renewable feeds co-processing using existing heavy ends

BBTCRenewable Feeds Co-processing

Using Existing Heavy Ends

Refinery Platform

Thursday, 30th September, 2021

■ Co-processing in fossil fuel refineries made up about 10% of total HVO production in

2019

■ Biofuel production from co-processing should triple by 2025 (~1.4 billion litres in 2025 vs.

0.5 in 2018)

■ Co-processing will be mainly implemented in Europe

Outlook to 2030: The Role of Co-processing

Source : IEA, 2020

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Renewable Feedstock Outlook

Type Feedstock Supply Demand Future Outlook

Refined oils

Palm Oil

Soybean Oil

Rapeseed Oil

Sunflower Oil…

Represent only a fraction of

total global production

Legislation not in favor of

crop-based bio feeds

Mid-term availability

guaranteed

Waste oils & fats

UCO

Tall oil

Tallow – Animal fat

POME

Limited additional supply

Already high collection rates

Support from legislation

Premium benefits

Highly constrained to existing

supplies

Py Oil (Fast pyrolisis)

&

Bio crude(Hydrothermal

liquefaction)

Converted:

Agricultural residue

Forestry residue

Algae

Sewage sludge

MSW

Pneumatic tires

Collection circuit to be built.

Variability in py-oil / bio

crude feedstock quality.

High potential from new

emerging feedstock

Technology / Legislation not

fully mature

High interest and support

from pioneering companies

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Axens’ History with Biofuels / Co-processing

1992

2006

1st biodiesel plant

start-up

Esterfip™ Technology

1st Esterfip™-H

plant

start-up

1st Industrial reference of Vegan®

Total La MèdeBiorefinery Project

2015 1st grass root

PrimeD®

Co-Processing Design

2018

2010

1st Co-processing

industrial reference

in a DHT unit

2014

2020

2021

Co-processing

Pilot tests on

H-Oil unit

1st Co-processing

trials in an FCC unit

Co-processing

lipids Pilot test on

FCC unit

Co-processing FPO

Pilot test on FCC

unit

2007

Co-processing paths

Refined Oils

Waste Oils & Fats

Renewable

Fuels

AromaticsPy Oil & Bio crude

Bio

Petrochemicals

feedstocks

Prime D ®

+ HyK ™

H-Oil ®

FCC

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Co-Processing Renewable feedstock in

Hydroprocessing units

Lipids Hydrotreatment – Reactions Scheme

H2-C-OO-C

H-C-OO-C

H2-C-OH

H2-C-OO-C

H-C-OH

H2-C-OH

H2-C-OO-C

H-C-OO-C

H2-C-OO-C

HOO-C

Hydrogenolysis

TG + 12 H2 3 C18H38 + 6 H2O + C3H8

1

2 Decarboxylation

TG + 3 H2 3 C17H36 + C3H8 + 3 CO2

H2

/ Hydrogenation

/ Hydrogenation

Methanation / WGS

CO2 + 4 H2 CH4 + 2 H2O

CO2 + H2 ↔ CO + H2O

3

Free Fatty Acids

Monoglycerides

Diglycerides

Triglycerides (TG)

Renewable

Oils & Fats:

