Fluid Catalytic Cracking. World class FCC experience and capability

Transcription

1 Flid Catalytic Cracking World class FCC experience and capability

2 50 YEAR FCC track record ENGINEER Largest Regen in the world - Soth Korea 33 contries arond the world >250 RCC/FCC reside catalytic cracking/flid catalytic cracking projects in the last 50 years 159 FCC Projects since 1990 >40 New Units at 14 grassroots refineries UK 22 x EPC Projects 37 x EPCm Projects >30 FCC Projects in the last 10 years

3 Or HSSE commitment Ptting safety first - Doing the right thing Amec Foster Wheeler has an extremely positive and proactive HSSE cltre and a prod safety record. To strengthen its cltre and reinforce the commitment to HSSE performance at all levels of the organisation, Amec Foster Wheeler developed and maintains its Beyond Zero program. Beyond Zero provides the mechanism to achieve the vision of sstainable, worldclass HSSE performance across Amec Foster Wheeler s global operations. For many years the company has had a goal of zero harm to people and the environment and wants to be recognised as a tre world leader in HSSE. To do this it mst have sstainable performance improvement - not only reaching target zero this year, bt going beyond this to achieve it next year and the year after that. By leading by example, Amec Foster Wheeler not only sets new standards for the health and safety behavior for its workers bt will also take its positive inflence ot into the environment in which we live and work. Amec Foster Wheeler s HSSE management system is certified to AS/NZS 4801, OHSAS 18001:2007 and ISO 14001:2004 (Environmental). 3 Photo cortesy of Woodside Energy Ltd. Why Amec Foster Wheeler? From concept to commissioning and beyond Amec Foster Wheeler is one of the few companies that provide spport throghot the complete life cycle of a project. Or regional operations are spported by teams of experts in or global network of oices. Or world class safety record, systems, people and technical knowledge means that regardless of size, complexity or location, we have the skills, experience and creativity to add vale throghot the entire asset lifecycle. We are independant with no ties to any licensor or manfactrer. Or experience with all licensors and a large spectrm of operating nits provides a niqe abilily to help all clients. Technical consltancy Stdies Front-end design Project management Detailed engineering Procrement Spply chain management Constrction Commissioning Training & development Asset spport Operations & maintenance Environment & sstainability Decommissioning

4 Flid Catalytic Cracking We are one of the world s most experienced contractors in the engineering and constrction of reside catalytic cracking/flid catalytic cracking (RCC/FCC) nits, with a track record stretching back more than 50 years. In the last 50 years we have ndertaken well over 250 RCC/FCC projects: design and constrction of over 40 new nits, and more than 200 revamps, expansions, pgrades and trnaronds for over 50 refineries in 33 nations. We have completed projects with all major RCC/ FCC technology process providers. This contining involvement with diverse process technologies has placed s in a niqely athoritative position in engineering, constrction, commissioning, start-p and operation of new and revamped catalytic cracking nits. We have developed a very detailed knowledge of the complex range of mechanical isses associated with these technologies. We have a core team of specialists with a wealth of RCC/ FCC experience, ensring that we can anticipate and overcome the challenges presented by even the most complex revamps or new eqipment installations. With or vale engineering skills and constrctability expertise, we deliver practical innovative soltions to meet or clients objectives shorter trnaronds, lower cost, lower risk, qality with operational reliability, pls world-class safety and start-p performance. The key to sccess is planning... and planning early. A complete range of services: Consltancy services whenever yo need them Detailed knowledge and close relationships with all RCC/FCC licensors Detailed Design with in-hose analysis and FEA (Finite Element Analysis) capability Capability to manage and close relationships with proprietary designed key manfactrers of complex eqipment and materials (e.g. cyclones, refractory, special valves, expansion joints) Integration stdies for a new nit within an existing refinery Heavy lift and transport stdies Constrctability stdies Trnarond stdies and detailed planning Fll EPC (engineer, procre, constrct) and project management Detailed Engineering method statements Management of field fabrication of very large eqipment at site, refractory lined, exotic material. With increasing interest in the refinery/petrochemical interface, emphasis has been placed in recent years on maximising prodction of propylene from catalytic cracking nits. Or considerable experience in this area incldes propylene prification nits, enabling prodct sitability for se as either a chemical or polymer grade.

