RFCC KBR Features

Residue FCC Design
for Performance
and Reliability
Phil Niccum
KBR
2009 KBR. All Rights Reserved.
You want to put Resid in the Cat Cracker?

Will the resid harm the Cat
Cracker?
Do we have the FCC
capacity?
What else must be
considered?
What are the technology
alternatives?
What Cats Like

Important Feed Characteristics
Large Saturated
Hydrocarbons
Clean
Reliable Supply
What Cats Dislike

FCC Feed Characteristics to Avoid
Vanadium
Increases catalyst make-up
Carbon Residue
Increases coke make
Increases required regenerator
size, air rate and catalyst cooler
duty
Aromatic Content
Negative Impact on conversion
and yield selectivity
Residue Upgrading Options for FCC Feed

ROSE: Addresses Contaminant Issue
Feed to FCC not Hydrogen Deficient
Low Capital and Operating Costs
Hydroprocessing: Addresses Contaminant Issue
High Cost (TIC, H2, Catalyst)
Coking: Addresses Contaminant Issue
Hydrogen Deficient Feed to FCC
Direct Feed to FCC: Contaminant Issue (Metals and CCR)
Vacuum Distillation: FCC Feed Lost in Vacuum Residue
Residue FCC Processing Challenges

More than just coke burning capacity
Reaction System
Minimize coke production
Fine feed atomization and low operating
pressure
Regeneration System
Manage heat generation from coke burning
Minimize catalyst deactivation
KBR FCC Rx System Technologies

ATOMAX-2 FEED NOZZLES
Fine atomization,
excellent riser coverage
ATOMAX
ATOMAX

DYNAFLUX STRIPPING
Better stripping efficiency, even in
high flux strippers
DynaFlux

RISER QUENCH TECHNOLOGY
Higher mix zone severity,
improves gasoline yield

and octane
Quench
Fresh Feed

CLOSED CYCLONES
30-40% less dry gas than
unducted riser termination
Closed Cyclones
KBR FCC Regenerator Technologies

Countercurrent Regeneration
Only one stage needed for residue
processing
Catalyst Cooler
Reliably cool regenerator
Generate valuable steam
KBR FCC Regenerator Technologies

Water In
Only one stage needed for residue
Water /
Steam Out
processing
Catalyst Cooler
Reliably cool regenerator
Generate valuable steam
Catalyst In
Fluidization
Air
Catalyst Out
Partial CO Combustion Better for Residue

Minimizes catalyst cooler requirements
Reduces size of major equipment
Regenerator vessel
Regenerator cyclones
Air blower
Reduces catalyst makeup by limiting vanadium-induced
deactivation
Partial combustion does require CO Boiler or other CO
destruction device
Vanadium Mobility
V2O5 generated in oxidative environment:

4 V + 5 O2 ----> 2 V2O5
Vanadia migrates to other particles via volatile vanadic acid:
V2O5 + 3 H2O ----> 2 VO(OH)3
Old Catalyst
(lots of vanadium)
New Catalyst
(no vanadium)
BEFORE MIGRATION
Old Catalyst
"New" Catalyst
(Vanadium equilibrated between particles)
AFTER MIGRATION
Complete Combustion Better for Gas oils

Simplifies Operation
Avoids afterburning even during start-up
Maintains regenerator temperature on HDT VGO

Reduces NOx emissions
Minimizes carbon on regenerated catalyst
Does NOT require CO Boiler or other CO destruction
device
KBR Counter-current Regenerator

Spent Catalyst
(high carbon)
+ Low O2
Spent Cat Distributor
DENSE
PHASE
BED
air
catalyst
Air Distributor
Regen Catalyst
(low carbon)
+ High O2
Spent Catalyst Distributor

Orthoflow FCC Installation
Spent Cat
Standpipe
Self- Aerated
Distributor
Troughs
Regenerator Design Comparisons

KBR Counter-current Regeneration.
Air travels up
Spent Catalyst
(high carbon)
Catalyst travels down
low O2
Dense
Phase
Bed
air
Low carbon catalyst contacts high O2 gas

minimizes burning rate and particle
temperature
catalyst
High carbon catalyst contacts low O2 gas

minimizes burning rate and particle
temperature
Dense phase particle contact dissipates heat
of combustion
Prevents high particle temperatures
Low particle temperature minimizes catalyst
deactivation
Catalyst
(low carbon)
high O2
Regenerator Temperature Control

Why use a Catalyst Cooler
Provide feedstock and product flexibility
Process high carbon residue feedstocks
Process VGO feeds at high reaction
temperatures for maximum propylene
Provide Process flexibility
Optimize cat/oil ratio
Optimize catalyst matrix and zeolite
Reduce catalyst costs
Minimize dry gas make at mix zone
KBR FCCU with Cat

Cooler
KBR Dense Phase Catalyst Cooler

Water In
Tubesheet
Catalyst In
Inner
Tube
Water &
Steam Out
Tubesheet
Catalyst
Return
Fluidization
Air
Slide
Valve
Scabbard -Outer Tube
Dense Phase Catalyst Cooler Technology