1 2

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Light

Ends

M/U H2

Off-gas

H2 Recycle

∞

ULSD

Feed

Wild Naphtha

Exotherm

Undesirable Impact

Desirable Impact

Bio-feed

Increased

corrosion

Impact on

Catalyst

Activity

H2 purity

CO/CO2 build-up

Cetane

Density

CFP

H2

consumption

Risk of

fouling

Increased

corrosion

Case Study: Impact of Co-Processing on DHT Units

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Reactor Inlet Internals

■ Filtering Tray – Hy-Clean™

Smart filtering tray system for

services prone to fouling and/or ΔP

Installed above the dist. tray without

relocation

Do not require any connection to

reactor wall

Baskets typically filled with grading

By-passable| 9

Smart DP Management

0

1

2

3

4

5

6

7

8

0

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16

0 200 400 600 800 1000 1200 1400

Pre

ss

ure

dro

p b

ar

VO

vo

l%

Days on stream

Reactor Pressure Drop

VO vol% DP Norm. dp 1 Norm. dp 2 Norm. dp 3 Norm. dp 4 max DP

Skimming

H2 Stripping

Skimming

FeS dispersant injection at reactor inlet

Customer GALP

3700 mm Refinery Sines

Unit name HD

Reactor Id. HD-V-1

TL 320 mm

ActiPhase 3D TRANS 30 80 mm 0.860 m3CatTrap 30 130 mm 1.398 m3

CatTrap 50 170 mm 1.828 m3

CatTrap 65 170 mm 1.828 m3

ACT 077 (11 mm) 160 mm 1.720 m3

ACT 935 (6.2 mm) 190 mm 2.043 m3 1.073 tons

ACT 955 (2.5 mm) 230 mm 2.473 m3 1.607 tons

ACT 971 (2.5 mm) 230 mm 2.473 m3 1.410 tons

HR 538 (1.6 mm) 210 mm 2.258 m3 1.445 tons

HR 648 (1.6 mm) 80 mm 0.860 m3 0.628 tons

Dense Reg HR 538 (1.6 mm) 2340 mm 25.160 m3 18.618 tons

Dense HR 1218 (1.6 mm) 12340 mm 132.681 m3 108.135 tons

TL HR 1218 (1.6 mm) 840 mm 8.411 m3 6.855 tons

Inert Balls (1/4 inch.) 150 mm 1.217 m3 1.704 tons

Inert Balls (3/4 inch.) 504 mm 3.268 m3 4.412 tons

Note 1: This drawing gives a description of the proposed loading diagram, nevertheless the scale is not proportional.

Note 2: Inert Balls volume in the reactor bottom to be confirmed with actual reactor scheme

Note 3: Inert Balls (3/4 inch.) to be loaded at least 100 mm above bottom screen

Note 4: Indicated weights are under oxyde form before Impulse™ treatment

Grading solutions

Period 1 Period 2 Period 3 Period 4

6 months 7 months 9 months17 months

on-going

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Co-Processing Renewable feedstock in FCC units

■ Owing to decreased demand in motor fuels, some

FCCUs are currently operating below their nameplate

capacities, allowing for co-processing bio feeds.

■ Fluid Catalytic Cracking process has the capability to:

Deal with heavy and polluted feeds

Can adapt to various grades/qualities of bio-oils

No systematic need for pre-treatment

Accomodate to feed capacity or yield pattern changes

Will absorb seasonal variations in bio-oil feed quality and

quantity

Will allow switching bio-feed sources

Generate various products from motor fuels to petchem bases

FCCUs as co-processing machines

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■ Careful handling of bio-oil material (polymerization, etc.)

Specifically designed injectors available

Independant lines, when necessary, to control temperature

■ Operating conditions swings due to possibly inconsistent supply

Wide offer of flexible hardware capable to withstand transient phases and

operational swings:

› RS² riser termination device to avoid catalyst entrainments to fractionation section,

› Stripper Packing to avoid hydrocarbons entrainments to regeneration section,

› etc.

■ Possible presence of noxious components

Very resilient process: most issues will be dealt with higher fresh catalyst make-

up rate

Presence of heavy material inconsequential for R2R™ (Dual Regeneration FCC)

■ Corrosion

To be assessed on a case by case basis versus original design capability

Expected impacts with co-processing in FCCUs

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Expected performances: Cracking potential vs. VGO feed

PalmSoy-

bean

Rape-

seed

Sun-

flowerCorn

Jatro-

phaUCO

Animal

FatFFA TOFA

H2O+COx L L L L

Dry GasJJJ JJ JJJ J

EthyleneL L

LL LL

PropyleneK L L

LL

ButenesK L L

LL

GasolineJ J K J

SlurryJJJ JJ JJJ J

CokeJ J

LLJ

• Similar behaviour per

category

• Systematic reduced dry gas

and slurry production

• Performance impeded by

large production of H2O, CO,

CO2.