5 All components within FCC have a design life bt the operational life achieved depends on how the nit is operated and the qality of installation. The aggressive environments encontered within the main vessel s reactor and regenerator are cased by high temperatres and erosion de to the circlation of hndreds of tonnes of abrasive catalyst. Contined operation beyond the anticipated design life can compromise ftre operational reliability. The eects of increased rn times between trnaronds All operators seek longer rn times between FCC trnaronds. The norm was historically three years, bt now five or six years are being sccessflly achieved. Assring operational reliability over this increased timeframe takes more thoght, planning and accrate prediction of component replacement reqirements. With a three-year rn, it was always possible to make patch repairs for reliable operation ntil the next planned trnarond; by stretching to a five-year rn, this stop-gap approach greatly increases the risk of failre. 5 With increased periods of time between trnaronds, it is good practice to start planning for the next, and the one after that, even before the crrent trnarond is completed. For a three-year campaign, this wold mean predicting component life for the next six years. By increasing operating cycles to five or six years, this pshes the prediction horizon to 10 or 12 years.

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7 An early start As soon as possible after a trnarond, and at least three years before the next, a stdy shold be carried ot to determine the optimm soltion for the next shtdown. This allows sicient time for the stdy/licensor selection, the licensor package development/engineering and eqipment procrement/manfactre. Key steps in the stdy phase Client needs Process/ technology improvements Typically a stdy generates a large range of options for reqired component changes. These can inclde new heads complete with cyclones, entire sections of regenerator shell, or new reactors. Cost-wise, there may be minimal capital cost dierence between the options, as costs are balanced between trnarond labor for repair against those of the new component with osite fabrication and installation. When the advantages of redced trnarond time, redced risk to the trnarond, improved reliability and the opportnities for process improvements are taken into accont, then the option for larger component changes often becomes more attractive. Maintenance reqirement A stdy carried ot as part of trnarond planning can reslt in redced risk, lower costs, increased rn time and improved process performance. 7 Licensor selection Cost estimate Feasible options Engineering & constrction Planning trnarond dration Conclsion and exection strategy Key considerations inclde: Client needs - desired trnarond, bsiness or market drivers Process/technology improvements - increase operational profit, reliability, and meet ftre environmental reqirements Maintenance reqirement - predicted component replacement and refractory repairs Licensor selection - an opportnity with associated yield advantages; pls any debottlenecking reqirements Cost estimate - in the order of +/-30% for the overall trnarond project Engineering, procrement & constrction strategy - method of delivery, crane reqirements, logistics, otline of the basic method of site assembly and shtdown exection Planning & trnarond dration - detailed schedles demonstrating plant downtime Risk/ what if analysis Risk/ What if analysis Critical sccess factors Key factors to be considered in planning all FCC trnaronds inclde: Working safely Assring ftre operational reliability Minimising downtime throgh meticlos planning Managing the risk of nknowns sch as emergent work or components not fitting Delivering the lowest overall cost Capitalising on opportnities for process improvements There are some key grond rles that shold be applied: Maximise pre- and post-trnarond activities Maximise work that can be done osite Adopt a fit-first-time approach Take advantage of the latest proven technology; this applies not only to the process improvements bt also to mechanical design and refractory installation With an early start, it s possible to trn a trnarond into an opportnity.

