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UOP FCC Propylene Production Tech Paper PDF
UOP FCC Propylene Production Tech Paper PDF
Factors influencing the selection of propylene yield design points and a comparative study
of an absorption-based gas concentration unit relative to cold-box recovery design show
how refiners can leverage existing assets to close the market gap for propylene production
I
ncreased propylene production
from FCC units has been widely
30
discussed over the past three to five
years, with reference to both new unit
construction and existing units. One of 60
25
the primary questions being asked of
C3 = production, ton/day
significantly larger equipment per barrel
temperature, 1000F
80 1200
processed, resulting in a higher capital
cost. To move the operation from 60 1100
gasoline to propylene mode derates the
operating capacity by approximately 1000
40
50%. In other words, if a unit is designed
for a gasoline mode throughput of 50
20 900
000 bpsd, to maximise severity to
propylene mode operation in the same
0 800
equipment the feed rate would need to
30 40 50 60 70 80
be reduced to approximately Hydrotreated feed, kBSD
25 000 bpsd.
The operating costs associated with Reactor pressure Reactor temperature, 1000 F
maximum propylene production are C3= wt% FF C3= production tonnes/day
Conversion, vol%
higher than for gasoline mode operation.
This further penalises the economics of
maximum propylene production. Lower Figure 2 Unit size vs throughput and severity
hydrocarbon partial pressure to
maximise propylene selectivity requires
additional steam use, and maximising
propylene (C3=) over butylenes (C4=) 1400
requires lower absolute operating
1200 Natural gas
pressure, both contributing to larger Refinery grade C3=
vessel requirements per barrel 1000 Polymer grade C3=
throughput. The catalyst systems for
maximum propylene production 800
$/ton
EEC, $MM
5000
$/hr
each system is shown in Figures 5a
and 5b. 150
The compression-based cold-box 4000
recovery system uses straight
compression and fractionation to
100 3000
recover light olefins, and is very efficient
when there is little or no naphtha in the
process. Such is the case with a steam 2000
cracker application. However, there are 50
naphtha products that need to be
recovered with an FCC system. 1000
The absorption-based system employs
an absorbent naphtha circulation that 0 0
allows the number of compression Gas con Cold box Gas con Cold box
stages to be reduced. Also, the
fractionation section is configured to Product recovery BF water LP steam
take advantage of low-cost heat Refrigeration HP steam Cooling water
integration with the main fractionator. Main column MP steam Shaft work
Case study
Gas con unit vs cold-box design Figure 6 Capital and utility costs
The objective of a gas con unit vs cold-
box design study was to determine which
Propylene product downgrade1
recovery system provided the best overall
product recoveries, operating flexibility,
and capital and operating costs. To C3+ mol% in dry gas2 C3= slippage to dry C3= downgrade to
evaluate these alternatives, the following gas3 (tonne/day) natural gas4 ($/day)
general work process was used: 3 mol% 10.2 $0
5 mol% 17.4 $6480 p 9 = $4.6 MM/year
The design basis was set as a 50 000
7 mol% 24.8 $13 460
bpsd FCCU operating in propylene mode
Simulation models were built for an 1 Economics based on a 50 000 bpsd FCCU.
absorption-based gas con unit and a 2 Additional slippage of C3+ was considered at 61.2% C3= and 38.8% C3.
cold-box light olefins recovery system 3 C3= was valued at refinery grade as a feedstock to an alkylation unit valued at $680 per metric
Each process design was optimised tonne per CMAI for October 2006.
to achieve 98% recovery of polymer- 4 C3= was valued as natural gas at $195 per metric tonne per CMAI for October 2006.
grade propylene and ethylene at 99.5%
purity Table 3
Preliminary equipment designs
were generated for each system erected equipment cost (EEC) into an The utility cost evaluation shows
Capital cost estimates were annual cost. that the absorption-based design is a
generated for each design. clear winner over the cold-box system,
All required product treatment Capital cost evaluation even when considering the error bands
units were considered (ie, guard beds, In the capital cost evaluation, the cold- for the calculations, as shown in
driers, treaters, mercaptan oxidation box designs had fewer pieces of Figure 6.
