49 Cracking Paraffinic Naphtha PDF

Naphtha Catalytic Cracking
for Propylene Production by

FCCU
Christopher Dean -
HIGH Olefins Technology Services LLC
Coking and CatCracking Conference

New Delhi, India – October 2013
Purpose (Objective)
• To present and discuss producing propylene (C3=)
by catalytic cracking paraffinic naphtha utilizing Fluid
Catalytic Cracking processes
2
Contents- Covering 3 Points
• Why Propylene from FCCU’s ?
• Naphtha Feedstocks – Supply Balances
• Naphtha Catalytic Cracking Processes
• FCC Catalytic Processes
• Traditional Steam Cracking (Comparison)
3
TYPICAL FCC
Paraffinic Naphtha
4
Benefits
• MOTOR GASOLINE
• PETROCHEMICAL FEEDSTOCKS
• Propylene (C3=)
TODAY & FUTURE PLANNING

• Minimizing to no gasoline production from FCC
• Additional Focus
• Light Olefins (Ethylene & Butylenes)
• Aromatics
5
Why Propylene from FCCU’s ?
• Europe, North America (US) refineries are facing
profitability challenges
• Gasoline demand declining both areas
• Middle Distillates (Diesel) markets increasing both
areas
• European surplus gasoline export markets are declining
• US lighter shale crudes, “tight oil” use is increasing that
produce more naphtha and less diesel
• Asia market is for distillates and petrochemical
feedstocks
• Large Middle East, Asia, India and South America
are building large integrated Refinery/ Petrochemical
7
Complexes
Petrochemicals Opportunities
Produced by Steam Cracking
Main Building Blocks Ethane & Liquid Feeds
Naphtha Reformers
• Olefins - Two Main Blocks
• Ethylene
• Propylene Secondary Source Produced by FCC’s
• Aromatics
• Benzene
• Paraxylene (other xylenes too)
• High Olefins - FCC (HOFCC) produces C3= and

byproducts of other light olefins and aromatics
8
Why Propylene ??
• C3= is the second important raw material after ethylene
• C3= by-product from steam cracking for ethylene with
traditional FCC’s the other main source
• Ethylene demand is expanding proportionally faster than
Propylene demand (Propylene was exceeding ethylene
growth up thru 2007-2008 Recession)
• To meet C2= demand new steam crackers are using
Ethane as feedstock!
• With new SC, C3= shortages are expected; Existing
FCC’s can’t meet the demand
On Purpose Propylene Processes (OPP) will be

developed
9
10
Ethylene & Propylene Supply Sources
Ethylene Supply Sources Propylene Supply Sources

Ethane Naphtha& Gasoil On Purpose Steam Crackers
Propane & Butane Other Refineries
12% 2% 13%
34% 30%
52% 57%
127 Million Tons (US) 2011* 79 Million Tons (US) 2011*
Data Courtesy of IHS CMAI

Steam Cracking Yields
Propylene/Ethylene( P/E) Ratio indicates propylene
selectivity
Meet Future C3= Demand in Asia A P/E Ratio 0.85 is required
11
WHY NAPHTHA CATALYTIC
CRACKING ?
NAPHTHA SUPPLY
12
Naphtha Supply Balances
Supply is Increasing Globally

• Steam Cracking
• Shifting to Ethane & Lighter Fuels from Naphtha & Gasoil
• LNG/NGL
• Increased Byproduct Condensates from Gas Production
• Lighter Crude Slates for refiner feedstocks
• Produce more naphtha
• Increasing demand for diesel not gasoline
• In North America: Fracking for Natural Gas and Shale Oil
(Tight Oil)
• Aromatics supplies are being squeezed ???
“Somewhat decoupling” of naphtha pricing from crude”

13
Naphtha Cracking
Steam Cracking - Thermal

• Not Selective to Propylene makes Ethylene (P/E Ratio)
• P/E Ratio of 0.55-0.68 (Naphtha & Gasoil Cracking)
• Steam Cracker capacities are world class size > 1000 KTA
Naphtha Cracking - Catalytic

