Leverage Technology to Win in the

Downturn

2010 AIChE Regional

Process Technology
Conference
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Galveston, Texas (Maximum
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Russell Anderson
Shell Global Solutions Downstream

Copyright of Shell Global Solutions US Inc October 2010 1

Disclaimer statement

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 Todays Refining Challenges

Refining Operations under wide range of pressures

Aging assets
Feedstock quality
Product quality
Product demand
Environmental legislation
Capital constraints

Low-cost revamps with fast return to enhance margin

and reliability
Vacuum Flasher Units
FCC
Hydrotreating / Hydrocracking

3
 The 5 key elements of Shell vacuum flasher technology

1. Proprietary furnace design

high outlet temperatures of up
to 815 F

4
 Key elements of Shell vacuum flasher technology low
column dp

2. Low Pressure Drop Vane

Inlet Device min. mist flow
and even vapor distribution

5
 The 5 key elements of Shell vacuum flasher technology

3. Proven wash oil section

design balancing wash
oil flow against coking

6
 The 5 key elements of Shell vacuum flasher technology

4. Proprietary low
pressure drop total
draw-off trays
typical 0.5 mbar per
tray, some trays
insulated

7
 The 5 Key elements of Shell vacuum flasher technology

5. Shell empty spray

section technology
heat & mass
transfer ensured at
min. pressure drop

8
 VFU reconfiguration to increase VGO

Observations
Average cycle 3 years, coking WO bed
Severe maldistribution Wash oil flow
Severe VR entrainment to HVGO

Complications
Column at max loading
Furnace at max duty

Wish list
More VGO
Cycle of 5 years
Payback < 1 year
Implementation during normal
turnaround
9
Current VFU after revamp all modifications
implemented during a normal turnaround period

Redesigned spray
Redesigned Wash oil header
Bed

New insulated draw-off

tray

New stripping trays

10
 Impact revamp on yields

Yield on intake before Yield on intake after

VFU products
revamp, % wof revamp, % wof
Off gas & slops 0.1 0.1
VGO 52.6 54.5
Vacuum residue 47.1 45.3

Increased VGO
Total Installed Margin Gain Simple
yield (% wof)
Costs (million (million Payback
USD) USD/year) (years)

1.1 1.9 1.56 0.71

On track to increase runlength from 3 years to 5 years

11
FCC Revamps Differentiators

Stripper
internals
Flue gas cleaning system PentaFlow
Packing
Third-stage
separator
flue gas
cleaning Riser and
system internals

Reactor and
regenerator
cyclones
Feed
Catalyst nozzles
Circulation
Enhancemen
t Technology

FCC technology value creation through Shell design features

12
 FCC Reactor Revamp

7.5 wt% conversion increase and increased capacity

Prior conditions
90 MB/D feed, disk and donut baffles and
modern feed nozzles

After revamp
New feed nozzles, riser with internals and
PentaFlow stripper packing

Conversion increased by 7.5 %wt

and Capacity by 2MB/D
~ 2 % increase due to feed nozzle
~ 1.5 % due to riser internals and
~ 4 % due to stripper internals

13
 Increased Catalyst Circulation by 50%

Prior conditions
60MB/D with conventional inlet hopper at
regen standpipe Regenerator
Bed
Restricted catalyst circulation due to low
regen slide valve dP

Results with CCET revamp

Regen slide valve dP increased by about 2psi
Regen standpipe flow became very stable
Catalyst circulation rate increased 50% from
40 to 60 t/min
Value to refiner over $2.5 mln/y
Catalyst Circulation
Enhancement
CCETs now installed in 8 FCC/RFCC units Technology

14
 Hydroprocessing: Shell/Criterion Differentiators

Experience & technology

Novel hydroprocessing technology solutions
Differentiated distillation technologies

van

Reactor internals
Near 100% catalyst utilization

Catalyst systems
Hydrotreating catalyst design
Hydrocracking catalyst design
Conversion optimization

15
 Shell hydroprocessing differentiators reactor internals
Inlet Device
Filter / Scale Catching Tray
Shell Reactor Internals
Maximize reactor volume
utilization

Integrated internals design

only 1 1.5 m height
up to 20% more catalyst
volume

Ultra Flat Quench

HD Tray

Bottom Basket

16
 Hydroprocessing differentiators Criterions
high performance hydrotreating catalysts

Catalyst Portfolio meets Demands of

Relative HDS volume activity, %
New Sulphur Specifications
500

400

300

200

100

1980 1985 1990 1995 2000 2005 2008/10

Catalyst activity gains in past 10 years have on average more than halved
the catalyst volumes required 17
 Differentiatormax diesel hydrocracking catalysts

Trilobe (TL) Z-2513

Z-503
Z-513 Z-2623
Z-603

MD selectivity
Z-623 Z-2723

Z-673
Z-3723
Z-723
Z-3733
Z-733
Z-803 Z-863
Z-753 Z-853
Triadvanced (TA) New Step-out portfolio

Activity
Conventional State-of-the-art New generation

New generation cracking catalysts deliver up to

5% more diesel from two-stage HCU
Triadvanced (TA) catalyst shape can boost
diesel selectivity by at least 1.5wt%
18
 New life for old reactors

1. Internals upgrade
Filter deck
HD High Dispersion Trays
RM-5030
UFQ Ultra-Flat Quench Decks
DN-3300

2. Tailored catalyst system

Metals: RM-5030 Z-673

Nitrogen: DN-3300
Yields: Z-673/Z-623
Z-623

19
 Reactor revamp transforms HCU performance

Results:
Distillate Yield
Increased cycle length
Higher diesel yield After
Percent of
Diesel sulfur <10ppm Fresh Feed
(Increments
Lower LPG of 5%)

Lower H2 consumption
Before

ULSD Sulfur Monitoring 0 200 400 600 800 1000 1200

120
Days on Stream
100

80
Top Bed
Changed $3.5 million annual benefit
Sulfur (ppm)

60
Operating Limit
40
Before After
20

Days on Stream 20
 Key Takeaways

Refining Operations under wide range of pressures

Aging assets
Feedstock quality
Product quality
Product demand
Environmental legislation
Capital constraints

Technology solutions for Hydroprocessing, FCC, and

Distillation
Low cost
Easy to implement
Increase reliability
Improve yields
Increase run length
21
Q&A

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