Improvements in the

RFCC process

Feb 22nd. 2011

I. Outline of S-OIL Refinery

II. Improvements of RFCC after 2010 T/A
1. Introduction of O2 Enrichment System
2. Flue Gas Cooler Modification

III. Summary

I. Outline of S-OIL
Refinery

Outline of
S-OIL Refinery

Improvements
Of RFCC 10 T/A

Summary

View of Refinery
CDU : 580,000 B/D
HOC : 253,500 B/D
Lube : 30,000 B/D
P-X : 700,000 TPA
BTX : 900,000 TPA

CHINA

SPM
R&D
S

#1/#2 CDU
NHC

Lube/Aromatic

Seoul

Ulsan
O
Onsan
Pusan

JAPAN

BCC / #3 CDU

Total Area : 2.5 mil. m2

Seoul Ulsan : 400 Km

Pusan Ulsan : 50 Km

II. Improvements of RFCC

after 2010 T/A

Outline of
S-OIL Refinery

Improvements
Of RFCC 10 T/A

Summary

Outline of RFCC Unit

R2R
(RFCC)

Feeds

Products

Objectives

R2R is a proprietary commercial RFCC process name of

Axens. (1 Reactor, 2 Regenerators)
RFCC : Residue Fluid Catalytic Cracking
HYVAHL-Residue (from HVL, storage)
Treated VGO (from MHC, storage)
Low sulfur Wax

Fuel Gas, Propane, Propylene, Butane,

LCN (LLCN, MLCN, HLCN), HCN, LCO, SLO

Maximizing Gasoline
Maximizing Propylene

Improvements
Of RFCC 10 T/A

Outline of
S-OIL Refinery

Summary

RFCC Scheme
FGTU

PROPYLENE
GAS RECOVERY
SECTION

R2 FLUE GAS

R1 FLUE GAS

FUEL GAS

Fractionator

2nd Regenerator

PROPANE
C4

Disengager / Stripper

L-L. GASOLINE
Catalyst
Cooler

SHU
525
1.5 KSCG

750
1.3 KSCG

M-L. GASOLINE
H-L. GASOLINE

HVY GASOLINE
Stripper
Packing

LCO

RISER
660
2.2 KSCG

1st Regenerator

COMBUSTION AIR

O2

FEED

SLURRY

Improvements
Of RFCC 10 T/A

Outline of
S-OIL Refinery

Summary

Introduction of O2 Enrichment System

Operational Difficulty
Combustion Air Constraints (#1 Reg. Cyclone & Superficial Velocity Limitation)
Feed Heaviness (MCR) Increase
73,000 BPD (MCR 3.5 wt%)

Charge Down
62,000 BPD (MCR 4.8 wt% T-VR)

Progress
Secondary Air Blower Installation (2007 T/A)
69,000 BPD

73,000 BPD (for 4 months of summer)

Introduction of O2 Enrichment System (2010 T/A)

73,000 BPD (MCR 3.5 wt%)

73,000 BPD (MCR 4.7 wt%)

Additional Tube Cluster Installation of Catalyst Cooler (2010 T/A)

+ 2 MMkcal/h heat duty is expected by O2 Enri. utilization (studied by S&W)

Outline of
S-OIL Refinery

Improvements
Of RFCC 10 T/A

Summary

Introduction of O2 Enrichment System

Results
Actual Result In 2010
T-VGO 2,000 BPD

T-VR (MCR 3.77

3.89 wt%)

Additional Treatment of T-VR according to feed availability

In the Future
Slide / Plug Valve Size-up (2013 T/A)
Conversion decrease due to treating heavier feed stock and CCR Limitation
CCR Increase (C/O Ratio increase) in order to increase conversion

Outline of
S-OIL Refinery

Improvements
Of RFCC 10 T/A

Summary

O2 Injection Package

< O2 Injection Package>

< O2 Diffuser>

Installation Item
O2 Injection Package (O2 Skid, Control V/V, Flow Meter etc)
O2 Diffuser Installation at Main Air Tie
O2 Pay Meter Installation by Vendor (near B/L Gas O2 Pipe)

Outline of
S-OIL Refinery

Improvements
Of RFCC 10 T/A

Summary

Economic Analysis
Effect
Investment Cost

Effect

1.4 mil. US $

T-VGO to T-VR 2,000 BPD

T-VR Max (Test Run)

Profit

5.8 mil. US $

IRR / Pay Out

764 % / 0.1 yr

Outline of
S-OIL Refinery

Improvements
Of RFCC 10 T/A

Flue Gas Cooler Modification

-. Flue Gas Treatment Unit Scheme

Summary

Outline of
S-OIL Refinery

Improvements
Of RFCC 10 T/A

Summary

Flue Gas Cooler Modification

Operational Difficulty
Enforced Domestic Environmental Regulation
In case of FGC Tube Leak, Unit S/D is needed due to CO regulation
FGC Outlet Temp. High (near Mech. DSN Temp.)
Progress
Case Study ( FGC 1 Train Install. Vs FGC Modification)
FGC Modification due to economics (studied by DuSan Heavy Industry)
FGC Modification
Separate 4 Modules for blocking leaked module
Install. Of Leak Detection System
Anti-vibrating Device install. (Ultrasonic)
New Economizer Install.

Outline of
S-OIL Refinery

Improvements
Of RFCC 10 T/A

Summary

Flue Gas Cooler Modification

Results
Energy Conservation
New Economizer Install. (Solomon EII 0.17, HP Steam + 13.1 Ton/h)
No Charge Loss in case of Tube Leak
No Tube Leak in 2010. (Future expectation)

In the Future
Effect
Require reliability of leak detection system
Consistent
HP Steam Production
MonitoringIncrease (13.1 Ton/h)

Outline of
S-OIL Refinery

Major Function
Of Q.M

Flue Gas Cooler Modification

Before Revamping

Summary

Outline of
S-OIL Refinery

Major Function
Of Q.M

Flue Gas Cooler Modification

After Revamping

Summary

Outline of
S-OIL Refinery

Improvements
Of RFCC 10 T/A

Summary

Economic Analysis
Effect
Investment Cost

Effect

10.1 mil. US $

HP Steam : + 13.1 Ton/h

Profit

7.1 mil. US $

IRR / Pay Out

66 % / 1.7 yr

Outline of
S-OIL Refinery

Improvements
Of RFCC 10 T/A

Summary

Summary
O2 Enrichment
O2 injection at #1 Regenerator
Additional Treatment of T-VR
Flue Gas Cooler Modification
Flue Gas Cooler Superheater Modification (4 Module)
New Economizer Installation
Additional HP Steam Production
No Charge Loss in case of Tube Leakage

Outline of
S-OIL Refinery

Improvements
Of RFCC 10 T/A

Summary

Fluidization
the operation by which the fine solids are transformed into a fluid-like state
through contact with a gas or liquid
* R2R uses air and steam to fluidize catalyst.

Solid-like state

Fluid-like state

Outline of
S-OIL Refinery

Improvements
Of RFCC 10 T/A

Fluidization Regimes

Summary

Outline of
S-OIL Refinery

Improvements
Of RFCC 10 T/A

Fluidization Regimes

Summary