CONFIDENTIAL FOR INTERNAL USE ONLY BETZ PROCESS CHEMICALS, INC. CHAPTER 3.8 FCC UNIT - METALS PASSIVATION Pages 12 - 14 of this chapter offer terms, concepts and definitions, 4 preliminary review of this material will be helpful to your understanding of the information presented below. OVERVIEW ‘The direct and indirect effects of feedstock metals on FCC operations are many, complex, and costly, Metals passivation can partially offset these effects resulting in economic benefits that are substantial, but not always easy to document. The main benefits associated with metals passivation are widely recognized and potentially common to all suppliers; however, the degree to which these lucrative benefits are actually realized can vary significantly depending on product selection and on how well a metals passivation program is managed. These universal benefits include: + Improved product yield structure (selectivity) + Increased unit conversion + Increased residuum or gas oil feed capacity + Reduced catalyst consumption For our purposes, there must be a minimum level of metal on the equilibrium catalyst before our survey efforts are warranted, These levels are 400 ppm for Nickel and 1200 ppm for Vanadium, When these levels are exceeded, the effects of the passivation program are projected based on those percent benefits listed in Table 3.81, These benefits are all commercially proven. TABLE 38-1 KEY PASSIVATION POINTS Nickel Passivation Vanadium Passivation Ppm on equilibrium catalyst which warrants survey 400 1200 Percent Reduction of H2/Coke Due to Metal 50 65 Percent Reduction of Microactivity Loss Due to Metal 0 30-50 Betz Process Chemicals Supplemental Benefits There is a growing realization in the industry that first generation nickel passivation chemicals and their generally loose application can result in a significant shortfall in benefits and/or excessive chemical costs. For those who seek to maximize their benefits While minimizing annual treatment costs, Betz Process Chemicals can offer an Page 1 (05/88) Copyright 1988 - Betz Process Chemicals, Inc. Chapter 3.8CONFIDENTIAL FOR INTERNAL USE ONLY BETZ PROCESS CHEMICALS, INC. attractive alternative throught A diversified product line formulated to the specific needs of varied feedstocks and operations, This includes unique patented chemistry in certain areas. Proven experience with nickel and vanadium passivators, Stringent/customized monitoring and control programs designed to avoid overfeed and deliver a greater portion of the potential benefits of passivation. Causes Of Problem Before we can discuss the specifics of the metals passivation program, we must define the impact of metals on the FCC Unit - See Chapter 2.3 for FCCU process description. Metals cause problems in two major ways: 2. Catalytically Active Metals (Ni, V, Cu, Fe - Nickel, vanadium, copper, iron) ‘cause an incremental change in Ay and Coke make over and above underlying base Ay Gnd Coke make. “Nickel and Copper are roughly four times more active Catalytically than vanadium, Since copper levels are usually low, and iron has negligible impact on most units, these metals are usually ignored. Metals poisons (V, Na, N, Ni, Pb - vanadium, sodium, nitrogen, nickel, lead Zan Block acesss-pallis to tool sites oF physteally destroy seolite sites: permanently kills zeolite sites, Sodium (Na) appears less frequently (usually with resids) but chemically reacts with the zeolite site. The effects of Na & V become more severe at levels above 3000 to 5000 ppm for Na and 1000 ppm for V. Basic nitrogen is a temporary poison until exposed to regenerator temperatures. Nickel acts to block access to contte eltes but has negligible effect on catalyst activity even at very high (> 5000 ppm) concentrations, Even a small wt. % increase in 7 make, causes a significant increase in compressor loadings (0.18 wt. % H» = 100 SCF/BBL) which may cause a unit limitation, Any change in Hy make also causes a counterbalancing change in C3¢ gasoline yield (0.18 we % Hy = 18 % wt. % C+ Gasoline). Conservatively a 1.0 wt. % increase in contaminant coke (ie., excess over base) occurs with each 100 SCF/BBL increase in Hy make, In reality, resid streams with high Conradson carbon levels (explained later) can’ form significantly more coke relative to hydrogen because they contain a high proportion of hydrogen deficient components such as asphaltenes. Any change in coke make also causes a counterbalancing change in C3+ Gasoline yield (1.0 wt. % coke = 1.0 wt. % C3+ Gasoline). As coke make increases, blower duty and/or regenerator temperatures may also increase. As coke make increases, the burning air rate or the blower duty increases to burn the excess coke off of the catalyst. The burning air rate is dependent upon the amount of coke produced. The increased amount of coke that is being burned releases additional heat in the regenerator, thereby increasing the Page 2 (05/88) Copyright 1988 - Betz Process Chemicals, Inc. Chapter 3.8CONFIDENTIAL FOR INTERNAL USE ONLY BETZ PROCESS CHEMICALS, INC. regenerator temperature, Due to heat balance considerations, the rise in the regenerator temperature will trigger a drop in catalyst circulation rate (ie,, catalyst to oil ratio) to maintain a constant reactor temperature, The cat-to-oil ratio decrease will then act to lower coke yield toward its original value, which is enough to offset added contaminant coke caused by metals, This reduction in coke yield is a result of both lower conversion (less catalytic coke) as well as more efficient stripping. Finally, as zeolite sites are destroyed or blocked, catalyst activity {conversion} drops (i.e. more cycle oils are made at the expense of gasoline). Some or all of the following economic losses may be caused by metals as the H2/coke increases and the catalyst activity decreases (1988 values): 1. Throughput reductions may be required if compressor, blower, or temperature limits are hit, Cost = loss of upgraded values: ~ resid cutbacks cost $10/BBL resid backed out + gas oil cutbacks cost $2/BBL gas oil backed out 2, Increased catalyst consumption may be required to control metals: Fresh catalyst costs $1,600 - $2,200/Ton Reject catalyst cost $200 - $500/Ton 3. Reduced gasoline yields (selectivity) result in a loss of approximately $10 - $15/BBL (i.e. the difference in value between gasoline and coke). HY DROGEN/COKE MAKE Hydrogen make is comprise of two components: AL Base Hydrogen - Typically 5-50 SCF/BBL of base hydrogen are generated by cracking at zeolite sites. From 4-20 SCF/BBL of this base hydrogen can be attributed to catalyst design. The balance is primarily due to the nature of feedstock, with resids making significantly more base hydrogen than gas oils (e.g., typical base Hz = 10-20 SCF/BBL for gas oil vs. 40-50 SCF/BBL for a 20% to 30% resid stream}, Reactor temperature, contact time, and cat-to-oil ratios can also cause some fluctuations, Passivation Has No Effect On Base Hydrogen Contaminant Hydrogen - Is excess hydrogen (above base) generated by cracking at active metal sites. Passivation Can Significantly Reduce Contaminant Hydrogen Page 3 (05/88) Copyright 1988 - Betz Process Chemicals, Inc. Chapter 3.8CONFIDENTIAL FOR INTERNAL USE ONLY BETZ PROCESS CHEMICALS, INC. Two basic coke types are encountered: A Contaminant Coke - is the wt % excess coke (above base) produced by metals induced cracking which is also the source of contaminant hydrogen. Most literature suggests that for every 100 SCF of contaminant hydrogen produced, a 1,0 wt % increase in coke make can conservatively be expected due to contaminant coke production. As previously noted, resids can produce significantly more coke vs Hy, This is the only portion of coke make that nickel passivators can affect. Base Coke - This includes all other forms of coke and can vary widely on a given unit, The wide fluctuations in this significant portion of total coke make account for direct monitoring difficulties. Base coke can be grouped into three categori: (1) CATALYTIC COKE - is generated via the cracking reactions that occur at zeolite sites. This zeolite cracking is the source of base hydrogen. Catalytic coke generation is directly proportional to catalyst/oil ratio, and increases geometrically with catalyst activity or conversion. It also varies with catalyst type and residence time. (2) CAT-TO-OIL COKE - is not really coke, but rather the strippable hydrocarbons trapped in the pores of catalyst going to