8 Process improvements Process technology improvements are driven by external factors, sch as market prices for feedstock and prodcts, and legislatory reqirements for environmental emissions or prodct specifications. Each trnarond is an opportnity for the refiner to exploit the price dierential between the FCC feedstock (generally atmospheric reside or vacm gas oil and reside) and prodcts. There are also wider considerations which relate to the nits connected to the FCC. Following a change to process configrations the FCC mst still work eectively. To ensre the nit is still in heat balance, a check is reqired on the coke yield. An increase liberates more combstion heat. A simple side-by-side FCC may reqire modifications to brn more coke, generating more heat. As the coke yield increases this may inclde pshing the regenerator to its design temperatre limit, changing the operation to rn in partial brn with external CO firing or by adding catalyst coolers. The excess heat liberated can be sed to raise steam to rn the main blower drive and the wet gas compressor. Upstream and downstream nit considerations Process nit Vacm gas oil hydrotreater Consideration for Revamp Extent of deslphrisation, metal removal and density redction Solvent deasphalter Amont of extraction from cracker feed Vacm distillation nit C3 splitter Naphtha splitter Osite and tility systems Ct point for vacm gas oil and reside Reqirement for chemical/polymer grade propylene Extent of mercaptan treating or hydrotreating for LPG, naphtha/light cycle oil Fel gas, steam condensate balances, amine, sor water and slphr systems Conversely, if the nit rns on a clean hydrotreated feed with low conversion, the nit may be in heat deficit and reqire additional heat inpt by brning more fel in the regenerator. This might occr when maximising clean distillate prodction which, for transport fels, normally reqires post-processing to remove slphr, adjst density and boost cetane. Changes to nit feed and prodct configrations may reqire modifications to any polltion abatement eqipment. Modifications may be reqired becase of changes to environmental legislation. Key FCC atmospheric polltants that shold always be considered inclde NOx, SOx and particlates. Controlling atmospheric polltants NOx is created in the regenerator from the oxidation of feed nitrogen captred on the coke and reaction with atmospheric nitrogen. The level of NOx generation can be modified by carefl control of the oxidation conditions in the regenerator and can sometimes be improved by changing the regenerator arrangement. Catalyst additives, sch as combstion promoter, also aect the levels of NOx generated. Use of other technology, sch as selective catalytic redction, might also be reqired. This end-ofpipe soltion is well-proven, reacting ammonia over a catalyst with the fle gas NOx to form diatomic nitrogen and water. Regenerator SOx emissions can be controlled sing additives in the catalyst. These promote the formation of hydrogen slphide in the reactor which redces the qantity of slphr entering the regenerator. Any slphr entering the regenerator is oxidised to slphr dioxide or slphr trioxide. Alternatively, and often complementing additives, the whole fle gas can be scrbbed with an aqeos soltion. This has the added benefit of removing particlates. Lastly, catalyst particlates can be seen as visible emissions from a FCC fle gas stack. There is a range of options that can achieve dierent fle gas particlate emission levels. Close copled primary/secondary cyclones can achieve 210 mg/nm³. Add-on abatement technologies can achieve lower emissions that are typically demanded by permitting athorities (see table, above right).

9 Choosing the best technology If changes are needed to the reactor or regenerator, a licensor will be an integral part of the pre-trnarond stdy. Most licensors will sell their technology into a competitordesigned nit. This enables refiners to choose the best technology soltions to meet their crrent challenges and ftre bsiness plans. The best response is received when a professionally written specification is issed for competitive tender and evalation, considering the technical advantages, reliability, proven track record and, most importantly, the commercial viability. Fle gas particle emission abatement technologies Abatement technology Particle emission level mg/nm³ Rogh ct tertiary 150 Fine tertiary with forth stage filter 70 Whole gas filtration 10 Electrostatic precipitator 30 Wet gas scrbber 20 Trning a trnarond into an opportnity Wear and tear means that maintenance-driven shtdowns on FCCs are inevitable. Therefore, the opportnity for process technology improvements arises at each shtdown. The challenge is for the refiner to maximise the benefits of the maintenance trnaronds by looking for new bsiness opportnities or margin enhancement opportnities. In execting the project, it is important to apply rigoros project management best practice to the scope definition and development to ensre the right technology and technical soltion can be delivered safely, at the right cost and in the right time-frame to deliver the expected retrn. Operators shold consider establishing maintenance reqirements early and look to combine this scope with other improvement opportnities. Rather than separate bdgets for process improvement and for maintenance work, a more holistic view is more likely to deliver the optimm soltion. 9

10 Life of asset services Amec Foster Wheeler We deliver projects, from concept to commissioning and beyond. For any development, we start adding vale from day one, helping or cstomers to evalate the opportnity, screen options, select the right option, and then realise the revene as qickly as possible. We deliver vale at the front end, then can bring or global EPC skills and experience to bear, developing the right exection strategy, and then delivering on time, safely, cost eectively, and right first time. Right throgh the life of yor asset we can provide the right spport, from trnaronds and brownfield projects throgh to long term asset spport, performance improvements, throgh to throgh to asset conversion, closre and remediation. Consltancy services Project delivery Consltancy services Project delivery Environmental Marine and coastal Geotechnical Permitting and reglatory Commnity and social aairs Water and wastewater Transportation Feasibility stdies, concept and pre-feed Cost and schedle planning and control Technology integration FEED design Engineering and procrement Fabrication and constrction Project management Start-p and commissioning

