Stripping Efficiency Improvement After Catalyst Stripper Packing Installation in RFCC Unit

2007.12

Location Of ONSAN Complex

Seoul Ulsan : 400 Km Pusan Ulsan : 50 Km Ulsan Onsan: 15 Km

CHINA

Seoul

S-OiL
Ulsan O Onsan Pusan JAPAN

Refinery Overview
SPM R&D Center

CDU CDU MHC HYC/HVL BTX/P-X CDU

R2R

Overall Process Flow Scheme

LPG Naph Kero #1 DSL #1 Atm. Residue CDU VDU

H2
HDO MDO DAO

Benzene

Lube Plant

BTX

Toluene Xylene C9 Aro.

X-C

Para Xylene Benzene

SDA
Crude

Lube Base Oil / Wax Asphalt

#2 CDU

LPG Kero DSL

Naph H2 VGO

#3HMP #2HMP H2 #1HMP HYC

LPG Naphtha Kerosene Diesel Lube Base Oil

#3 CDU

#2 VDU
H2

MHC #2HVL #1HVL

Naph DSL
MTBE

R2R
Propylene RFCC MTBE LPG Gasoline LCO Slurry

Hydrotreated Residue Naph DSL

Atm. Residue Vac. Residue

Hydrotreated Residue

RFCC
RFCC
(Residue Fluidized Catalytic Cracking)

Unit

The purpose of RFCC unit is to convert heavy feedstocks such as AR or VR into lighter valuable products mainly Gasoline,C3=,LPG and Light Cycle Oil. Besides the valuable products, the catalytic reactions produces dry gas,slurry oil and coke. The cracked gaseous products are treated in the fractionator and downstream units. The coke ,deposited on the catalyst in the reaction zone, is burnt in the regeneration zone.

RFCC Process(R2R)
Design : 40,000 BPD Current: 73,000 BPD
.New .New .New .New Air blower Catalyst cooler Feed injector/Stripper Packing Tower internal

Licensor : Axens(IFP,France) Feed : Treated (VR + VGO) 1 Reactor / 2 Regenerators(R2R) Main Products
. Propylene (10 vol%) . Gasoline (55 vol%)

Conversion : 80 vol%

Catalyst Stripper(1)
Catalyst Stripper in FCC Unit
The FCC process is using small particles of catalyst which behave as a fluid when aerated with gas. The catalyst is continuously circulated from the reaction zone to the regeneration zone. The Catalyst Stripper located in Reactor bottom section which recovers volatile hydrocarbon contained in the catalyst particles before the catalyst enters regenerators.

Catalyst Stripper(2)
Catalyst Stripper in FCC Unit
The internals in the Catalyst Stripper improve hydrocarbon recovery by prompting intimate contact of the stripping steam and catalyst, however R2R Unit doesnt have the internals and this is known to cause the increase of coke yield and stripping steam consumption.

R2R Reactor & Regenerators

R1 FLUE GAS R2 FLUE GAS
2nd Regenerator Fractionator

FUEL GAS PROPYLENE

GAS RECOVERY SECTION

PROPANE C4

Disengager / Stripper

LT. GASOLINE HVY GASOLINE

740 1.15 KSCG 526 1.25 KSCG

Catalyst Cooler

LCO

660 1.90 KSCG

RISER

1st Regenerator

Combustion Air FEED SLURRY

Packing nstallation Backgrounds

H2 on Coke level in R2R Unit was around 7~8 wt%.

(While, well-designed catalyst stripper internals could achieve below 6 wt% )

Under the bottleneck of Air Blower. Frequent Catalyst Cooler isolation by tube leak 2 Licensors was competitors.
( Axens (manufactured by Koch-Glitsch), ABB Lummus )

Charge down.

Commercial experiences was key reason for selection.

( Axens (20 units, as of 2005), Lummus (No, as of 2005))

Before Packing Installation

Hydrocarbon Reactor

- Stripping Steam Ring.

. . . . Upper steam ring Main steam ring Lower steam ring Half moon steam ring

- Steam Flow :10.7 T/H

Stripper Stripping Steam

- H2 on Coke : 7~8 wt%

After Packing Installation

Hydrocarbon Reactor

- Stripper Steam Ring

(Upper ring removed)

- 8 Layers Structured Packing - Stripping Steam : 8.0 T/H

(Steam Reduction : 2.7 T/H)
Packing Stripper Stripping Steam

- H2 on Coke : 5~6 wt%

Stripper Packing (8 Layers)

Structured Packing Picture (S-OiL)

Installed Packing Picture (S-OiL)

SHELL

RISER Packing

Stripping Efficiency Improvement

Before 36.0 10.8 5.0 7~8 After 39.0 8.0 3.4 5~6

- CCR (Ton/min.) - Steam (Ton/h) - Steam/CCR (kg/Ton) - H2 on Coke (wt%)

o In spite of higher CCR and lower Stripping Steam rate, Stripping Efficiency was improved. (H2 on Coke can be decreased)

H2 on Coke After Packing Installation

H2 on Coke / Stripping Steam

H2 on Coke

Stripping steam

12.0 H2 on Coke,wt% 10.0 8.0 6.0 4.0 2.0

12000 Stripping steam, kg/h 10000 8000 6000 4000 2000

0.0 0 2005-03-01 2005-03-31 2005-04-30 2005-05-30 2005-06-29 2005-07-29 2005-08-28 2005-09-27 2005-10-27 Date

Economics Analysis
- Total Investment Cost : 1 billion won (including installation cost) - Steam (MP) reduction : 2.8 Ton/h * CO2 emission reduction : 5,000 Ton/Year - Payout periods (IRR) : About 2 years (40%) (excluding Charge increase)

Reference (By Axens)

Reference (By Axens)

Reference (By Axens)

Reference (By Axens)

Reference (By Axens)

Reference (By Lummus)

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