STATE-OF-THE-ART TECHNOLOGY

Axens offers state-of-the-art FCC technology for traditional gas oil cracking and residue cracking. The technology was developed originally by Total as a cost-effective, flexible and reliable means to profit from market opportunities. Through the efforts of a partnership between Axens (technology developer and licensor), IFP Energies nouvelles (R&D), Total (operations expertise) and Shaw Stone & Webster (engineering innovation), this advanced FCC technology is offered to the market place. Proven innovative technology features developed by Axens and others have combined to bring our customers the best available technology.

KEY TECHNOLOGY FEATURES

• Best available feed injection system with over four million BPD of installed capacity

• Mixed Temperature Control (MTC) recycle for optimized reactor riser performance

• High containment riser separation systems to achieve an extremely short residence time

• Efficient separation: no catalyst carry-over to the main fractionator, even during start-up.

• Unique post-separation quench technology • High efficiency stripper internals and patented

structured packing stripper designs • High reliability, all cold-wall construction • One and two-stage regenerator designs depending

on feedstock quality and processing requirements. • Proven catalyst cooler options when required,

over 50 MW (170 million Btu/hr) capability • Low maintenance air distributor designs • Exclusive licensor of Belco’s flue gas scrubbing

technology for new units. • High severity PetroRiserSM for maxi propylene • Dedicated R&D facilities for continual

advancement of the technology.

R2R Two-Stage Regeneration Resid FCC

SINGLE STAGE PROCESS DESCRIPTION

When processing traditional distillate feeds or blends with Conradson Carbon Residue (ConC) content less than about 2 to 3 weight per cent, a single stage regeneration system operating in complete or partial combustion mode is generally adequate. The reaction system is the heart of the process and is defined from the point of catalyst introduction into the riser to the catalyst discharge from the stripper. The entire system needs to be designed to work in concert to maximize performance for maximum distillate, gasoline or LPG production.

FCC/R2R™

VGO & RESID FLUID CATALYTIC CRACKING TECHNOLOGY

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Proprietary feed injection nozzles ensure instantaneous and intimate mixing of the feed, atomizing steam and hot regenerated catalyst which combine at the base of the reactor riser. The nozzles are specially designed and installed to ensure long, trouble-free operation while providing optimal performance with low coke and gas production. Above the main feed injection point, recycles can be used to fine-tune the reactor performance, promote better feed vaporization and control the catalyst-to-oil ratio (C/O). This recycle is MTC or Mix Temperature Control. The cracking reactions in the riser progress rapidly and must be stopped abruptly at the riser terminus to avoid over-cracking and product degradation. Removing the catalyst stops the catalyst reactions using a proven advanced riser separation device that separates the product vapor from the catalyst quickly and efficiently. The separated vapor may then be further stabilized by injecting a quench material to freeze thermal reactions. The vapor products are then sent to the main fractionator (M.F.) and gas plant for separation.

To Flue GasTreatment

Regenerator

AirMTC

Feed Injection

Reactor Riser

Stripping Steam

Stripper Internals

Riser SeparationSystem: RS2

Quench

To M.F. &Gas Plant

Single Stage Regenerator FCC

The separated catalyst flows into an intense steam stripping zone to recover value products entrained with the catalyst. Maximum stripping efficiency is attained with commercially proven, highly efficient structured packing. Packing provides better contacting to allow for higher throughput with lower steam use.

Stripper Structured Packing Element

On the regeneration side, a counter-current turbulent fluid bed provides intimate mixing of air and catalyst for controlled regeneration and low NOx production. High efficiency internal cyclones and downstream flue gas treatment facilities are provided to meet even the most stringent environmental regulations. For new units, Axens’ licenses include the market-leading Belco flue gas scrubbing technology. Other design features such as robust air and steam distributor devices and mechanical design know-how provide unit reliability with minimal down-time. All Axens designs utilize cold wall construction exclusively to minimize thermal stress, ensure safe operation, and provide maximum on-stream factor.