(eg, proprietary Merox process), amine equipment than the absorption-based The higher utility cost associated with
unit and selective hydrogenation design and could arguably be considered the cold-box system is due to higher
process (SHP) unit to have a lower cost, but the differential refrigeration and hence compression
Detailed simulation models were fell well within the error bars of the cost load requirement to condense C3+ from
used to generate utility costs associated estimates, as shown in Figure 6. The the main fractionator overhead vapour,
with each design. economics shown are based on the EEC. and higher LP and HP steam
Capital and operating costs were Since the design of the reactor, consumption. With the absorption-
estimated for the alternatives based on a regenerator and the C3 splitter are based gas con unit, all of the
+30% error band. A total annualised cost common between the gas con and fractionation and absorption equipment
(TAC) was calculated to provide a single recovery designs, these costs are is on heat integration with the main
metric with which to compare the considered to be the same for both fractionator, and the energy contained
alternative process designs. A capital designs and are not included in the within the main fractionator is the
recovery of 20% was used to convert EECs represented in Figure 6. cheapest source of energy available.
Costs, $MM/yr
Absorber/
stripper
C1/C2
Main
column
C3/C4/C5
Absorber lean oil circulation The the absorber to achieve the desired
absorber feed, which is the main recovery.
fractionator receiver liquid, is routed to
the absorber. In the propylene mode Revamp unit designs
(more LPG and less gasoline yield), the The feasibility of employing the
feed to the absorber is rich in LPG and absorption-based gas con with high LPG
contains less gasoline. To achieve a high and low naphtha yields has occasionally
propylene recovery in the absorber, lean been challenged, based on a perception
oil circulation from the debutaniser to that there simply is not enough naphtha
the absorber must be increased. Lean oil absorbent available to maintain system
circulation could approach 200% of the efficiency. There is, in fact, more than
net gasoline. However, the actual enough. The primary absorber is designed
flowing volume of lean oil is not that to circulate both stabilised and wild
different than from the traditional naphtha absorbent (Figure 9). In gasoline
design operating in gasoline mode. For mode operation, 80% of the absorbent is
example, the feed to the debutaniser in wild naphtha from the main column
the propylene mode will contain a small overhead receiver and 20% is stabilised
amount of net gasoline and a large naphtha from the debutaniser. As the
amount of recycle. For the gasoline + unit is moved to maximum propylene
LPG mode operation, the feed to the generation, the absorbent ratio changes
debutaniser will contain a large amount towards 80% stabilised naphtha and 20%
of net gasoline and small amounts of wild naphtha, but the net liquid leaving
gasoline recycle. The net result in terms the bottom of the absorber stays
of heat balance on the debutaniser is no essentially the same. This is a very
different from the traditional system. important point, as the same equipment
This is a big advantage with an capacity is applicable over a large range
absorption-based gas con unit design. of operating severity.
The debutaniser reboiler requirement This flexibility in the absorption-based
and heat integration with the main FCC gas con design has enabled many
fractionator will be little affected when refiners in recent years to shift their
the FCCU switches modes of operation: operations towards higher propylene
gasoline + LPG mode to propylene yields in the range of 712 wt% FF within
mode, or vice versa existing main equipment constraints,
Absorber efficiency The number of while maintaining high levels of light
absorber trays is a variable that can be olefins recovery. Balancing the target
used to increase absorption efficiency. propylene generation, percentage
For propylene mode operation, an recovery and the cost of modifications to
additional 2030 trays and two more achieve the refiners objectives is an
intercooler loops may be required for important part of every revamp study.
www.eptq.com
When trying to maximise the value of concentration unit is still the best choice
existing assets, the additional capital for the entire severity range of operation.
required to achieve a propylene recovery
An optimally designed It provides a lower cash cost of
of 97% may not be economic when absorption-based gas production relative to a cold-box design
compared to that of a 96% recovery case. due to lower utility consumption and
A single percentage change in design
concentration unit is still gives additional flexibility across a broad
recovery can require substantial the best choice for the range of propylene yields, allowing the
equipment modifications or replacement. operator to adjust FCC yields to meet
A process study normally reveals unit entire severity range of changes in the marketplace while
limitations and provides the refiner with operation maintaining efficient operations. This
answers that lead to the most economic capability is especially important during
case for revamp implementation. times of volatile energy prices.
UOP has been involved in many unit normally the primary variable that can Competing economic forces and real
revamps with high propylene recovery be adjusted for a revamped unit to market data that suggests the optimal
targets. In one of the more aggressive achieve a higher propylene recovery yield of propylene from a FCCU is 1012
cases, the refiner achieved a 58% increase Heat integration with the FCC wt% FF, which is substantially lower
in throughput, while simultaneously main fractionator Proper design of the than the theoretical limits associated
achieving a 30% increase in propylene main fractionators heat integration with most feeds and operating systems.
