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Cracking Since 1990, KBR has designed more than a dozen FCC units and revamped more than 160 FCC units worldwide Meeting Today’s Challenges Reners today face the choice of purchasing light sweet crudes at a premium price or investing in bottom-of-the-barrel upgrading. Yet with stringent environmental requirements and a dwindling supply of quality crudes, upgrading is the only solution to remain competitive. Frontrunner in FCC Not only are we a recognized leader in FCC, but we also pioneered the technology in the late 1930’s. This led to a KBR and ExxonMobil joint venture alliance in the design, construction and operation of the world’s rst commercial FCC unit at ExxonMobil’s Baton Rouge, Louisiana renery in 1942. It also marked the beginning of a solid partnership with ExxonMobil in FCC technology that remains today. Renery ROI Our FCC experts hold industry-leading experience in designing, engineering, procurement and construction services. We evaluate modications to increase capacity, improve and maximize product yield and enhance on-stream factor and mechanical reliability. Accelerate ROI, ROCE, RONA and cash ow Design, engineer, construct and service FCC units Increase protability Achieve cost objectives Reduce safety incidents Overcome resource constraints Identify new opportunities for improvement Revamp and replace technology Extend the life of FCC investment Sustain benets Stay current with environmental regulations Our experts can help clients: At the ExxonMobil FCC project in Altona, Australia, KBR proved that FCC solutions offer long term reliability and low capital costs. Fluid Catalytic Cracking Long-Term Reliability Rigorous testing, ongoing research, catalyst evaluation, feedstock characteristics and product yield assessment make KBR a cut above. With KBR, our clients count on unmatched FCC solutions that are low in capital cost and high on quality, long-term reliability and operability. Technical Services Following start up of the unit as well as during normal operation, technical service engineers assist reners in gaining maximum value from investment in KBR technology through routine renery visits and consultation. We maximize clients ROI using our licensed technologies through technical services for operations and turnarounds. Lower Capital Costs Orthoow™ FCC process technology, which includes supporting Orthoow converter and combines the disengager, stripper and regenerator vessels This unique design minimizes the cost of construction, and also reduces the amount of eld mechanical work and testing, research, catalyst evaluation, feedstock characteristics make KBR a cut above. KBR’s Technology Center (KBRTC) contains numerous pilot plants, analytical Fluid Catalytic Cracking KBRTC specializes in cold ow modeling – the simulation of process characteristics at near ambient temperatures and pressures. Creating realistic cold ow models is a unique talent and KBR is a leading practitioner of this technique. FCC Advanced Process Controls KBR’s Advanced Process Control and large number of interactive variables. Our APC system Severity Control Pressure Balancing and Control Fractionator Control Vapor Recovery Unit Advanced technology allows KBR’s operators to simulate all aspects of plant operations and controls, as well as startups, shutdowns and emergencies. Fluid Catalytic Cracking Quick, Safe & Effective Revamps KBR’s approach to revamping draws upon unrivaled skill in all aspects of FCC technology. For fast-track implementation of the latest technology improvements, KBR and our industrial fabrication and construction partner, InServ, provide lump-sum turnkey revamp and turnaround solutions that include: Increased capacity and conversion Greater feedstock exibility Gasoline yield improvement Octane improvement Improvements in reliability, maintainability, environmental Leading-edge technology and service that spans 100 years Fluid Catalytic Cracking Design solutions. Optimize processes. Enhance productivity. Accelerate ROI. Why Wait? KBR turns visions into reality with our proven FCC technologies and advanced features