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1 © 2016 W. R. Grace & Co. | Confidential Driving FCC Units into Maximum Propylene | Nov, 2016
Driving FCC Units into Maximum Propylene to Increase Profitability
Maria Luisa Sargenti – Marketing Manager EMEA GPS | Lisbon | Nov 14-16, 2016
2 © 2016 W. R. Grace & Co. | Confidential Driving FCC Units into Maximum Propylene | Nov, 2016
How does Grace support refiners?
Planning Operation Blending/Pump
Profitability Reliability Right product mix
*2016: early switch from summer to winter „brew“
Extensive technology screening
tailored solution
Manufacturing and technology focus with strong technical sales and service component
Six Sigma, Laboratory support, optimum
product mix
C4=
(Alky, ETBE) Propylene
Gasoline/LCO Min. Bottoms
Octane*
3 © 2016 W. R. Grace & Co. | Confidential Driving FCC Units into Maximum Propylene | Nov, 2016
Gasoline/C4= Demand
The demand for gasoline continues to grow globally • 2016 growth is predicted to be 1.1% globally. • C4= as well as iC4 are valuable precursors to low sulfur high RON gasoline
blending components
Gasoline demand drives C4= demand
Downstream ProcessingFCC Cracking Overcracking
Feed
VGO/ResidCracking
Naphtha Olefins
Naphtha Paraffins
O
Gasoline
Pool
Blending
Hydrogen transfer
ETBE
Alkylate
4 © 2016 W. R. Grace & Co. | Confidential Driving FCC Units into Maximum Propylene | Nov, 2016
The Catalyst Approach
For refiners targeting more C4= and Octane, • Conventional ZSM-5 additive is designed to crack gasoline olefins down to C5= to
maximize C3= • ACHIEVE® 400 and GBA™ deliver superior selectivity of C4= / C3= by preferentially
cracking gasoline olefins at C7 and above and promoting reactions that favor C4= production
Grace offers both catalyst and additive solutions: ACHIEVE® 400 and GBA™
C6=
C7=
C8= 2 C4= 44% C3= + C5= 56%
C3= + C4= 95% C2= + C5= 2%
2 C3= 83% C2= + C4= 16%
Selectivity C3=/C4=
0.64
1.0
11
Reactant
ACHI
EVE®
400
G
BA™
Relative Reactivity
100
12
1.5 Con
vent
iona
l ZSM
-5 A
dditi
ve
Buchanan et al., J. Catal., 158, 279 (1996)
5 © 2016 W. R. Grace & Co. | Confidential Driving FCC Units into Maximum Propylene | Nov, 2016
Higher Diffusivity Matrices
Flexible Hydrogen Transfer
Higher Activity
Advanced Metals
Tolerance
Dual Zeolite Technology
Boosting Octane with ACHIEVE® 400
ACHIEVE® 400 increased C3= and C4= Selectivity favoring C4= Objective: • Increase LPG olefinicity • Preferentially C4= for alkylation
unit Unit Information: • UOP Side-By-Side design • 100 kbd • VGO and ATB blend Operating Constraint: • Maintain total LPG make
provided an estimated $12MM/yr benefit or $0.43/BBL net of OPEX
Feedstock properties: 24.0 - 24.5 API - 0.25 – 0.5 wt% S - 1.35 – 1.6 wt% MCR, Economics are calculated as incremental yields at constant crude prices.
ACHIEVE® 400
Base
ACHIEVE® 400
ACHIEVE® 400 ACHIEVE® 400
Base
Base Base
Catalagram, No. 117 | Fall 2015
6 © 2016 W. R. Grace & Co. | Confidential Driving FCC Units into Maximum Propylene | Nov, 2016
GBA ™ Technology
GBA™ is Grace’s newest additive designed to crack gasoline olefins more selectively to C4= and boost octane via isomerization activity
• GBA™ provides a flexible additive approach to boost C4= even further while maintaining superior C4=/C3= selectivity
0.5
1.0
1.5
2.0
2.5
3.0
3.5
4.0
1 2 3 4 5 6 76.0
6.5
7.0
7.5
8.0
8.5
9.0
4.5 5.0 5.5 6.0 6.5 7.0 7.5 8.0
C3=, wt%FF
C4=
, wt%
FF
OlefinsUltra® HZ GBA™
ΔLPG, wt%FF
ΔRON
OlefinsUltra® HZ GBA™
7 © 2016 W. R. Grace & Co. | Confidential Driving FCC Units into Maximum Propylene | Nov, 2016
Higher Profitability with GBA™
For a 50 kBD FCCU,
GBA™ may provide $2–5MM/yr additional uplift over conventional LO additives
$5M $3M
$2M
Conventional ZSM-5
Higher C4= Selectivity Higher Octane Total Value
Estim
ated
FC
C p
rofit
abili
ty, $
M
8 © 2016 W. R. Grace & Co. | Confidential Driving FCC Units into Maximum Propylene | Nov, 2016
Light Olefins Additives Portfolio
OlefinsUltra® for applications where moderate-to-high propylene production is required
OlefinsUltra® HZ for propylene focused operations
OlefinsUltra® MZ is Grace’s newest additive
designed specifically for very high propylene applications
GBA™ is Grace’s newest additive designed to crack gasoline olefins more selectively to C4= and boost octane via isomerization activity
Performance
Light Olefins
OlefinsUltra®
OlefinsUltra® HZ
OlefinsUltra® MZ
GBA ™
9 © 2016 W. R. Grace & Co. | Confidential Driving FCC Units into Maximum Propylene | Nov, 2016
Global Propylene Market Supply - 2030
• Most propylene is produced by steam crackers as a by-product of ethylene.