Flexibility for Cracking Heavy Feedstocks
Key Features of Catalyst Cooler

Water In
High Heat Transfer Coefficient

Flow-Through Design Provides
Heat Removal Flexibility
No Fluidization Impingement
on Tubes
16 Coolers Operating Since 1990
with No Erosion Related Shutdowns
Water /
Steam Out
Catalyst In
Fluidization
Air
Catalyst Out
Key Features of Catalyst Cooler

High Heat Transfer Coefficient
Flow-Through Design Provides
Heat Removal Flexibility
No Fluidization Impingement
on Tubes
16 Coolers Operating Since 1990
with No Erosion Related Shutdowns
Easy To Remove Tube Sheet
Easy Removal
of Tube Bundle
From Top
Cooler Tube Bundle Lift at KPI

Performance of Dense Phase Catalyst Cooler

Heat Removal Duty vs. Catalyst Circulation Rate
Catalyst Cooler Duty (% of

Design)
130
120
110
100
90
80
70
60
50
0
20
40
60
80
100
120
140
Catalyst Circulation Rate Through Cooler (% of Design)
Regenerator Temperature Control

Cat Cooler can adjust automatically to feed changes
Cat Cooler Duty
Regen Temp
Regen Temp
100
728
90
80
724
70
60
50
720
40
30
716
20
10
0
712
0
10
15
Time (hours)
20
25
Regenerator Temperature (C)
Catalyst Cooler Duty (% of design)
Cat Cooler Duty
Example of Increasing Feed CCR and Metals

70,000 BPSD
atmospheric resid direct
to FCC
Catalyst cost at
$2,000/ton
Va/Ni ratio is 1/1
Dealing With Regenerator Bed Temperature
Coke Yield, wt%
12
10
Partial
Burn
Total Burn
Catalyst Cooling
200 MMBtu/hr 400 MMBtu/hr
8
6
4
2
0
0
4
ConCarbon, wt%
Catalyst Cost, $/bbl
Catalyst Makeup Costs

Va/Ni=1
2.5
Va/Ni=4
2
1.5
1
0.5
0
0
10
20
30
40
50
60
Total Metals, wppm
Typically consider alternatives at 20 ppm total metals
Other Advantages
of Countercurrent
Regeneration
Regenerator Comparisons
Side Entry vs. Center Entry with Catalyst Distributor
Side Entry Regenerator
Center Entry with Spent

Catalyst Distributor
Regenerator Design Comparisons

Co-current Regeneration
Highest carbon catalyst contacts
fresh air with 21% O2
Spent Catalyst
+
(low carbon)
low O2
Heat transfer to fluid bed is not rapid
enough to prevent high particle

temperatures
Dilute
Phase
Bed
air
burning rate
catalyst
Rapid O2 transfer produces high
High particle temperatures
accelerate catalyst deactivation

Catalyst
+
(high carbon)
high O2
Catalyst Interior Particle Temperature Rise
Temperature
spike
Countercurrent
Additional
Deactivation
Combustion Rate
Temperature
Cocurrent
Highest O2, high coke,

rapidheat release,
little diffusion resistance
Lowest O2, high coke,
controlledheat release,
little diffusional resistance
Time
Concurrent Regeneration
Rapid burning results in rapid temperature increase inside the particle
Burning rates remain relatively high during the first 25-30% of combustion
Temperature spike inside the particle
Temperature rise- water- metals all combine to deactivate catalytic sites
Much lower burning rates mitigates interior temperature rise
Burning rates remain well below cocurrent for most of the combustion
Lower burning rates allow the heat to be dissipated to flue gas
Commercial Catalyst Activity

Improvement From Counter-Current Regeneration
Catalyst Data:
BASE CASE
Co-Current
REVAMP
Counter-current
Delta
Surface Area, m/g
143
162
+18
Avg. bulk density, g/cc
0.90
0.88
-0.02
Pore volume, cc/g
0.34
0.39
+0.05
MicroActivity, wt%
68.5
73
+4.5
Mechanism of KBR FCC NOx Reduction

Spent Catalyst
(high carbon) +
2 C + 2 NO ----> 2 CO + Nitrogen
low O2
NO produced in bottom of bed

contacts carbon near top of bed
catalyst
When spent catalyst distributed

across top of regenerator bed...
Dense
Phase
Bed
air
Less than 10% of nitrogen in coke

burns to NOx in Counter-Current
Regeneration
Regen Catalyst
+
(low carbon)
Two Stage Units Add Complexity

Higher
Investment
(up to 20%)
Operations More
Complicated
high O2
Major Equipment Summary

KBR Orthoflow
Two Stage Regenerator
Major Reaction Vessels
Catalyst Slide Valves
Flue Gas Slide Valves
Catalyst Transfer Lines
Catalyst Transfer Line

Expansion Joints
Orifice Chambers
0 (for full burn)

