Improvements in the RFCC process

Feb 22nd. 2011

I. Outline of S-OIL Refinery II. Improvements of RFCC after 2010 T/A

1. Introduction of O2 Enrichment System 2. Flue Gas Cooler Modification

III. Summary

I. Outline of S-OIL Refinery

Outline of S-OIL Refinery

Improvements Of RFCC 10 T/A

Summary

View of Refinery
CDU : 580,000 B/D HOC : 253,500 B/D Lube : 30,000 B/D P-X : 700,000 TPA BTX : 900,000 TPA

CHINA

SPM
R&D
S

Seoul

#1/#2 CDU NHC BCC / #3 CDU Lube/Aromatic

Ulsan O Onsan Pusan

JAPAN

Total Area : 2.5 mil. m2

Seoul Ulsan : 400 Km Pusan Ulsan : 50 Km

II. Improvements of RFCC after 2010 T/A

Outline of S-OIL Refinery

Improvements Of RFCC 10 T/A

Summary

Outline of RFCC Unit

R2R (RFCC)
R2R is a proprietary commercial RFCC process name of Axens. (1 Reactor, 2 Regenerators) RFCC : Residue Fluid Catalytic Cracking HYVAHL-Residue (from HVL, storage) Treated VGO (from MHC, storage) Low sulfur Wax

Feeds

Products

Fuel Gas, Propane, Propylene, Butane, LCN (LLCN, MLCN, HLCN), HCN, LCO, SLO

Objectives

Maximizing Gasoline Maximizing Propylene

Outline of S-OIL Refinery

Improvements Of RFCC 10 T/A

Summary

RFCC Scheme
FGTU 2nd Regenerator Fractionator GAS RECOVERY SECTION

FUEL GAS PROPYLENE PROPANE C4

R1 FLUE GAS

R2 FLUE GAS

Disengager / Stripper

L-L. GASOLINE
Catalyst Cooler

SHU
750 1.3 KSCG 525 1.5 KSCG

M-L. GASOLINE H-L. GASOLINE

HVY GASOLINE
Stripper Packing

LCO

RISER
660 2.2 KSCG

1st Regenerator

COMBUSTION AIR

O2

FEED

SLURRY

Outline of S-OIL Refinery

Improvements Of RFCC 10 T/A

Summary

Introduction of O2 Enrichment System

Operational Difficulty Combustion Air Constraints (#1 Reg. Cyclone & Superficial Velocity Limitation) Feed Heaviness (MCR) Increase 73,000 BPD (MCR 3.5 wt%) Progress Secondary Air Blower Installation (2007 T/A) 69,000 BPD 73,000 BPD (for 4 months of summer) 73,000 BPD (MCR 4.7 wt%) Introduction of O2 Enrichment System (2010 T/A) 73,000 BPD (MCR 3.5 wt%) Additional Tube Cluster Installation of Catalyst Cooler (2010 T/A) + 2 MMkcal/h heat duty is expected by O2 Enri. utilization (studied by S&W) Charge Down 62,000 BPD (MCR 4.8 wt% T-VR)

Outline of S-OIL Refinery

Improvements Of RFCC 10 T/A

Summary

Introduction of O2 Enrichment System

Results
Actual Result In 2010 T-VGO 2,000 BPD T-VR (MCR 3.77 3.89 wt%) Additional Treatment of T-VR according to feed availability

In the Future Slide / Plug Valve Size-up (2013 T/A) Conversion decrease due to treating heavier feed stock and CCR Limitation CCR Increase (C/O Ratio increase) in order to increase conversion

Outline of S-OIL Refinery

Improvements Of RFCC 10 T/A

Summary

O2 Injection Package

< O2 Injection Package>

Installation Item

< O2 Diffuser>

O2 Injection Package (O2 Skid, Control V/V, Flow Meter etc) O2 Diffuser Installation at Main Air Tie O2 Pay Meter Installation by Vendor (near B/L Gas O2 Pipe)

Outline of S-OIL Refinery

Improvements Of RFCC 10 T/A

Summary

Economic Analysis
Effect Investment Cost 1.4 mil. US $

Effect

T-VGO to T-VR 2,000 BPD T-VR Max (Test Run)

Profit IRR / Pay Out

5.8 mil. US $ 764 % / 0.1 yr

Outline of S-OIL Refinery

Improvements Of RFCC 10 T/A

Summary

Flue Gas Cooler Modification -. Flue Gas Treatment Unit Scheme

Outline of S-OIL Refinery

Improvements Of RFCC 10 T/A

Summary

Flue Gas Cooler Modification

Operational Difficulty Enforced Domestic Environmental Regulation In case of FGC Tube Leak, Unit S/D is needed due to CO regulation FGC Outlet Temp. High (near Mech. DSN Temp.) Progress Case Study ( FGC 1 Train Install. Vs FGC Modification) FGC Modification due to economics (studied by DuSan Heavy Industry) FGC Modification Separate 4 Modules for blocking leaked module Install. Of Leak Detection System Anti-vibrating Device install. (Ultrasonic) New Economizer Install.

Outline of S-OIL Refinery

Improvements Of RFCC 10 T/A

Summary

Flue Gas Cooler Modification

Results
Energy Conservation New Economizer Install. (Solomon EII 0.17, HP Steam + 13.1 Ton/h) No Charge Loss in case of Tube Leak No Tube Leak in 2010. (Future expectation)

In the Future Effect Require reliability of leak detection system HP Steam Production Increase (13.1 Ton/h) Consistent Monitoring

Outline of S-OIL Refinery

Major Function Of Q.M

Summary

Flue Gas Cooler Modification

Before Revamping

Outline of S-OIL Refinery

Major Function Of Q.M

Summary

Flue Gas Cooler Modification

After Revamping

Outline of S-OIL Refinery

Improvements Of RFCC 10 T/A

Summary

Economic Analysis
Effect Investment Cost 10.1 mil. US $

Effect

HP Steam : + 13.1 Ton/h

Profit IRR / Pay Out

7.1 mil. US $ 66 % / 1.7 yr

Outline of S-OIL Refinery

Improvements Of RFCC 10 T/A

Summary

Summary
O2 Enrichment O2 injection at #1 Regenerator Additional Treatment of T-VR Flue Gas Cooler Modification Flue Gas Cooler Superheater Modification (4 Module) New Economizer Installation Additional HP Steam Production No Charge Loss in case of Tube Leakage

Outline of S-OIL Refinery

Improvements Of RFCC 10 T/A

Summary

Fluidization
the operation by which the fine solids are transformed into a fluid-like state through contact with a gas or liquid * R2R uses air and steam to fluidize catalyst.

Solid-like state

Fluid-like state

Outline of S-OIL Refinery

Improvements Of RFCC 10 T/A

Summary

Fluidization Regimes

Outline of S-OIL Refinery

Improvements Of RFCC 10 T/A

Summary

Fluidization Regimes