RESIDUE CRACKING: TWO-STAGE R2R

When processing residues containing high levels of metals (Ni, V and Na) and ConC values of 3-10 wt%, more sophisticated FCC designs are required. The Axens Reactor-2-Regenerator (R2R) design was developed to specifically meet the challenge of heavy resid processing. The R2R process scheme is shown hereafter with emphasis on the regeneration system as the reaction system is nearly identical to the single stage FCC design. The unique two-stage regeneration system permits safe regeneration of catalyst containing high levels of metals, principally vanadium that would otherwise rapidly deactivate the catalyst. The first regenerator burns 30-70% of the coke and essentially all of the hydrogen in the coke. Regeneration conditions are mild and vanadium on the catalyst cannot form V2O5 due to the incomplete combustion mode of regeneration. The catalyst is therefore protected from vanadic acid attack. The partial burn, first stage regenerator also provides significant heat rejection in the form of CO. In the second regenerator, the catalytic activity is restored by completely removing the remaining coke from the catalyst in a dry atmosphere (hydrogen

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To Flue GasTreatment

To M.F. &Gas Plant

2nd StageRegenerator

AirLift Air

MTC

Feed

Stripping Steam

Stripper Internals

Riser SeparationSystem: RS2

Quench

1st StageRegenerator

Air

removed in First Regenerator). As such, when V2O5 is formed at elevated temperature, there is little moisture available to form vanadic acid and hence the catalyst structure and activity are preserved. The two-stage regeneration system allows an Axens unit to operate at significantly higher metals levels on the catalyst, thereby reducing the catalyst make-up requirements and operating cost.

Additional reactor section enhancements include:

• MTC to enhance feed vaporization and control the riser temperature profile for operation in distillate mode

• Riser Mixor element to limit catalyst back-mixing and enhance yield selectivity.

HEAVY DUTY CAT COOLERS PROVEN FOR THE TOUGHEST FEEDS

When additional heat removal is required for either one- or two-stage regenerators, external catalyst coolers can be employed. Axens offers a proven dense-phase catalyst cooler design. Reliable performance with heat removal duties exceeding 50 MW (>170 million Btu/hr) has been

demonstrated. The robust designs feature the highest possible efficiency and flexibility with heat duty control from 0-100% by means of positive catalyst flow control.

PETROCHEMICALS FROM VGO & RESID

When the process objective is maximum propylene production, specific technology features must be added to the FCC/RFCC unit. The challenge is particularly great when the feedstock contains residue.

Axens’ strategy to maximize propylene production includes the following elements:

• Maximize the yield of light olefins and liquid using high severity with strategic hardware to promote low delta coke as discussed above

• Utilize ZSM-5 catalyst additive at optimum concentrations to convert the light olefin precursors in the cracked gasoline product

• Addition of a separate riser for light cut naphtha (LCN) recycle cracking at higher temperature than the main riser - PetroRiserSM – with effluent quench

R2R - Two stages of catalyst regeneration for feeds with high metals and high ConC

3

Sept

.10-

FCC

/R2R

Even under high severity conditions in the main riser, ZSM-5 additive is not effective to convert C5 and C6 olefins and iso paraffins which represent a large portion of the gasoline cut. In order to convert this material, it has been found that more severe conditions were required. As these operating parameters are too severe for the main stream, a dedicated reactor - the Petroriser - was added to the FCC/RFCC unit.

PetroRiserSM

LN Recycle

Main Riser

&Feed

PetroRiserSM

LN Recycle

Main Riser

&Feed

The high severity main reaction riser and higher severity LCN PetroRiser results in high C3 and C4 olefin production and highly aromatic naphtha which may be directed to aromatics recovery.

There is an additional benefit of the second high severity riser when processing resid. The added heat load in the PetroRiser acts as a “chemical” catalyst cooler. Due to the very low coke produced when cracking light cut naphtha, the added heat demand on the overall system provides a synergy for resid cracking.

COMMERCIAL EXPERIENCE

Over forty new FCC/R2R units have been licensed representing almost 2 Million BPD of capacity. Proprietary technology elements have been implemented in over 150 revamps, including units originally designed by all FCC licensors worldwide.

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