11 11 Asset management Amec Foster Wheeler has an otstanding track record in execting refinery projects, from world-scale grassroots refinery complexes, to major expansions and revamps, complex trnaronds, refinery/petrochemicals integration, clean fels projects to meet new legislation, reside pgrading to prodce higher-vale prodcts, right throgh to smaller maintenance-type projects and ongoing asset spport. We also have over a centry s worth of fired heater experience. Asset management De diligence and site assessments Asset integrity and optimisation Operational readiness and implementation planning (OIP) Operator training, systems and management Operations & Maintenance term services Brownfield pgrades and expansions Sht-downs/trnaronds Dtyholding Late life management Mothballing and decommissioning

12 Indstry experience Amec Foster Wheeler has experience in the exection of FCC nit realisation and revamping. Star Petrolem Refinery Company (SPRC) refinery Scope of work Client reqired improvement in gasoline and propylene yields and improvement in ongoing reliability Pre-FEED, FEED for SPRC refinery at Map Ta Pht, Rayong, Thailand Detailed engineering, procrement and constrction management Project exection Reactor technology was pgraded throgh total replacement of all internals and riser system Exection was completed piece-large Bespoke spport systems were developed to sit the configration dring the replacement of the stripper section All first-stage regenerator primary and secondary cyclones and other internal components were replaced in parallel, piece-small throgh a large shell window Second-stage regenerator secondary cyclones were replaced piece-large in-sit (external cyclones) Precision srvey tilised throgh eqipment fabrication and trnarond exection with sccessfl fit-first-time of installed eqipment Highlights Simltaneos revamp of RFCCU Reactor and Regenerator Total Rainaderij Antwerpen refinery Scope of work Existing refinery revamp - FCCU 2 nit regenerator cyclones replacement as part of the 2018 trnarond at the refinery in Antwerp, Belgim Project exection Replacement regenerator cyclones along with head, overhead line, air distribtor, spent catalysts standpipe and distribtor Highlights No plot space for a major crane Crane limited to lifting head only Cyclones and large air distribtor removed installed whilst head removed. Frame designed on air distribtor to spport cyclones Giant trial assembly of head cyclones and air distribtor in vendors works to confirm all fit Pertamina Balongan refinery Scope of work Detailed Engineering Stdy and FEED for revamp of refinery in Indonesia Inspection Heavy lift consltancy Constrction management Commissioning Project exection Regenerator cyclone Replacement old head resed. Head 16.4 metres diameter. Lift weight approaching 700 tonnes. Replacement riser and stack Highlights De to transport restraints and costs, existing head will be resed Novel methods developed to minimise trnarond dration. New cyclones and Plenm assembled pre-trnarond in head frame Head deflection analysis to avoid damage of refractory dring lifting

13 Milazzo Refinery Scope of work Upgrading of reactor design, new reactor top head new cyclones system and internals New riser and spent catalyst standpipe New additional tertiary and forth stage separators New trbo-expander New regenerator spent catalyst distribtor and air rings New fle gas lines complete of special valves, expansion joints and spporting system Project exection Modlar design to minimise pre T/A works dring the plant operation Laser scanning Pre T/A works from March 2014 p to end of April All works completed within the project schedle T/A May 2015, mechanical works 51 days New trbo-expander installed within 12 months from the delivery at site Highlights Pnematic test of existing/new pressre parts Mechanical/refractory lining works planning Ploiesti Refinery Scope of work New reactor top head, new plenm chamber e cyclones system + new 13 nozzles welded to the existing reactor shell Reinforcement of the existing reactor spporting strctre/fondations and pipe racks New stripper and debtaniser towers Project exection Pre T/A March-May, T/A= 27 days mechanical works Shop trial fit of cyclones system Reactor head/plenm/cyclones system preassembling on temporary strctres Fondation reinforcement sing chemical bolts and carbon fiber plates Eqipment templates to anticipate piping erection Pre-assembled anchor bolts for new towers Highlights Dimensional checks of new components verss existing ones Extensive exection of shop fnctional test (e.g. flapper valve with new cyclone flly assembled) Refractory lining installation/cring/dry-ot 13 Stanlow Refinery Scope of work Design, engineering, procrement and constrction management services Concept development, design and overseeing the manfactre and delivery of the new regenerator head and cyclones. Spported Essar with transportation and lifting Project exection Revamp to replace regenerator cyclones Planning for the trnarond started in 2009, with the new regenerator head and cyclone assembly being delivered to site as planned on 24 March 2013 Hge crane being delivered to site in over 120 containers The trnarond began in early October 2013 Highlights 450-tonne nit, the world s largest transported regenerator head and cyclone assembly The new head and cyclone assembly was lifted to 70 metres above the grond and into its final position in jst over three hors The two new regenerator overhead line sections, weighing 54 tonnes and 69 tonnes, were then sccessflly installed, all ahead of schedle The seeds of sccess of this project were sown with its early start, developing the concept in pre-feed, with or strong and experienced team then seeing the work throgh to site Meticlos planning, attention to detail and trnarond best practice optimising osite and pre-trnarond work and minimising work dring the trnarond - delivered a safe and sccessfl otcome