from our alliance partner ExxonMobil. Together, we can design, construct and optimize FCC solutions no matter where client facilities are located. To learn more, visit: www.kbr.com/fcc or e-mail rening@kbr.com. MAXOFIN™ www.kbr.com www.kbr.com Fluid Catalytic Cracking Technology To learn more, visit: www.kbr.com/fcc or e-mail rening@kbr.com. Breakthrough technology offering greater exibility Optimum Design, Maximum Yield Fluid Catalytic Cracking Technology To learn more, visit: www.kbr.com/fcc or e-mail rening@kbr.com. Advanced design, superior performance Maximum Coverage = Outstanding Yields ATOMAX-2 provides optimal yields and ATOMAX-2™ Feed Nozzles Fluid Catalytic Cracking Technology To learn more, visit: www.kbr.com/fcc or e-mail rening@kbr.com. Market-leading solution to enhanced yields Maintain Desired Yields Rapid removal of product vapors from FCC converters after riser cracking is paramount to maintaining desired yields. Our Closed Cyclone Riser Termination system, developed jointly by KBR and ExxonMobil, consists of interconnecting ductwork that routes product vapors directly into secondary cyclones and out Fluid Catalytic Cracking Technology To learn more, visit: www.kbr.com/fcc or e-mail rening@kbr.com. Greater efciency, enhanced performance Safeguard Reactor Products Upgrades to FCC units typically increase catalyst circulation which elevates stripper catalyst ux rates. This increase signicantly reduces stripper efciency by entraining hydrocarbon product gases into the regenerator. Once entrained, regenerator temperatures rise requiring the stripper to use additional combustion air while more hydrocarbon product is burned and lost. Managing Flux Rates KBR DynaFlux™ stripping technology addresses two challenges seen in conventional strippers: high local catalyst ux and poor lateral mixing. Developed jointly by KBR and ExxonMobil, DynaFlux technology allows the FCC stripper to effectively manage elevated ux rates. DynaFlux consists of three main components: two- stage stripping, the Flux Tubes™ proprietary bafe and Lateral Mixing Elements™ (LME) that increases the mean catalyst residence time, minimizing ow short- circuiting while improving mixing. Reducing Hydrocarbons, Increasing Circulation Many FCC units employ a two-stage stripper, but when coupled with our DynaFlux technology, unstripped hydrocarbons are is passed, stripper efciency plunges and ooding occurs. Flux Tubes extend the operating range of the stripper to prevent ooding and provide a signicant efciency gain without Fluid Catalytic Cracking Technology To learn more, visit: www.kbr.com/fcc or e-mail rening@kbr.com. High-efciency, robust abatement solution Achieving Environmental Requirements catalysts in ue gas exit the regenerator. CycloFines™ Third Stage Separator Flue gas from gas FLOW Fluid Catalytic Cracking Technology To learn more, visit: www.kbr.com/fcc or e-mail rening@kbr.com. Proprietary design, compelling results ” in the Regenerator Rening Technology To learn more, visit: www.kbr.com rening@kbr.com Vacuum Distillation and Solvent Extraction ROSE versus Vacuum Distillation Increases in rened product demand have forced reners to use larger amounts of heavy oil in their feed mix, which yield higher fractions of processable residue. To maximize protability, residues like atmospheric tower bottoms are processed in vacuum distillation units (VDU) or undergo a less energy intensive solvent extraction procedure, such as KBR’s Vacuum Distillation Vacuum gas oil (VGO) recovery limited by maximum Nominal B.P. of heaviest 1200°F or higher, limited only by product Vac Resid Distillation Limited More FCC feed Distillates (ROSE unit) $$ Rening Technology To learn more, visit: www.kbr.com rening@kbr.com Reference: V. Patel, R. Igbal and O. Eng, “To vacuum or not to vacuum”, 06/2007, HYDROCARBON ENGINEERING. The results are presented in Table 2. This study demonstrated that regardless of which heavy crude was processed, overall renery product yields and operating margin of a VDU and ROSE combination can be achieved with a lower capital cost when ROSE, without the vacuum tower, is used to process atmospheric