the regenerator loading. Wt % cat-to-oil coke increases as catalyst circulation rates increase (less efficient stripping). (3) CARBON RESIDUE (OR CONRADSON) COKE - is a wt% measure of the carbon after destructive distillation of a feed sample. It is a measure of the non-catalytic coke forming tendency of a feed, ive., the high boiling point compounds and asphaltenes that undergo little cracking in the reactor, and as a result, quantitatively appears as coke in the regenerator. (By definition, this produces no Hz in the reactor, but to be technically correct, a nominal 1%-2% may be cracked, and is accounted for in catalytic coke and base hydrogen.) Hydrogen and coke make for a given unit and catalyst will generally exist in a single relationship with active dehydrogenation metals, If this relationship can be developed for a given unit, than a controlled curve can be established. This curve is then used to do the following: » 2) 3) 4) Evaluate the passivation program Be sure current performance is in line with previous performance Optimize the chemical program Eliminate erroneous feedrate adjustments METALS VS. HYDROGEN/COKE MAKE ‘The marketing method involves the calculations necessary to define active metals. Page 4 (05/88) Copyright 1988 - Betz Process Chemicals, inc. Chapter 3.8CONFIDENTIAL, FOR INTERNAL USE ONLY BETZ PROCESS CHEMICALS, INC. ‘A. Equivalent Metals In order to reflect the differences in catalytic activity between Ni and V, many the industry (including Nalco and Phillips) exclusively use a term called "Equivalent Metals" for monitoring and scorekeeping purposes: Equiv, Metals = 4Ni+V B. Aged Metals In reality as metals are repeatedly subjected to regeneration, their catalytic activity is substantially reduced. This is called aging. The amount of deactivation that occurs varies with metals levels in the feed and catalyst makeup rates, Typically (15-35%) of equivalent metals retain their catalytic activity. C. Active Metals Active metals are the portion of the aged metals that retain their catalytic activity after passivation. If we plot equivalent m-tals against hydrogen (see Figure 3,8-1) the resulting curves can understate or possibly fail to detect the benefits of passivation. Note the large discrepancy between apparent improvements and true improvements. If we plot aged metals against hydrogen (see Figure 3.8-2), the resulting curves yields a better measure of the improvements from passivation. By plotting Active Metals versus hydrogen (see Figure 3.8-3), we can generally obtain a model which yields a true measure of improvements due to passivation. Passivators react with the active metals to form a bi-metallic compound that is, catalytically inactive, With a nickel passivator, the catalytic activity of vanadium remains unaltered and vice versa. Also unaffected by nickel passivation is the catalyst activity loss caused by accumulated metals. Since hickel is the most active metal catalytically, the estimated 45% - 65% Ni deactivation anticipated through passivation normally results in a 35%-75% reduction in metals related coke and hydrogen production. ‘The significant reductions in hydrogen make gained through metals passivation are usually the easiest improvements to detect. Although significant reductions in coke make can be attributed to metals passivation, it has proven difficult in practice to detect such changes by direct measurement. As a result indirect measures must be made (and justified) to claim attendant benefits. These ‘measures usually relate coke make reduction to Hz reductions. ‘The performance of a nickel passivator can be documented using the Active Metals versus H>/CHg ratio graph. The unit charge rate is 25,000 BPD. Page 5 (05/88) Copyright 1988 - Betz Process Chemicals, Inc. Chapter 3.8CONFIDENTIAL FOR INTERNAL USE ONLY BETZ PROCESS CHEMICALS, INC. ESTIMATED HY DROGEN/COKE BENEFITS Ontreated Active Metals, ppm 2400 Hy/CHg Ratio 92 Aydrogen, SCF/BBL (!) 