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INCREASED TREATMENT COMPLEXITY

■ Context:

Customer willing to leverage available overdesign margin in VGO FCCU

Potentially easy access to FPBO* material nearby

No unit modification besides new storage and injection facilities for FPBO

FPBO from spruce/pine, birch and, wheat straw feedstocks

■ Results

4% FPBO in 100% UCO+HCGO retained to comply with the above

Same operating conditions maintained with <1% drop in conversion

Fresh catalyst injection rate increased to deal with high Fe+Ca+Na contents

Distribution of bio-material in products:

Expected performances / Case Study

Dry gas 35%

LPG 5%

Gasoline 5%

LCO 20%

Slurry 35%| 14

* Fast Pyrolisis Bio Oil

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Co-Processing Renewable feedstock in EB units

■ H-Oil is the most suited technology for Residue

conversion application

Upflow Reactor, Recycle of Rx Liquid to ebullate catalyst

bed

Low and constant ΔP over the catalyst bed,

Nearly isothermal

High residue conversion: up to 95+% on Vacuum

Residue

No limitation on feed quality

■ On-line daily Addition/Withdrawal of catalyst:

Constant catalyst activity, whatever metal content in the

feed

Constant product quality

No Cycle length limitations

Fully automated system

H-Oil Platform specificitiesCatalyst Addition

Recycle Cup

Expanded

Catalyst Level

Settled

Catalyst Level

Hydrogen and

Feed Oil

Catalyst Withdrawal

Recycle Oil

Distributor

Grid Plate

Ebullated

Bed

Gas/Liquid

Separator

Possibility with EB to process « unrefined bio feeds »| 16

■ H-Oil operating conditions: High temperature (400-430°C),

High Pressure (160-180 bar)

Decarboxylation/ hydrogenation reactions

Conditions for complete Methanation

■ Bio-Feed qualities Metals and phospholipids – handle by CAR

› High silicium content but lower total metal than SRVR

Phospholipids - also prone to precipitate at 150-160°C. Selection of injection point

Nitrogen & Sulfur – dilution effect on VR

› Product qualities will be improved

■ Yields Increase Diesel range yield (+11%)*

Increase C3 formation (+8%)*

Small Increase on Hydrogen consumption (+4%)*

H-Oil Platform: a co-process VO machineCatalyst Addition

Recycle Cup

Expanded

Catalyst Level

Settled

Catalyst Level

Hydrogen and

Feed Oil

Catalyst Withdrawal

Recycle Oil

Distributor

Grid Plate

Ebullated

Bed

Gas/Liquid

Separator

* For 10% co-processing| 17

■ The reaction yields a lot of C3.

Potential impacts on membrane/PSA/gas plant and ppH2

■ CO and catalyst poisoning.

daily addition & withdrawal will help: should be check with spent catalyst

analysis.

■ High amount of unsaturated VO result in very high reaction exotherm

VO can be sent to 1st & 2nd reactors separately to reduce exothermicity risk

■ Chlorides content: corrosion potential

■ Check CO2 material balance with membrane supplier

VO up to 10% these challenges can be overcome easily

VO processing challenges:

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Selecting the optimum injection point

Type Characteristics

Refinery Injection Point

Hydroprocessing FCC H-Oil

Refined oils▼Level of FFA /

poisons

Specific grading

▲H2 Consumption

Loss of liquid yields

Subsequent treatment



▲H2 Consumption

Waste oils & fats▲Level of FFA /

metals & poisons

Specific grading

▲H2 Consumption

Metallurgy upgrades /

Pretreatment



▲Tolerance to polluted

feeds



▲H2 Consumption


feeds

Py Oil (Fast pyrolisis)

&

Bio crude (Hydrothermal

liquefaction)

Unstable compounds

▲TAN / Chlorides

▲Oxygen/water level

Specific grading

▲O2 level

Pretreatment by

hydrogenation

Few experimental data


feeds

Separate injection point


feeds

▲H2 Consumption

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Multiple options for a « greener » futureNear-term solutions with no/minor modifications

Co-processing in existing refinery

units:

Simple, efficient and flexible

High potential to provide low carbon

renewable fuels at min CAPEX

Capturing premium « green » benefits

Maximum re-use of existing refining

infrastructure

Flexibility to respond to market fluctuations

Higher value products with High energy

content and improved cetane number

Our added value:

Continuous R&D on bio-fuels with

unique IFP pilot plant facilities

Revamp experience

+25 years of industrial feedback

Robust Catalyst

Internals portfolio

axens.net

Thank you

renewable feeds co-processing using existing heavy ends

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