New Separator Technology Development Objectives Quickly separate catalyst from gas Reduced dry gas, increased gasoline & olefins Lower delta coke High particle collection efficiency Avoid remixing or backmixing of vapor products achieve plug flow no underflow in the dipleg Minimize impact on riser hydrodynamics Stable under upset conditions, limit carryover to main fractionator ARTC April, 2002:Continuous Improvement at the Jiddah Refinery 13
Riser Separation System ( RSS ): Compact Two Chamber Device gas outlet collector entrance window vapor exit to cyclones separation chamber deflector gas outlet collector separation chamber separation chamber gas outlet windows stripping chamber stripping gas entrance window dipleg riser dipleg stripping gas catalyst outlet dipleg deflector ARTC April, 2002:Continuous Improvement at the Jiddah Refinery 14
Separation Chambers compact design low residence time low pressure drop easy to seal diplegs high separation efficiency limited underflow with sealed, low flux diplegs efficient pre-stripping in the diplegs good catalyst distribution into stripper (broad diplegs) Anti Coking Ring Pre- Stripping Main Stripping Ring Riser Stripper Internals Window connecting separation and stripping chambers Separation Chamber Stripping Chamber ARTC April, 2002:Continuous Improvement at the Jiddah Refinery 15
Stripping Chambers stripping gas combines with riser gas cyclones no back-mixing in vessel (low residence time) surge volume to prevent catalyst carryover to MF direct connection to reactor cyclones (only 1 duct) no expansion joints on cyclones or riser vapor quench compatible Opening for stripper gas Slip Fit for Thermal expansion Stripper Cyclones Window connecting separation and stripping chambers Separation Chamber Stripping Chamber ARTC April, 2002:Continuous Improvement at the Jiddah Refinery 16
Effect of RSS on Yield Selectivity C5-220 C gasoline yield (wt%) 48 47 46 45 44 43 42 41 40 Lower gas and delta coke with reduced post riser time Results in higher C/O and overall conversion/gasoline 2 sec 15 sec 39 55 60 65 70 75 80 Conversion (wt%) ARTC April, 2002:Continuous Improvement at the Jiddah Refinery 17
RSS Benefits Compact design - good revamp opportunities Surge volume prevents catalyst carry over during upsets Fully contained vapor Minimum pressure drop Low flux diplegs with integrated pre-stripping Widely dispersed catalyst entry to stripper (packing further improves radial mixing) Vapor quench option ARTC April, 2002:Continuous Improvement at the Jiddah Refinery 18
Step 4 Improved Catalyst Stripping Improved Reaction System Feed Injection Mixed Temperature Control Rapid Separation System Stripper ARTC April, 2002:Continuous Improvement at the Jiddah Refinery 19
Stripping Technologies Disk-Donut Structured Packing Low Hydrogen on Coke Low Steam Rates Utilize Entire Stripper Cross Section Effective At Very Higher Flux Rate - REVAMPS Reduced Regenerator T ARTC April, 2002:Continuous Improvement at the Jiddah Refinery 20
Stripper Internals Disc and Donut Internals are effective given enough catalyst volume But the flow pattern leaves much to be desired Disc&Donut Trays Partial Utilization, Channeling Structured Packing Full Utilization, Lateral Mixing ARTC April, 2002:Continuous Improvement at the Jiddah Refinery 21
Packing Utilizes the Entire Stripper Stripper Volume Utilization 100% 80% 60% 40% 20% 0% 30 15 54 Disc & Donut Active Volume Trapped Steam 97 KFBE Packing Stagnant Catalyst Steel ARTC April, 2002:Continuous Improvement at the Jiddah Refinery 22
Packing Out-Performs Competitors High Efficiency Trays 100 KFBE Packing Performance vs Disc/Donut Trays =f(steam, flux - lb/hr/sf) Percent Displaced 90 80 70 Packing is superior even at very low flux Modern High Efficiency Trays Ideal CC KFBE 30K KFBE 60K KFBE 90K KFBE 120K Ideal 7 Tray U- 60 U- 90 U- 120 60 0 0.5 1 1.5 2 2.5 3 kg steam/1000 kg of Catalyst Packing requires less steam and/or less stripper volume for the same gas displacement. Fluxes > 120,000 lb/hr/sf (2000 lb/min/sf) are possible ARTC April, 2002:Continuous Improvement at the Jiddah Refinery 23
KFBE TM Technology Fluidized bed internals technology by Koch-Glitsch Achieves near ideal conditions for gas-solid contacting Highly efficient design minimizes volume required Ideal for capacity revamps Commercial, no plugging Exclusively offered by Axens / S&W ARTC April, 2002:Continuous Improvement at the Jiddah Refinery 24