92 4 Hydrogen, SCF/BBL Gasoline Benefit wee 3? Ib/day (7,877,000 Ib/day charge) 44900 BBL/day (275 #/B) 163 Value ($15/BBL, 1988 value), $/D $2445, Chemical Cost $300/d Licensing Gost $750/d Savings $1395/d (D100 SCE/BBL per 1.0 42/CHy Ratio + 1.18 wt % = 100 SCF/BBL, incl. Hy and Coke Note that this example is an antimony program which involves a Phillips licensing cost in the range of $,01-1/2 to $.04/BBL (in this case, $.03/BBL). The use of other Betz ProChem products requires no licensing consideration or is covered by Betz patents. As previously noted, vanadium and sodium are the only metals that cause any significant deterioration in catalyst activity (conversion), It should also be noted that nickel Passivation has no effect on volume % conversion. The reason for this is that any decreases in hydrogen and coke make caused by nickel passivation quantitatively go into C+ Gasoline and none goes into cycle oils. Since volume % conversion is commonly calculated by subtracting volume % cycle oils from 100, conversion would remain unchanged. This can best be illustrated by expanding our prior yield structure example as follows: BEFORE TREATMENT AFTER TREATMENT wr% VOL % WI% VOL% Coke 6.5 - 3.25 fe Hy 0.5 : 25 - CiC2 15 - La - cy 5.0 9.0 58 10.4 cy 11.0 17.0 13.2 20.4 C+ Gasoline 44.0 51.0 44.6 51.6 Cycle Oils 31.5 30.0 31.5 30.0 Total 100.0 107.0 100.0 124 Conversion 68.5 70.0 68. 70.0 These H/Coke modeling methods will apply to both nickel and vanadium passivation. Page 6 (05/88) Copyright 1988 - Betz Process Chemicals, Inc. Chapter 3.8CONFIDENTIAL FOR INTERNAL USE ONLY BETZ PROCESS CHEMICALS, INC. CATALYST ACTIVITY Vanadium passivators react with vanadium and prevent the vanadium from destroying the activity of a zeolite catalyst. The exact reaction equation is not known at this time; however, it is a fact that the passivated vanadium does not reduce the zeolite activity. Only vanadium is affected by this passivation process. It is true that the catalytic activity of vanadium (1,., hydrogen and coke production) is reduced by passivation, but the increased hydrogen generally associated with increased catalyst activity can mask this benefit on a commercial unit, The hydrogen and coke benefit of vanadium passivation has been discussed. During a commercial program, the effect on hydrogen and coke would be monitored. Conversion Changes Vanadium can cause a serious reduction in catalyst microactivity. This microactivity loss can be directly related to a loss in unit conversion, (About 1 microactivity unit is equivalent to 1/2 conversion units). About 30 to 30 percent of the catalyst microactivity lost due to vanadium poisoning would not have been lost if the vanadium had been passivated. NOTE: The vanadium passivator is not a co-catalyst. It does not increase the activity of a catalyst. [t reacts with vanadium and prevents the vanadium from doing harm. (Example: a catalyst with a maximum microactivity of 74 will not exceed 74 with vanadium passivation.) While sodium also causes a loss in catalyst microactivity, the vanadium passivation has no effect on sodium. Catalyst Changes The benefit of vanadium passivation can be realized in two ways. The conversion benefit has been discussed, In most units, a targeted unit conversion is maintained with catalyst; therefore, as the catalyst activity increases, the amount of fresh catalyst necessary to maintain unit conversion will be reduced. In this mode of operation, the vanadium passivation will yield a more active catalyst. Therefore, the actual benefit of passivation is a reduction in the amount of fresh catalyst necessary to maintain unit conversion. Unit Yield Changes The use of vanadium passivation gives the refiner economic operating flexibility. If the refiner takes the benefit of passivation in terms of catalyst savings, then the unit conversion and yield profiles should remain unchanged. When the refiner wishes to increase his unit conversion (i.e, gasoline yield) with vanadium passivation, the yield profile of the unit will be altered. The breakdown of the new yield structure with passivation will be similar to the structure from the same catalyst without passivation operating at the same microactivity. Note: Vanadium passivation does not appear to alter the basic cracking characteristics of the catalyst, The process simply prevents the vanadium from damaging the catalyst. Page 7 (05/88) Copyright 1988 - Betz Process Chemicals, Inc. Chapter 3.8CONFIDENTIAL FOR INTERNAL USE ONLY BETZ PROCESS CHEMICALS, INC. Sample Test Data (equal vanadium levels): WITHOUT TREATMENT WITH TREATMENT Conversion, % 1 74 Liquid yield, wt.