14 Trecate Refinery Aspropyrgos Refinery Scope of work New reactor top head, new riser and cyclone system New regenerator top head and cyclone system. New s&t and a/c heat exchangers Debtaniser reboiler and cat. Naphta stripper overhead condenser modification Pmps impeller and electric motors replacement Project exection Pre T/A 6 months, T/A=26 days mechanical works Temporary strctres for regenerator/reactors top heads and relevant cyclone systems pre-assembling Highlights Mechanical/refractory works careflly planned to match very tight project schedle Constrction/maintenance teams coordination Scope of work Dring the years 3 major T/A have been carried ot on the existing FCC nits: New reactor top head, new riser and cyclone system New regenerator top head and cyclone system and fle gas line main valves and expansion joints New feed injection section New wet gas compressor New S&T and A/C heat exchangers Replacement of C3/C4 splitter colmn Pmps modification/replacement Project exection f f T/A= 31 days mechanical works Shop trial fit of cyclones systems Reactor head/plenm/cyclones system preassembling on temporary strctres Waterjet ctting of existing reactor head Detailed planning of T/A seqence Highlights Refractory works for maintenance reasons Removal of coke in reaction circit Coordination of constrction and maintenance teams

15 Other projects Client and location Unit capacity (BPSD) Description of project Scope of work* Licensor Year of completion ESTL Replacement of both Reactor and Regenerator Heads and cyclones E+ assistance to ISAB Exxon Ongoing ISAB Priolo, Italy 37,700 Replacement of both Reactor and Regenerator Heads and cyclones New internals for the Orifice chamber E+ assistance to ISAB UOP Stone & Webster also involved in some specific portions Ongoing 15 Pertamina Balongan, Indonesia 125,000 RFCC major revamp Regen replacement Cyclones and other Works EPaCa Ongoing S-Oil Soth Korea 669,000 New HS-FCC New technology largest regen in the world Detailed FEED then PMT Ongoing Total Antwerp Belgim 104,000 FCC2 regen head Cyclone O/H Line and bellows replacement EPc Ongoing Essar Stanlow, UK 270,000 FCC revamp Redesign of external riser & regen air distribtors FEED, EPCa Ongoing SARLUX Sarroch, Italy BSR Dng Qat Vietnam OMV-PETROM Petrobrazi Refinery, Romania 94,000 Revamp of FCC Regenerator revamp Air blower replacement Wet gas compressor replacement Expander replacement CO boiler modification 130,000 RFCC Revamp Pre- FEED FEED Replacement Cyclones in both Regen and Reactor 35,000 Revamp RX/regenerator Main fractionator GasCon nit LPG fractionator FEED + EPC UOP Ongoing Es/FEED 2016 FEED + EPC UOP Jne 2015 Hellenic Petrolem Refinery Aspropyrgos, Greece 50,000 (Reactor/ Regenerator) Revamp of the reactor head and cyclones replacement of the existing FCC nit EP ExxonMobil STC-II 2015 Milazzo Refinery Milazzo, Italy 52,000 Revamp Reactor/regenerator Expander (new)/ fractionator + GasCon FEED + EPCm UOP (expander) KBR (reactor/ regenerator) Amec Foster Wheeler Fract + GasCon 2015

