platforms can be ideally tailored and combined.

LPG Olefins • GRACE‘s light olefins Additives portfolio

provide a cost/performance optimised, widely field proven technology for the market.

• Newly launched OlefinsUltra® MZ additive holding highest intrinsic activity for LPG olefins in the market.

C4=/C3= ratio, Octanes • The newly launched ACHIEVE®-400

(Dual zeolite technology) and/or GBA™ additive solution close the technology gap for the objective to maximise C4=/C3= ratio plus Octane.

EMEA Growth Perspective • Market trends seems to show further growth

for gasoline demand. In parallel high demand specifically for C4= and Octane.

• C3= demand expected to remain high in the future.

• Residue processing FCC units will continue to process lower quality feedstocks.

• GRACE continues to develop catalyst technologies to meet new challenges.


Maria Luisa Sargenti| Marketing Manager EMEA Grace Catalysts Technologies [email protected] www.grace.com

mailto:[email protected]

driving fcc units into maximum propylene to increase profitability · 2018-02-13 · driving fcc...

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