% 44. 46. Gas yield, wt.% 45. 45. Coke yield, wt.% Me % Ha, wte% 2a 1.6 Cy Cy, wm 99 12 Car Cay WH 26.0 30.3 Cy Cra, wte% 29.7 32.5 C43 ~ Cag WE 18.41 17.0 Shurry, wt% 14.2 Ma ‘The above test data is an example of the yield benefit of vanadium passivation if the fresh catalyst makeup rate doesn't change. The increase is in the C4 - Cg and Cy - Cy cuts (gasoline) with the corresponding decrease coming from the Cy3 - Czq cycle oils (28% of the liquid decrease) and the slurry (72% of the liquid decrease). Figure 3.-4 titled "Microactivity Versus Vanadium" for all data illustrates a potential trend for the sample operating data, The scatter in the data is typical for this type of analysis and is due to the inaccuracies of the microactivity test and the test for vanadium on the catalyst. However, the catalyst manufacturer's data does substantiate a downward trend line which will be the basis of the discussion which follows. Below are the estimated benefits calculations in terms of microactivity for vanadium passivation. Operating at 3002 ppm and using the slope of the microactivity versus vanadium curve, we can conservatively estimate that 8.5 microactivity units are lost due to the level of vanadium on the catalyst. Our commercial experience is such that with vanadium passivation we can prevent 40% of the loss due to poisoning. Therefore, the microactivity benefit of passivation is 3.4 units, ESTIMATED MICROACTIVITY BENEFITS CALCULATIONS - VANADIUM PASSIVATION a, Conversion Basis Treated Vs Untreated Vanadium, ppm 3002 (1) Microactivity Loss, Vol % 85 A Microactivity improvement 34 A Onit Conversion (est.) 17 Gasoline Benefit Vol % La (68, max - 59.5) Page 8 (05/88) Copyright 1988 - Betz Process Chemicals, Inc. Chapter 3.8CONFIDENTIAL FOR INTERNAL USE ONLY BETZ PROCESS CHEMICALS, INC. ESTIMATED MICROACTIVITY BENEFITS CALCULATIONS - VANADIUM PASSIVATION (continued) a. Conversion Basis (cont'd) BBL Gasoline/Day 258 Value ($5/BBL, 1988 Value} $1290/day b. Catalyst Basis ‘Treated Vs Untrea (1) Microactivity, Vol % Constant at 59.5 Vanadium 3700 3002 4 Vanadium 698 (2) Additional Catalyst Makeup to Achieve A Vanadium 37 Value ($1500/ton, 1988 Value]) $855/D (U see Microactivity vs. Vanadium (Figure 3.8-4). The maximum, 68, is based on activity estimate with 2000 ppm V. Passivation benefit can be taken in two basic ways - actual conversion improvement on the unit or catalyst reductions. In terms of unit conversion, it is estimated that roughly 1/2 of the microactivity benefit would be directly reflected as an increase in unit conversion, On this basis, a 3.4 volume percent microactivity benefit relates to a 1.7 volume percent increase in unit conversion. This corresponds to 258 bbls/day of gasoline valued at $1290/day. The catalyst benefit would be a constant microactivity at 3700 ppm vanadium instead of the average 3002 ppm vanadium. The A698 ppm vanadium would result in a catalyst savings of approximately .57 tons/day. This catalyst savings equates to approximately $885/day. It should be pointed out at this time that the benefit in terms of microactivity of vanadium passivation increases substantially as metals on the catalyst increase. Any change in operation towards higher metals loading will add more justification to the treatment program. With a program cost of $150/day, this program is more than justified. Note that no licensing fee is required. The Betz ProChem Metals Passivation Program offers many advantages which are summarized below. FEATURES OF THE BETZ PROCHEM PROGRAM Product Capabilities Including: A. Nickel passivating agents that have been field demonstrated to react preferentially with ACTIVE nickel rather than aged/deactivated nickel. B. _ Passivating agents designed to be specific to vanadium. Page 9 (05/88) Copyright 1988 - Betz Process Chemicals, Inc. Chapter 3.8CONFIDENTIAL FOR INTERNAL USE ONLY BETZ PROCESS CHEMICALS, INC. C. High laydown efficiencies (percent of product fed which remains on the catalyst) to minimize loss of unreacted chemical to the fractionator. D. An advanced service program designed to optimize chemical usage and provide