1 (for partial burn)
CO Boiler
Total Installed Costs

KBR Orthoflow
Converter
5050
5850
Air Blower
3900
4120
Flue Gas System
1300
2370
Catalyst Storage Drum
250
300
Bulk Materials
1140
1370
Total $(000)
11640
14010
--
120.4 %
Delta Cost
Percent of Total Installed Cost

KBR Orthoflow
Converter
43.4
50.3
Air Blower
33.5
35.4
Flue Gas System
11.2
20.4
Catalyst Storage Drum
2.1
2.6
Bulk Materials
9.8
11.7
100.0
120.4
Total (%)
Orthoflow FCC Converter

Maximum Operating Flexibility
FEEDSTOCK
FCC Type
VGO
R2-R
Resid
COMBUSTION
Complete
Partial
X
High Efficiency
KBR Orthoflow
CONCLUSION: The Orthoflow regenerator handles

VGOs or Resids in complete or partial combustion
without compromise
Regenmax Technology
Regenmax Technology
Baffle Provides Staging In Single Vessel
Upper
Bed
Baffle
Lower
Bed
Orthoflow
Spent Catalyst
Flue Gas
RegenMax
Spent Catalyst
Upper
Bed
Catalyst
Bed
Regen Catalyst
Air
Flue Gas
Catalyst
Air
Lower
Bed
Regen Catalyst
Air
Catalyst
Backmixing
Regenmax Technology
RegenMax Baffle
RegenMax Model
Photo of Regenmax Baffle
Regenmax Benefits
Burns catalyst clean in partial CO combustion
Without requiring an increase in catalyst inventory or unit size
Achieves this in a single, simple regenerator vessel

Less costly than building
two-stage regenerators
Feedstock operating
flexibility
Can switch to complete
combustion when desired
Reliability of Regenmax
Baffle does not interfere
with catalyst flow from
upper bed to lower bed
High percentage of
open area
Unique design limits
backmixing
No change in density
profile in bed
No flooding or other
flow problems
KBR Orthoflow Advantages for Residue Processing

Reaction Features
Low Pressure Short Contact Time
Minimizes gas and coke
Regeneration Features
Ultimate regenerator operating
flexibility accommodates the reactor

heat demand
Full or partial CO combustion
Dense phase catalyst cooler
Economy of design and operation

Single stage regeneration
Low NOx emissions
Mobil Altona
Thank you very much
Questions?

RFCC KBR Features

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RFCC KBR Features

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Formatos disponíveis

Residue FCC Design

2009 KBR. All Rights Reserved.

You want to put Resid in the Cat Cracker?

2009 KBR. All Rights Reserved.

What Cats Like

2009 KBR. All Rights Reserved.

What Cats Dislike

2009 KBR. All Rights Reserved.

Residue Upgrading Options for FCC Feed

Vacuum Distillation: FCC Feed Lost in Vacuum Residue

2009 KBR. All Rights Reserved.

Residue FCC Processing Challenges

2009 KBR. All Rights Reserved.

KBR FCC Rx System Technologies

excellent riser coverage

2009 KBR. All Rights Reserved.

KBR FCC Rx System Technologies

high flux strippers

KBR FCC Rx System Technologies

improves gasoline yield

2009 KBR. All Rights Reserved.

KBR FCC Rx System Technologies

unducted riser termination

2009 KBR. All Rights Reserved.

KBR FCC Regenerator Technologies

2009 KBR. All Rights Reserved.

KBR FCC Regenerator Technologies

Partial CO Combustion Better for Residue

2009 KBR. All Rights Reserved.

V2O5 generated in oxidative environment:

(Vanadium equilibrated between particles)

2009 KBR. All Rights Reserved.

Complete Combustion Better for Gas oils

Maintains regenerator temperature on HDT VGO

2009 KBR. All Rights Reserved.

KBR Counter-current Regenerator

Spent Cat Distributor

2009 KBR. All Rights Reserved.

Spent Catalyst Distributor

2009 KBR. All Rights Reserved.

Regenerator Design Comparisons

Catalyst travels down

Low carbon catalyst contacts high O2 gas

High carbon catalyst contacts low O2 gas

Dense phase particle contact dissipates heat

Low particle temperature minimizes catalyst

2009 KBR. All Rights Reserved.

Regenerator Temperature Control

KBR FCCU with Cat

2009 KBR. All Rights Reserved.

KBR Dense Phase Catalyst Cooler

2009 KBR. All Rights Reserved.

Scabbard -Outer Tube

Dense Phase Catalyst Cooler Technology

2009 KBR. All Rights Reserved.

Key Features of Catalyst Cooler

High Heat Transfer Coefficient

Key Features of Catalyst Cooler

2009 KBR. All Rights Reserved.

Easy To Remove Tube Sheet

Cooler Tube Bundle Lift at KPI

Performance of Dense Phase Catalyst Cooler

Catalyst Cooler Duty (% of

Catalyst Circulation Rate Through Cooler (% of Design)