• It is foreseen that other on-purpose propylene supplies will contribute 27% of global propylene supplies in the form of propane dehydrogenation (PDH), methanol-to-olefins (MTO), and metathesis.
• Refinery FCC units also contribute (will continue) to a significant portion of global propylene supplies
Steam Cracker
48%
Refinery
25%
Other "On Purpose"
27%
Source: WoodMackenzie
10 © 2016 W. R. Grace & Co. | Confidential Driving FCC Units into Maximum Propylene | Nov, 2016
FCC Operating Conditions and Propylene Yield
FCC units • Have been historically geared for maximising gasoline yield
• Low yields of propylene are typically obtained in such max gasoline modes
• However propylene yields can be increased by adjusting the following operating conditions:
• high riser outlet temperature
• high catalyst-to-oil ratio
• high e-cat activity
• low reactor pressure
11 © 2016 W. R. Grace & Co. | Confidential Driving FCC Units into Maximum Propylene | Nov, 2016
Global FCC Propylene Yields Based on ECat Pilot Plant Testing
Highest FCCU propylene producers are in Asia Pacific and EMEA
Average = 5.3 wt.% Max = 8.0 wt.%
Average = 5.8 wt.% Max = 11.9 wt.%
Average = 4.9 wt.% Max = 7.1 wt.%
12 © 2016 W. R. Grace & Co. | Confidential Driving FCC Units into Maximum Propylene | Nov, 2016
Heavy feeds processing
Grace catalysts are the top class for nickel tolerance (EMEA ecat benchmarking)
Grace supplies 63% of the resid segment with NEKTOR technology
1000080006000400020000
0.6
0.5
0.4
0.3
0.2
0.1
0.0
Ni Equivalents (Ni+V/4+0.4/0.33*Sb) [mg/kg]
Ecat
ACE
Hyd
roge
n Yi
eld
[wt .%
F F]
AB
NEKTOROther Grace
Catalyst family
Average Ecat Data per Customer EMEA - Q1 2016
N = 74
0
20
40
60
Past 2003 2007 2015
Nr.o
f Uni
ts
FCCU Feed Trends(Europe / Middle east / Africa)
HT VGO SR VGO RESID
SR VGO processing is declining, in contrast, Resid processing is increasing.
HT/VGO27%
Grace63%
Competitors37%
RESID73%
EMEA Market Segmentation 2016
13 © 2016 W. R. Grace & Co. | Confidential Driving FCC Units into Maximum Propylene | Nov, 2016
Optimising catalyst for resid to propylene
• High zeolite stability and metals tolerance to meet resid feedstock requirements.
• State of the art Vanadium trapping functionality
• Balanced mesoporosity to achieve the optimum level of coke-selective bottoms cracking
• Appropriate level of H-transfer activity to increase LPG olefins.
• Additional use of the OlefinsUltra® family additive
• Industry leading attrition resistance for minimum losses.
Metals tolerance Coke Selectivity
Bottoms cracking activity
Propylene selectivity
Physical properties
FCC Catalyst key features
14 © 2016 W. R. Grace & Co. | Confidential Driving FCC Units into Maximum Propylene | Nov, 2016
Catalyst System for Maximum Propylene
ProtAgon™ 4G • is the latest generation of Grace’s
propylene maximization technology. Yields of over 12wt% have been achieved with this catalyst technology.
• is manufactured using the Grace EnhanceR™ Technology Platform, and is an extension of the ProtAgon catalyst family, which is the market leader in the EMEA region
Refineries in EMEA are utilising the ProtAgon™ 4G catalyst to achieve excellent propylene yields
15 © 2016 W. R. Grace & Co. | Confidential Driving FCC Units into Maximum Propylene | Nov, 2016
Case Study | Best in class C3=
OMV Schwechat | FCC Unit data
• OMV Schwechat refinery is one of the largest and most technologically
advanced inland refineries in Europe. • The refinery operates integrated petrochemical production facilities, and
supplies plastics manufacturer Borealis with petrochemical precursor products, making propylene a key product for the Schwechat refinery.