accurate operating data. E, Betz POF (Point-of-Feed) service provides no-charge bulk delivery and Inventory control on storage tanks supplied by Betz. Also, Betz ProChem uses an effective chemical feed system as outlined below. The chemical injection point should be after all heat exchanger/furnaces. An electric meter pump is recommended. A quill should be used to assure thorough mixing of the product with the feedstock. A dilution slipstream is mandatory. The actives in the metal passivator chemicals can plate out on the feedline and eventually plug the line without a slipstream. A low flow indicator on the slipstream is recommended. This can consist of an in-line orifice with a differential pressure indicator set to alarm at a zero of low differential pressure. Service/Monitoring of a Program Includes the Following: ‘A, Customized computer programs to help regulate chemical, catalyst, and fresh feedrates. In a complex and dynamic system like the FCC, identification of the optimum control range for chemical feed and maintaining feed within this range can be an elusive goal. By the same token, the introduction of a metals passivator (often concurrent with resid) alters any historical relationships between catalysts metals and hydrogen/coke make that may previously have been relied on to adjust catalyst makeup or fresh feed rates, To help pinpoint optimum control ranges in this new environment and suggest day-to-day changes to stay within these limits, Betz ProChem offers a comprehensive technical services package augmented by customized on-site and in-house computer programs that are reviewed and updated frequently as the data base for a given unit expands. A sampling of these capabilities includes: 1, ON-SITE COMPUTER PROGRAM/TECANICAL CAPABILITIES ~ Can be used to evaluate changes in chemical feed, catalyst makeup or fresh feed rates - Projects future metals levels and can be used to predict key variables (Hz make and microactivity) with and without changes = Can be used to warn of approaching hydrogen or conversion limit Page 10 (05/88) Copyright 1988 - Betz Process Chemicals, Inc. Chapter 3.8CONFIDENTIAL, FOR INTERNAL USE ONLY BETZ PROCESS CHEMICALS, INC. Laydown efficiency calculations for passivators and other metals Projection of benefits or the effect of operational changes Analysis for key metals in catalyst and oi! 2. OFF-SITE COMPUTER/TECANICAL CAPABILITIES - Develop customized relationships between metals and hydrogen make/conversion = Calculate % nickel passivation 3. BASELINE UNIT SURVEY 4. PRELIMINARY ENGINEERING a. Estimate Ni/Sb laydown efficiencies and aging factors. b. Estimate target passivator residuals to approach full passivation, c. Estimate pretreatment/maintenance feed rates to attain target residual on catalyst Custom relate hydrogen/conversion changes to metals. fe. Establish hydrogen/conversion control limits (jointly). £. Estimate benefits (optional/present in proposals/secure "go-ahead"). g. Develop customized on-site computer program. 5. STARTUP (HIGHFEED) a. Provide a rapid turnaround catalyst sample to assure timely conversion to maintenance feed upon reaching target passivator residual, (usually a 2:4 Ni/Sb ratio on the equilibrium catalyst). 6. FIRST PROGRAM OPTIMIZATION a. Stepwise alter chemical feed rate to seek true optimum passivator residual. b. Monitor passivator laydown efficiency to identify true optimum chemical feed vs, metals in fresh feed. c. Alter feed point to seek true optimum (optional. 4. Validate/refine constants and equations within on-site computer program, Page 11 (05/88) Copyright 1988 - Betz Process Chemicals, Inc. Chapter 3.8CONFIDENTIAL FOR INTERNAL USE ONLY BETZ PROCESS CHEMICALS, INC. 7. PROGRAM FINE TUNING/REPORTING a. Quarterly review computer program and further modify (if necessary) based on expanded data base. », Regular reports with each service call plus periodic full scale reviews, KEY CONCEPTS/DEFINITIONS A Yield Structure The yield structure is a weight % or liquid volume % breakdown of the distribution of cracked products obtained from an operating unit as illustrated below: VOL % Coke - a zi be, : o3 9.0 ca 17.0 C+ Gasoline 51.0 slurry & Cycle oils 30.0 Total 107.0 Conversion 70.0 Since most plants focus on liquid volume it is important to note that coke and light gas are not included in yield structure. Also note that due to molecular rearrangements, liquid yield exceeds 100% of fresh feed. ‘Yield Companents/Subgroups 1. CONVERSION - by definition is the % of feed converted to products with a boiling point less than 430°F (i.e, gasoline and lighter), This definition implies that it includes light gases but this is rarely true in practice. Many plants simply subtract liquid volume % cycle oils from 100% to calculate volume % conversion Check plant conventions. 