tower bottoms. The margin contributed by the addition of the ROSE is the highest for those crude oils for which the DAO yield can be maximized, while staying within the limits of feed qualities for This case study employed an FCC as the gas-oil conversion unit, but similar economic advantages could be realized when the DAO is fed to a hydrocracker. While this study focused on a grassroots facility, similar results would be obtained for many revamp situations, where the addition of residue processing capacity may open up opportunities for a heavier but cheaper renery crude slate. Protability, Arab heavy ATB Protability, Maya ATB US$/bbl crd.10.3211.0611.11 US$/bbl crd.11.8312.2812.34 722774778 828860864 —5256 —3135 —14766 —16186 Payout (years) over Case 1—2.81.2Payout (years) over Case 1—5.12.4 Table 2: Comparative study of VDU-only, VDU-ROSE, and ROSE-only processing strategies for two heavy crudes To Vacuum or Not to Vacuum Rening Technology To learn more, visit: www.kbr.com rening@kbr.com Increasing the Value of Low-Value Feedstocks IGCC Provides Environmental Benets with Flexible Feedstocks power, hydrogen, synthesis gas and steam. IGCC provides several benets over conventional combustion-based power generation technologies: A wide range of feedstocks can be processed Cycle efciencies in the range of 55% are possible, compared to conventional steam Low air and water emissions are afforded, resulting in an environmentally friendly means of eliminating the bottom of the barrel. IGCC Drives Efciency Gains in Solvent While current capital costs for standalone IGCC of an IGCC plant with KBR’s solvent deasphalting process provides an economical solution for heavy oil disposal. A comparison of a ROSE-only In the rst option (Fig. 1a), a ROSE unit processes 19,400 BPSD of vacuum tar from a visbreaker. The oil (DAO) and asphaltenes. The asphaltenic ROSE bottoms are blended with cutter stocks comprising FCC cycle oil, decant oil, and kerosene to produce plant gasies the ROSE bottoms to produce 360w of electrical power from the same amount of feedstock. In addition, while the fuel oil production declines by only 19% for option 1, the production decline is 64% for option 2, further illustrating the benet of a combined ROSE-IGCC process. IGCC Power Generation Vi sb re aker Va cu um Re si due 1548 k t/yr 28,500 PSD Li ght gas es 43 k t/yr Va cu um ga oi ls 173 k t/yr At m gas o ils 130 k t/yr Cr ac ed naphtha 96 k t/yr RO SE Cu tter St oc k Fuel oil 915 kt/yr DA O 421 k t/yr RO SE Bo ttom s 685 k t/yr Vi sb eaker Va cu um Ta r 19425 BPSD COMBINED CYCLE PLANT Vi sb eaker Va cu um Re si due 1548 k t/yr 28,500 PSD Li ght ga se 43 k t/yr Va cu um ga ils 173 kt /yr At m ga s oi ls 130 k t/yr Cr cke d naphtha 96 k t/yr Fu el oi 2532 k t/yr RO SE Cu tter St oc 1426 k t/yr DA O 421 k t/yr RO SE Bo ttoms 685 k t/yr Vi sb re aker Va cu um Ta r 19425 BPSD Fig 1b: Option 2: ROSE unit + IGCC plant Rening Technology To learn more, visit: www.kbr.com rening@kbr.com Reference: H. David Sloan, Howard J. Simons, John Grifths and David J. Bosworth: “Solvent Deasphalting and Gasication to reduce fuel oil”, 06/13-14/1996, European Rening Conference, Belgium. As Table 1 illustrates, the initial investment in a ROSE-IGCC combined process is high. However, the efciency gains realized by utilizing the IGCC plant make the combined an IGCC plant is reduced to the bottom end of industry estimates, or should the price of high sulfur fuel oil relative to crude and other products drop, then the ROSE-IGCC option would become economically viable without the need for an electricity price subsidy. Finally, the proper location of the IGCC plant in the renery can have a positive economic inuence, from both a product price and overall plant thermal efciency point of view. IGCC Power Generation CaseDescriptionCapex ($MM)IRR (%) Option 1Add ROSE Option 2Add ROSE+IGCC571 Table 1: Preliminary economics Rening Technology To learn more, visit: www.kbr.com rening@kbr.com Su ge Dr um Pe lle ti ze r Ve ss el Sc re en fo r Dewa te ri ng and Dr yi ng Ho t Li qui As phaltene Pe ll ets Wa te Ci rc ulated Water So lid Pe lle ts fo r St orag