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Selectively increasing gasoline production in FCC - PowerPoint PPT Presentation

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Selectively increasing gasoline production in FCC

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  1. Selectively increasing gasoline production in FCC

  2. GO-ULTRA Outline • What is GO-ULTRA? • GO-ULTRA Performance • Kinetics • Comparison of Commercially Available Gas Oil Catalysts • Applications • Commercial Experience • Summary

  3. 1. What is GO-ULTRA? GO-ULTRA™ is the first catalyst based on our new ONYX™ manufacturing technology GO-ULTRA has unique characteristics: • Optimized pore size distribution • maximum gasoline yield • reduced overcracking: lower coke and LPG • Higher LPG olefinicity • Novel ADM-25 matrix with unique AlO4/5 active sites • improved bottoms cracking at low delta coke

  4. GO-ULTRADelivers Superior Performance • Higher activity • Best coke-selectivity • Lowest bottoms at constant coke • Higher LCO/bottoms • Maximum gasoline • Flexibility with rare earth • Flexibility with matrix • Higher LPG and gasoline olefinicity

  5. GO-ULTRAUnique Pore Size Distribution • Optimized pore size distribution gives maximum gasoline • reduced overcracking to LPG and coke: also more olefinic LPG

  6. GO-ULTRA27Al MAS NMR • Active site optimization with ADM-25: unique, penta-coordinated Al (“AlO4/5”): • Leads to enhanced Bronsted and Lewis acidity • Highly active for coke-selective bottoms cracking • Low delta coke → low RGT GO-ULTRA Difference = Pentacoordinated “AlO4/5” species RUBY

  7. 2. GO-ULTRA Performance • Extensive lab testing has consistently verified the selectivity improvements in GO-ULTRA • Example shown: 4 different pairs of GO-ULTRA and RUBY samples. Each pair has constant active ingredients • Deactivation: CD, 1000/1000 Ni/V • VGO: API = 22, K = 11.6, CCR = 0.43 wt%, S = 0.81 wt% • ACE testing • 9 g. catalyst • 1.2 g/min. oil injection rate • Injection time varied from 75 sec. (CTO 6) to 150 sec. (CTO 3)

  8. ActivityΔ= GO-ULTRA minus RUBY GO-ULTRA is 1.5–2.8% more active than RUBY

  9. 430°F- Yields @ 68% ConversionΔ= GO-ULTRA minus RUBY GO-ULTRA = 2-3% more gasoline than RUBY

  10. Bottoms @ 68% ConversionΔ= GO-ULTRA minus RUBY GO-ULTRA: 1-2% more bottoms converted to LCO

  11. Yields @ 3% CokeΔ= GO-ULTRA minus RUBY GO-ULTRA vs Ruby: • 3-3.5% more gasoline • up to 2.0% more LPG • 3.5-4.0% lower bottoms

  12. LPG @ 3% CokeΔ= GO-ULTRA minus RUBY GO-ULTRA vs Ruby: • more C3= and C4= • equal to better isobutane

  13. Gasoline Olefins

  14. GO-ULTRA + ZSM-5 More gasoline + higher gasoline olefinicity = more light olefins from ZSM-5 MAX PROPYLENE APPLICATIONS C4= APPLICATIONS

  15. Max Propylene Application Constant ZSM-5 Additive

  16. GO-ULTRA Minus RUBYAverage D Yields in ACE Testing Average of four test comparisons using constant formulation sample pairs

  17. 3. Kinetics Results from Kinetic Modeling For details, see paper AM-10-175 from the Spring NPRA 2010 Significance of fit: - 24 degrees of freedom (35 data points minus 11 fitting parameters) - Mult-r2 = 0.997  VERY GOOD FIT

  18. Kinetics: Summary • A simple first order kinetic model has been developed which fits ACE data with high precision • Will be difficult to improve the fit using more elaborate models/mechanisms • The kinetic model proves the mechanisms behind the performance improvements of GO-ULTRA: • Activity • Coke selectivity • Bottoms conversion • Gasoline selectivity • Olefinicity • According to the model, in ACE testing, deactivation by coke is the main variable connecting CTO and yields

  19. 4. Comparison of Commercially Available Gas Oil Catalysts • GO-ULTRA • RUBY Reference • Competitor 1 • Catalyst claim: maximum gasoline • Competitor 2 • Catalyst claim: superior zeolite stability • Competitor 3 • Catalyst claim: superior coke selectivity

  20. Comparison of Gas Oil Catalysts: Gasoline • GO-ULTRA ahead by 1.5-2.5% gasoline

  21. Comparison of Gas Oil Catalysts: Bottoms and Coke GO-ULTRA lowest in bottoms and coke

  22. 5. Application • Optimize yields • Gasoline production • Lowest bottoms • Isoconversion: bottoms  LCO • Isocoke: bottoms  gasoline • Use in combination with ZSM-5 additive • More C3= / C4= precursors • Increase operational flexibility • E.g. lower delta coke  higher CTO • “Do something neat with the feed” • Higher feed rate • Poorer quality • Pretreat optimization • E.g. adjust CFHU to focus on S removal, allow aromatics to increase. Could be very attractive economically!

  23. 6. Commercial Experience With GO-ULTRA GO-ULTRA became commercially available mid 2009 First unit acquired almost immediately Currently in five units. More are coming – quickly!

  24. Refinery # 1 FCCU Yields GO-ULTRA entered the unit on day 4 of month 2 At turnaround, GO-ULTRA changeout was 65% TURNAROUND

  25. Refinery #1 Ecat Results

  26. Commercial Experience: Summary Initial commercial results confirm the impressive performance of GO-ULTRA Ecat data validates the activity, stability and selectivity of GO-ULTRA

  27. 7. Summary of Presentation GO-ULTRA is Albemarle’s latest catalyst to maximize profitability in gas oil FCCUs. It delivers superior performance: best coke-selectivity, lowest bottoms, and maximum gasoline GO-ULTRA is rapidly penetrating the VGO market. It is already in 5 units. More are on the way! Initial commercial results are confirming the impressive performance improvements of GO-ULTRA GO-ULTRA catalysts are available today