Timeline of propylene maximisation and catalyst optimisation in OMV Schwechat FCC unit
16 © 2016 W. R. Grace & Co. | Confidential Driving FCC Units into Maximum Propylene | Nov, 2016
V Case Study | Best in class C3=
DCR Pilot Plant testing* Testing: • Ecat samples from both trial periods • Actual feed samples from OMV • Same riser outlet temperature (ROT)
as the Schwechat FCC unit • Grace catalyst system exhibited
significantly higher propylene selectivity at constant conversion, as well as higher propylene yield at constant coke
*DCR testing is widely accepted as the most accurate methodology for replicating real-life FCC unit conditions
17 © 2016 W. R. Grace & Co. | Confidential Driving FCC Units into Maximum Propylene | Nov, 2016
Case Study | Best in class C3=
The unit objectives • are closely linked to market
demand for refined petroleum products.
• maximum propylene and minimum slurry being the primary targets
• C2= and iC4= are highly desired for petrochemical use and a ETBE etherification unit.
• C2= produced by the FCC unit supplements ethylene generated by the steam cracker and is beneficial to OMV.
18 © 2016 W. R. Grace & Co. | Confidential Driving FCC Units into Maximum Propylene | Nov, 2016
Case Study | Best in class C3=
FCC Unit data / simulation model The FCC unit’s profitability has been
improved due to: • Higher propylene and isobutylene
selectivity • Improved dry gas selectivity at higher C2=
selectivity • Improved bottoms upgrading • Excellent attrition resistance • Lower catalyst usage. • Improved FCC operational flexibility
Profitability increase of ca $3/MT FF from catalyst (based on propylene increase only)
PTQ, 2Q 2016 : “Maximizing Propylene Yields in FCC Units - A Case Study at OMV Schwechat Refinery”; Ignacio Beltran , OMV ; Matthias Scherer, GRACE RT ; et al .
19 © 2016 W. R. Grace & Co. | Confidential Driving FCC Units into Maximum Propylene | Nov, 2016
Maximise profitability from resid to C3=
GRACE customised catalyst technology with controlled zeolite acidity at highest intrinsic activity & combined with state-of-
the art alumina sol matrix plus tuned ZSM-5 activity.
Grace’s catalyst delivered improved profitability for CEPSA’s FCC unit
Performance Base catalyst ProgREss-26 Conversion, wt% Base +1.0
C3=, wt% Base +0.6
C4=, wt% Base +0.9
LPG, wt% Base +2.1
LPG olefins, vol% Base +2.2
Total Naphtha, wt% Base -0.46
LCO, wt% Base +0.44
Slurry, wt% Base -1.55
Coke, wt% Base -0.10
Unit profitability, M€/yr Base + 4.0
Cepsa’s Gibraltar - San Roque Refinery: A Case Study for Boosting Unit Profitability through FCC Catalyst Selection for Propylene Maximisation
PTQ Q4/2016
20 © 2016 W. R. Grace & Co. | Confidential Driving FCC Units into Maximum Propylene | Nov, 2016
Pool Question
What are key FCC Catalyst features for resid to propylene? a. Propylene selectivity, physical properties, low price b. Metals tolerance, bottoms upgrading, propylene selectivity, physical
properties, maximise FCC profitability c. High e-cat activity, high riser outlet temperature, high catalyst-to-oil
ratio, low reactor pressure d. All of them
21 © 2016 W. R. Grace & Co. | Confidential Driving FCC Units into Maximum Propylene | Nov, 2016
Final remarks
GRACE best available technologies to provide industry standard: Residue
• GRACE will further strengthen its position in the important residue upgrading segment by the newly launched EnhanceR™ and MIDAS® platform based technologies.
• In order to max. profitability both platforms can be ideally tailored and combined.
LPG Olefins • GRACE‘s light olefins Additives portfolio
provide a cost/performance optimised, widely field proven technology for the market.
• Newly launched OlefinsUltra® MZ additive holding highest intrinsic activity for LPG olefins in the market.
C4=/C3= ratio, Octanes • The newly launched ACHIEVE®-400
(Dual zeolite technology) and/or GBA™ additive solution close the technology gap for the objective to maximise C4=/C3= ratio plus Octane.
EMEA Growth Perspective • Market trends seems to show further growth
for gasoline demand. In parallel high demand specifically for C4= and Octane.
• C3= demand expected to remain high in the future.
• Residue processing FCC units will continue to process lower quality feedstocks.
• GRACE continues to develop catalyst technologies to meet new challenges.
22 © 2016 W. R. Grace & Co. | Confidential Driving FCC Units into Maximum Propylene | Nov, 2016
Maria Luisa Sargenti| Marketing Manager EMEA Grace Catalysts Technologies [email protected] www.grace.com