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Successful Start-up of the World's Newest FCC

IP.com Disclosure Number: IPCOM000217588D
Publication Date: 2012-May-08

Publishing Venue

The IP.com Prior Art Database

This text was extracted from a PDF file.
This is the abbreviated version, containing approximately 14% of the total text.

Page 01 of 13

Successful Start-up of the World's Newest FCC


S. Tragesser and J. Reeves

Kellogg Brown & Root, Inc. 601 .lefferson Ave
Houston, TX 77002

and


T. Barnreiter

ConocoPhillips

Ferndale Refinery

3901 Unick Road

Ferndale, WA 98248

ABSTRACT

With much of the attention in the refining industry being focused on clean fuels today, it is refreshing to report the startup of the world's newest FCC unit by ConocoPhillips at the Femdale refinery in Washington.

In 1999, ConocoPhillips Ferndale refinery made a decision to replace their 1950s vin- tage Thermofor Catalytic Cracking Unit (TCC) with a modern KBR Orthoflow'" Fluid Catalytic Cracking Unit (FCC). At the time of the shutdown, Ferndale's TCC Unit was the last TCC operating in the United States. The basis for this decision was the im- proved reactor yield slate, improved reliability, reduction in catalyst cost, and environ- mental benefits. The new FCC Unit, located in Ferndale, Washington, was commis- sioned in March 2003. As a result of extensive preparation and training by ConocoPhil- lips, the initial startup of the unit occurred very smoothly and without any difficulties.

In addition to the new FCC Unit, ConocoPhillips installed new regenerator flue gas cleanup technology including (1) a CO Incinerator for elimination of carbon monoxide and (2) a Flue Gas Scrubber system for removal of sulfur oxides and particulate matter. Also included within the revamp scope was the addition of a new regenerator air blower system and catalyst storage hoppers.

The revamp reused the existing TCC main fractionator, wet gas compressor system, and vapor recovery unit. These areas under went fairly modest modifications to sup- port the higher yields of gasoline and LPG that the FCC produces.

DESIGN BASIS

ConocoPhillips' primary goal was to maximize low sulfur gasoline production from feed- stocks consisting of vacuum gas oil and residuum blends with Conradson Carbon values up to 4.0 at a fresh feed rate of 30,000 BPSD. Two unique design cases were consid- ered for the project; (1) 100% ANS Vacuum Gas Oil (VGO) and (2) Blend of Canadian VGO and Canadian Residuum. To achieve these obJectives~ design operating conditions

KBR-EMRE FCC Licensee Symposium 2003 Page 1


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Successful Start-up of the Wor|d's Newest FCC

were optimized in conjunction with KBR/ExxonMobil Research and Engineering (EMRE) advanced technologies. Included within Ferndale's OrthoflowTM FCC Unit are Closed Cy- clones riser termination to minimize over-cracking of valuable products, Riser quench for improved conversion and gasoline yield, ATOMAX-2TM Feed Injection Nozzles for im- proved gasoline and LPG yield, DynaFluxTM Stripper internals for minimizing loss of valuable products to the regenerator, and counter-current catalyst regeneration for minimizing nitrogen oxides. With the wide range of design feedstocks, unit flexibility was extremely important. KBR built flexibility into this unit by designing it to operate in both complete...