yield over the original nameplate design. with the gas con is typically the most The premium propylene and butylene
To achieve this goal, the unit was complex part of most revamps. Different command over other products, such as
progressively debottlenecked in stages to scenarios of heat exchange with the gasoline, is enough to give many refiners
identify the true limits of the equipments main fractionator are normally the incentive to invest in their
components, enabling the best use of identified to stay within the main existing assets.
capital investment to achieve the fractionators limitations and reduce
refiners objectives. equipment modifications
While no two units are ever designed Alternative absorber configuration Platforming, Merox and MD are marks of
or operated the same, there are some The conventional UOP scheme can be UOP.
typical capacity constraints that require modified to increase propylene recovery
revamping to enable higher severity or to the stripper bottoms and C2- rejection
higher throughput operation of the gas to the primary absorber lean gas. The References
1 Chemical Market Associates Inc (CMAI),
con unit, including: traditional recycle of stripper overhead 2004 world light olefins analysis, www.
Wet gas compressor capacity The vapour back to the inlet of the high- cmaiglobal.com.
increase in light ends and LPG make will pressure condenser is eliminated. This 2 Chemical Market Associates Inc (CMAI),
2006 world light olefins analysis, www.
increase the load in the wet gas offloads the condenser and the high- cmaiglobal.com.
compressor. However, for most revamps, pressure receiver, allowing for more 3 Purvin & Gertz, 2006 global petroleum market
the reactor pressure is normally increased economic new unit design and greater outlook, www.purvingertz.com.
4 US Energy Information Administration (EIA),
to accommodate the reactor cyclone potential to retain existing equipment Annual energy outlook, www.eia.doe.gov.
design within the existing reactor shell in revamp situations. This also provides 5 Houde M, Rebalance gasoline surplus by
constraints. Increasing the reactor pressure a means to revamp units for higher maximizing FCC propylene, ERTC 2005,
results in an increase in the compressor throughput or severity of operation that www.uop.com/objects/RebalanceGasoline
Surplus.pdf.
suction pressure, which often offsets the are constrained by plot space to increase
decrease in molecular weight to the high-pressure condenser duty. The
compressor. Due to the high cost of wet stripper feed preheater can also be
gas compressor replacement, in many eliminated to improve feed conditioning
cases the operating conditions for the to the stripper and give better propylene Keith A Couch is senior manager of
revamp are set within the maximum recovery. These changes can result in FCC and treating technologies for
capacity of the existing compressor casing. greater than 99% propylene recovery UOPs refining conversion development
It is important to note that rotating and C2- rejection sufficient to make department in Des Plaines, Illinois, USA.
equipment vendors have also improved polymer-grade propylene specification Couch holds a BS in chemical engineering
their technical offerings and can now while eliminating the need for a from Louisiana Tech University.
often re-rate existing equipment beyond downstream deethaniser column. Email: Keith.Couch@uop.com
previously considered limitations: Jim P Glavin is product line manager
Fractionators/absorbers capacity In Incentives for UOPs FCC, alkylation and treating
most revamps, the capacity constraints of Global propylene demand trends remain technologies in Des Plaines, Illinois, USA.
trayed columns can be overcome with strong, and with the change towards Glavin holds a BS in chemical engineering
the use of high-capacity trays, such as the lighter feedstocks in new steam crackers from the University of Illinois and a MBA
proprietary MD trays or packing. The there will be a growing reliance on from the University of Chicago.
typical limiting areas are the HCO section FCCUs to balance the supply side of the Email: Jim.Glavin@uop.com
of the main fractionator, top section of propylene equation. The technology Dave A Wegerer is a senior associate in
the debutaniser, the stripper and the exists today to help make this happen. process design and development with
absorber UOP believes the FCC process is flexible UOPs equipment development department
Cooling temperature and absorber enough to meet the challenge associated in Des Plaines, Illinois, USA. Wegerer holds
lean oil circulation For propylene with closing the global market gap for a BS in chemical engineering from the
yields less than 12 wt% FF, a traditional propylene. We believe this will happen University of Illinois.
cooling water heat-removal system is through a combination of new units Email: Dave.Wegerer@uop.com
generally sufficient to meet the desired designed for elevated propylene yields Jibreel A Qafisheh is a process specialist in
propylene recovery. A chilled water and revamps of existing facilities to UOPs FCC engineering technology centre
system can be applied if the unit has increase propylene yield and recovery in Des Plaines, Illinois, USA. Jibreel holds
other constraints that cannot be within logical equipment constraints. a MS in chemical engineering from the
overcome. However, this is not typically UOP has determined that an Illinois Institute of Technology.
required. Absorber lean oil circulation is optimally designed absorption-based gas Email: Jibreel.Qafisheh@uop.com