2. COKE MAKE - is the weight % of high molecular weight, hydrogen deficient polymers and carbon formed in the reactor plus any unstripped oils on the catalyst entering the regenerator. 3. HYDROGEN MAKE - is the amount of hydrogen generated through cracking expressed as SCF/BBL or wt % of feed. 4. DRY GAS = Hy+CysCy Page 12 (05/88) Copyright 1988 - Betz Process Chemicals, Inc. Chapter 3.8CONFIDENTIAL, FOR INTERNAL USE ONLY BETZ PROCESS CHEMICALS, INC. WET GAS = Dry Gas + C3 + Cy ALKYLATION FEED = C3- Cy. These components ultimately can be converted to gasoline through alfylation. 5¢ GASOLINE = Cy through 430°F boiling compounds C3+ GASOLINE = Alkylation eed + C5+ Gasoline HYDROGEN METHANE RATIO - is a molar or volume % ratio of hydrogen (variable) to methane (roughly constant). CAUTION: “Hydrogen methane ratio" is another loosely defined component in practice. Depending on plant convention we have seent ay/CRy A/C y's H/C y's+C2's C. Terms and Data L 2 4 5. FRESH CATALYST - this is new, clean ( 100 ppm Metals) catalyst that is routinely added (make up) to the unit to replace lost or old (withdrawal) catalyst. REJECT CATALYST - this is used, contaminated (500-1000 ppm Metals) catalyst that has been re-conditioned to deactivate most of the metals. It's used as an inexpensive makeup catalyst, sometimes referred to as equilibrium catalyst. EQUILIBRIUM CATALYST - catalyst in circulation within the system. SPENT CATALYST - coke laden catalyst flowing from reactor to regenerator. REGENERATED CATALYST - de-coked catalyst flowing from regenerator to reactor. ZEOLITE SITE - an active acid site on catalyst bead where cracking is initiated. LAYDOWN EFFICIENCY (LE) - the percent of material introduced to the Reactor/Regenerator system that is absorbed onto and remains on the equilibrium catalyst. SELECTIVITY - the propensity of a catalyst to make a given product. High gasoline selectivity catalysts yield a higher % gasoline in yield structure than low gasoline selectivity catalysts, Page 13 (05/88) Copyright 1988 - Betz Process Chemicals, Inc. Chapter 3.810. ML 12. 13. 4 15, CONFIDENTIAL FOR INTERNAL USE ONLY BETZ PROCESS CHEMICALS, INC. INVENTORY - tons of catalyst in circulation. Often noted in upper left hand corner of catalyst analyses sheets supplied by Davison or Engelhard (catalyst suppliers), MICROACTIVITY, MAT YIELD, ACTIVITY - Davison or Engelhard Nomenclature for volume % conversion measured on an equilibrium catalyst sample under ASTM standardized test conditions. GAS PRODUCING FACTOR (GF, GPF) - appears only on Davison catalyst analyses. It's the volume ratio of hydrogen produced by an equilibrium catalyst sample compared to a fresh catalyst standard under standard test conditions. CARBON PRODUCING FACTOR (CF, CPF) - similar to gas factor except compares coke weight percents. GROSS METALS - reported on catalyst analyses sheets, This is a total weight % or ppm level of a metal appearing on a digested equilibrium catalyst sample, Does not discriminate between catalytically active and dead metals. CATALYST/OIL RATIO - the weight ratio of the catalyst circulation rate to the combined feedrate, HEAT BALANCE - The FCC Unit is "heat-balanced” in the sense that the heat for vaporizing and reacting feed is derived by combustion of the produced coke in the regenerator, and the released heat is transferred by the catalyst circulation to the reactor. An overall energy balance shows that the energy released by the combustion of coke becomes the sensible and latent heat of the reactor effluent and flue gas. Page 14 (05/88) Copyright 1988 - Betz Process Chemicals, Inc. 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