DAO
Solvent Deasphalting
Coker Naphtha
SDA Bottoms
Naphtha
Asphalts
Visbreaking
Vacuum Residuum
Heavy Coker Gas Oil
Distillates Fuel Oil Bottoms Lube Oil
Solvent Dewaxing
BATON ROUGE BAYTOWN TEXAS CITY WHITING LAKE CHARLES KINGSHILL LINDEN PHILADELPHIA GARYVILLE NORCO
Top 10 combined Cat Cracking
6
Typical FCC Complex
Ref: /dts/osta/otm/otm_iv/otm_iv_2.html
Aviation Gasoline Automotive Gasoline Solvents
Naphtha
Crude Oil
Kerosene
Desalter
Jet Fuels Kerosene
Hydrocracking
Distillate AGO
Gas Oil Hydrotreating Fluidized Catalytic Cracking
• Three fixed bed reactors & processed 2,000 barrels/day
12,000 barrels/day commercial unit went on stream at Sun’s Marcus Hook Refinery in 1937 Other adoptees: Gulf, Sinclair, Standard Oil of Ohio, & The Texas Company
• Sun & Houdry Process Corporation started development on a moving bed
process in 1936
Pilot Thermofor catalytic cracker was started in 1941 First commercial 20,000‐barrel/day unit commissioned at Magnolia’s Beaumont Refinery in 1943
13
Fluidized Catalytic Cracking
• Up‐flow dense phase particulate solid process credited to W.K. Lewis, MIT • Originally developed as the Winkler coal gasification process
Features Deep catalytic cracking Fluid catalytic cracking Fluid catalytic cracking Fluid catalytic cracking Fluid catalytic cracking Fluid catalytic cracking Fluid catalytic cracking Fluid catalytic cracking for maximum olefins Fluid catalytic cracking, high olefin content Fluid catalytic cracking, residual Fluid catalytic cracking ‐‐ pretreatment Resid cracking Resid cracking
Bayway configuration?
Petroleum Refining Technology & Economics – 5th Ed. by James Gary, Glenn Handwerk, & Mark Kaiser, CRC Press, 2007
11
Fluidized Catalytic Cracking Technologies
Provider Shaw ExxonMobil Research & Engineering KBR Lummus Technology Shaw Shell Global Solutions UOP Lummus Technology KBR KBR Haldor Topsoe A/S Shaw Axens
Company
State
Site
ExxonMobil Refining ExxonMobil Refining BP BP PDVSA Hovensa LLC ConocoPhillips Sunoco Marathon Petroleum Motiva Enterprises
Louisiana Texas Texas Indiana Louisiana Virgin Islands New Jersey Pennsylvania Louisiana Louisiana
Light Naphtha
Isomerization
Polymerization Naphtha
Isomerate
Alkylate
Reformate Heavy Naphtha
Atmospheric Distillation Naphtha Hydrotreating Naphtha Reforming
• Products may be further processed
Further hydrocracked Alkylated to improve gasoline anti‐knock properties
3
Characteristics of Petroleum Products
Large conversion to light products requires some coke formation
Refining Overview – Petroleum Processes & Products, by Freeman Self, Ed Ekholm, & Keith Bowers, AIChE CD‐ROM, 2000
• Attractive feed characteristics
Small concentrations of contaminants
• Poison the catalyst
Small concentrations of heavy aromatics
• Side chains break off leaving cores to deposit as coke on catalyst • Must be intentionally designed for heavy resid feeds
12
Early Fixed & Moving Bed Catalytic Cracking
• Cyclic fixed bed catalytic cracking commercialized in late 1930s
Houdry Process Corporation formed in 1930 First Houdry catalyst cracker started up at Sun Oil’s Paulsboro, New Jersey, refinery in June 1936
8
FCC Riser/Regenerator Combination
Refining Overview – Petroleum Processes & Products, by Freeman Self, Ed Ekholm, & Keith Bowers, AIChE CD‐ROM, 2000
Fluidized Catalytic Cracking
Chapter 6
Gases
Polymerization Sulfur Plant
Sulfur
Gas
Sat Gas Plant
LPG Butanes Alkyl Feed
Alkylation
Fuel Gas LPG
Gas Separation & Stabilizer
the gasoline pool
5
U.S. Refinery Implementation
Vacuum Cat Cracking: Cat Cracking: Distillation Fresh Feed Recycled Feed Atmospheric Downstream Downstream Downstream Crude Distillation Charge Capacity, Charge Capacity, Charge Capacity, Capacity (barrels Current Year Current Year Current Year per stream day) (barrels per (barrels per (barrels per stream day) stream day) stream day) 524,000 596,400 475,000 420,000 440,000 525,000 250,000 355,000 275,000 250,000 242,500 288,600 237,000 247,000 235,000 225,000 75,000 163,200 142,000 95,000 242,000 215,500 175,000 165,000 147,000 149,000 145,000 138,500 131,000 120,000 0 8,000 8,000 4,000 3,000 0 0 0 0 0