Unveiling The Modern FCC
in a Diesel & Petrochemical
Oriented Refinery
Nicolas LAMBERT
1
Agenda
 Market Trends
 Modern FCC Capabilities with Regards to the
Petrochemical Industry
 Recent Application Case Review: SATORP
 Potential Further Improvements and Deeper
Integration of Similar Scheme
WRA - Abu Dhabi International Downstream, May 2015
2
Agenda
 Market Trends
 Modern FCC Capabilities with Regards to the
Petrochemical Industry
 Recent Application Case Review: SATORP
 Potential Further Improvements and Deeper
Integration of Similar Scheme
WRA - Abu Dhabi International Downstream, May 2015
3
Middle East: Product Demand Will Be Driven By…
Mbdoe
Incremental Demand
2014-2030
(Mt/y)
 This region accounts for around
20% of the global demand growth
(50) 1.0
0.72
(25) 0.5
0.67
0.49
 Demand growth in all categories,
especially for Gasoline, Other and
on-road Diesel
0.35
0.28
0.0
0.04 0.10
0.13
Fuel oil
Off Road Diesel
On Road Diesel
Jet Kerosene
Motor Gasoline
Naphtha
LPG
Other*
Other* = Kerosene (≠ Jet Kerosene), Refinery Gas, Ethane, Petroleum Coke, NGL,
Lube oils, Bitumen, Paraffin Wax, Refinery Losses, …
WRA - Abu Dhabi International Downstream, May 2015
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ME Gasoline & Diesel Demand
Source: Hart Energy WRFS 2014
Gasoline
Specifications
Timeline
Gasoline
Quality Highlights



« Regular » grade (RON 90 or 91) will be gradually replaced by RON 95
« Premium » grades (> RON 95) currently offered (Kuwait, UAE, Qatar)
MTBE will be the main Octane Number enhancer after 2015
ME Gasoline Demand by Sulfur Category
3.5
(150) 3.0
ME Diesel Demand by Sulfur Category
(300) 6.0
Mbpd
(250) 5.0
(Mtpy)
2.5
(200) 4.0
(100) 2.0
(150) 3.0
1.5
Mbpd
(Mtpy)
(100) 2.0
(50) 1.0
(50) 1.0
0.5
0.0
0.0
2014
2014
> 500 ppm
2025
51 - 500 ppm
2035
11 - 50 ppm
< 10 ppm
2025
2035
> 2000 ppm
500 - 2000 ppm
51 - 500 ppm
11 - 50 ppm
<10 ppm
Need for high quality, low sulfur diesel and gasoline
WRA - Abu Dhabi International Downstream, May 2015
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Agenda
 Market Trends
 Modern FCC Capabilities with Regards to the
Petrochemical Industry
 Recent Application Case Review: SATORP
 Potential Further Improvements and Deeper
Integration of Similar Scheme
WRA - Abu Dhabi International Downstream, May 2015
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The FCC Alliance
WRA - Abu Dhabi International Downstream, May 2015
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FCC Technology Features
 Stripper packing
 Prevents the loss of valuable products
 Allows operation at higher ROT for same
regenerator/MAB capacity
 > 60 references, >30 operating
 Feed injectors
 Ensure proper feed distribution to
maximize catalytic reactions while
minimizing thermal reactions
 > 100 references
WRA - Abu Dhabi International Downstream, May 2015
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FCC Technology Features
 Catalyst cooler and MTC (Mix
Temperature Control)
 Allows operation at higher severity/coke
make at full conversion vs. unit mechanical
design
 > 65 references for Catalyst Cooler
 RS² Riser Termination Device and
Vapor Quench
 Ensure limited thermal degradation of
products through reduction of residence
time and HC outlet temperature
 > 25 references for RS², 13 operating
WRA - Abu Dhabi International Downstream, May 2015
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Agenda
 Market Trends
 Modern FCC Capabilities with Regards to the
Petrochemical Industry
 Recent Application Case Review: SATORP
 Potential Further Improvements and Deeper
Integration of Similar Scheme
WRA - Abu Dhabi International Downstream, May 2015
10
World-class Integrated Project: SATORP
Propylene, Aromatics & Fuels Production
Crude
CDU
SR Naphtha
Benzene
Paraxylene
Aromatics Complex
ParamaX™
Naphtha
Naphtha
Light Naphtha, Raffinate
Toluene rich cut, Heavy Aro
H2
Gasoline
Pool
Heavy Naphtha
Kerosene
VDU
Diesel
VGO
HCK
Bleed
Gasoline
HP FCC
Propylene
HCGO
Delayed
Coker
Refinery : 400 000 bbl/d
FCC: 32700 bbl/d (183T/h)
LPG
Coke
Products:
 Fuels: Gasoline, Kero, Diesel
 Petrochemicals: Propylene, Paraxylene (700 kta), Benzene
WRA - Abu Dhabi International Downstream, May 2015
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Closing the Heat Balance: Tailor-made Solutions
 Turbulent Regenerator with
Swage and Air Rings
 HCO/Slurry recycle to Stripper or
Riser
 Air Heater & Torch Oil injection
able to operate continuously
 Added benefit: more valuable
energy recovered from flue gas
thanks to a lower acid dew point
WRA - Abu Dhabi International Downstream, May 2015
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Agenda
 Market Trends
 Modern FCC Capabilities with Regards to the
Petrochemical Industry
 Recent Application Case Review: SATORP
 Potential Further Improvements and Deeper
Integration of Similar Scheme
WRA - Abu Dhabi International Downstream, May 2015
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Maximizing Distillate Production
Heavy Aromatics purge recycle
 Improved heat balance
MTC usage
 Improved global conversion
ZSM-5 injection
 Enhanced propylene
production through
conversion of
intermediate olefins
Feed processing at Maxi
Distillate optimal conditions
Co-processing of Coker HGO
 Improved margins
Light slurry recycle upstream feed
injection
 Improved bottoms conversion
WRA - Abu Dhabi International Downstream, May 2015
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Potential Improvements for Similar Scheme
CDU
Heavy Aromatics
purge
Gasoline
Pool
Kerosene
Diesel
VDU
Increased
capacity /
Heavier
crude
Benzene
Paraxylene
Aromatics Complex
ParamaX™
HCK
HP FCC
Coker HGO
Delayed
Coker
Propylene
Slurry Oil
Coke
WRA - Abu Dhabi International Downstream, May 2015
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Potential Opportunities for Similar Scheme
 Coker HGO co-processing (10-15%)
• No penalty on C3= production through severity increase
• Yields interesting quantities of LCO
• No impact on LCN quality
• Helps improving the heat balance
• Marginal impact on downstream hydrotreatment
• Additional revenue could be as high as 16 MMUSD/year
› Compared with conventional VGO
› Price spread considered: 200 USD/ton
 Heavy Aromatics purge / Slurry Oil recycle
• Disposal of low value cuts / Nil fuel oil production
• Direct contributor to the heat balance (coke production)
• Yields minor amounts of valuable products
WRA - Abu Dhabi International Downstream, May 2015
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Conclusions
 More than ever, the FCC unit can hold a predominant
place in the refining scheme, whichever are the
production objectives
 Deeper integrations between refinery and
petrochemical complex pave the way for further
enhancements of the FCC technology oriented
towards petrochemical bases production
 Opportunities must be seized to improve FCC
operation and margins
WRA - Abu Dhabi International Downstream, May 2015
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axens.net
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