• Propylene Selective not Ethylene
• P/E Ratio of 1.0 to 2.4
• Naphtha FCC capacities 20 MBPD == 64 KTA of ethylene
SC 20 MBPD = 264 KTA
14
Naphtha Cracking Comparisons
Paraffinic Naphtha Feedstock Driven

Catalytic & Thermal Processes
• ACO (Advanced Catalytic Olefin)
• KBR License
• Riser Technology
• HS-FCC (High Severity FCC)

• Axens/S&W License
• Downer Reactor
• Steam Cracking
• Generic
15
Advanced Catalytic Olefins (ACO)Process
16
HS-FCC Key Components
Regenerator
Feed injection
Downflow
reactor Catalyst / product
separator
Stripper using
structured packing
Courtesy Axens/S&W
Courtesy Axens/TechnipS&W
17
Features & Advantages of HS-FCC
Features
• Downflow Reactor (Downer)
• High Reactor Temperature
• High Catalyst to Oil Ratio
• Short Contact Time
Advantages
• High Propylene Yield
• High Butylene, iso-butylene Yields
• High Gasoline Octane ( High Aromatics Content)
• Minimized Dry Gas
18
CATALYST FLOW HS-FCC
Reactor
FCC Feed Oil
Regen. Downer
Low Over
Conversion Cracking
Reactor Residence Time
Riser Back mixing
Feed Oil Regen.

FEED INJECTOR
Catalyst Feed
quick contact
of
feed & catalyst
Injector
Catalyst
US Patent 6186658
SEPARATOR
Product Gas + Cat
Product Gas
Guide Vane
US Patent
6146597
Quick separation
Catalyst & Gas
Separator Centrifugal
force
Catalyst
HS-FCC Naphtha Process
• Retrofit Type to
existing FCCU
• Standalone Unit
22
Full Range Naphtha Yields 25
Olefins wt%
Catalytic Cracking Steam Cracking

Downer Reactor Furnace Reactor
7.1% 7.4%
8.6% 28.1%
C2=
4.83% C2=
C3= C3=
15.46%
16.8% C4= C4=
C4== C4==
P/E of 2.4 P/E of 0.55

Naphtha Cracking Fluid Processes
ACO Commercial HS-FCC Semi-Commercial Unit
Demonstration Unit Mizushima, Japan
Ulsan, South Korea
26
Conclusions
Petrochemical Opportunities
• Naphtha Fluid Catalytic Cracking is a viable “On
Purpose Propylene Process”
• Naphtha Catalytic Cracking produces higher
propylene selectivity than Steam Cracking
• Naphtha Catalytic Cracking will help meet future
propylene demand
• Naphtha Catalytic Cracking byproducts of other light
olefins and aromatics for petrochemicals
• Paraffinic Naphtha Catalytic Cracking processes are
in the initial stages of commercialization
27
THANK YOU
The End
Questions ???
28

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Naphtha Catalytic Cracking

for Propylene Production by

Coking and CatCracking Conference

TODAY & FUTURE PLANNING

• High Olefins - FCC (HOFCC) produces C3= and

On Purpose Propylene Processes (OPP) will be

Ethylene Supply Sources Propylene Supply Sources

127 Million Tons (US) 2011* 79 Million Tons (US) 2011*

Data Courtesy of IHS CMAI

Meet Future C3= Demand in Asia A P/E Ratio 0.85 is required

Supply is Increasing Globally

“Somewhat decoupling” of naphtha pricing from crude”

Steam Cracking - Thermal

Naphtha Cracking - Catalytic

Paraffinic Naphtha Feedstock Driven

• HS-FCC (High Severity FCC)

Reactor Residence Time

Riser Back mixing

Feed Oil Regen.

Catalytic Cracking Steam Cracking

P/E of 2.4 P/E of 0.55

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