16 Client and location Unit capacity (BPSD) Description of project Scope of work* Licensor Year of completion ESSO Port Jerome, France 260,000 FCC revamp FEED, EP SARLUX Sarroch, Italy 320 t/h fle Gas Revamp of the fle gas line to trboexpander Revamp of CO boiler Replacement of air blower EPCM UOP 2012 Samref 2013 Sadi Arabia FCc revamp replacement reactor cyclones with new top head and replacement mid section of regen E, BDP, Cs Hellenic Petrolem Refinery Aspropyrgos, Greece 50,000 (Reactor/ Regenerator) Wet gas compressor section circit replacement E (Ca) ExxonMobil 2011 Essar Stanlow, UK 270,000 FCC regenerator cyclone replacement with new head 14m dia 450 tonne lift (Shell) E, BDP, P SARAS Sarroch, Italy 445 t/h Fle Gas from FCC Catalyst Regenerator Revamp of existing CO boiler EP Mažeikių Nafta Refinery Mažeikiai, Lithania 60,000 Revamp and maintenance Basic design + E UOP 2009 Nizhnekamsk Refining and Petrochemical Complex Nizhnekams, Tatarstan 1 million tons/year New grass roots refinery, deep conversion and petrochemical complex FS, Licensors selection, FEED, LLI procrement assistance Axens 2008 Exxon - Sarpom Trecate, Italy 35,000 Revamp and maintenance Replacement of reactor and regenerator heads and cyclones Installation of new air blower and 5th SS booster pmp Other modifications to existing eqipment EPCM Exxon 2007 IOCL Paradip India 300,000 Grassroots FCC FEED, M Salavat Rssia 120,000 New FCC (SGS/Shell) FEED, E

17 Client and location Unit capacity (BPSD) Description of project Scope of work* Licensor Year of completion Total Antwerp, Belgim 96,700 Unit revamp Basic design + FEED UOP 2005 Hellenic Petrolem Refinery Aspropyrgos, Greece 44,000 Replacement of regenator head and cyclones installation of new wet gas compressor major revamping of the gas-con section E(Cm) Exxon Tamoil Rainerie de Collombey, Switzerland 15,750 New Unit (RFCCU) EPC Axens 2004 Raineria di Milazzo Milazzo, Italy 42,500 Revamp and maintenance of existing FCC nit EP Lmms 2000 TotalFina Antwerp, Belgim --- FCC/AlkyFeed revamp Basic design + EPCm ExxonMobil --- Reactor Replacement. 900Te lift by Gantry system and strand jacks also involved changing of Standpipes and additional five pairs of Regen cyclones ExxonMobil --- Regen Head replacement 17m Dia. 650Te Lift 20 pairs of cyclones EPC EP *Glossary of scopes BDP = basic design package Cs = constrction services E = engineering EPaCa = engineering, procrement assistance, constrction assistance EPc = engineer, procre, (constrction) EPC = engineering, procrement, constrction EPCa = engineering, procrement, constrction assistance EPCm = engineering, procrement, constrction management E (Cm) = engineering, constrction management EP = engineering and procrement Es = estimating FEED = front end engineering design FS = feasibility stdy LLI = long lead items M = management PMT = project management team

18 Amec Foster Wheeler ( designs, delivers and maintains strategic and complex assets for its cstomers across the global energy and related sectors. Employing arond 35,000 people in more than 55 contries and with 2016 revenes of 5.4 billion, the company operates across the oil and gas indstry from prodction throgh to refining, processing and distribtion of derivative prodcts and in the mining, power and process, pharma, environment and infrastrctre markets. Amec Foster Wheeler oers fll life-cycle services to oshore and onshore oil and gas projects (conventional and nconventional, pstream, midstream and downstream) for greenfield, brownfield and asset spport projects, pls leading refining technology. Amec Foster Wheeler shares are pblicly traded on the London Stock Exchange and its American Depositary Shares are traded on the New York Stock Exchange. Both trade nder the ticker AMFW Global soltions connected excellence in all we do To find ot more amecfw.com linkedin.com/company/amecfw yotbe.com/amecfw facebook.com/amecfw Amec Foster Wheeler 2017