Together in Technology

As the world’s second-largest net importer of crude oil and the third-largest consumer behind the United States and China, the Japanese government has long recognized the importance of maintaining close relationships with oil- producing countries.

The Japan Cooperation Center Petroleum (JCCP) was founded in November 1981 to promote technical cooperation and personnel exchanges with the oil-producing countries in the downstream sectors of the oil industry under the auspices of the Ministry of Economy, Trade and Industry (formerly Ministry of International Trade and Industry). In April 2001, JCCP merged with the International Cooperation Division of the Japan Petroleum Energy Center (JPEC), and, in cooperation with Japan’s leading oil companies such as Nippon Oil Corp. (Nippon Oil), assumed the responsibility for training overseas technical and administrative staff in Japan, the dispatch of Japanese experts abroad, and the sponsoring of international seminars, conferences, studies and research.

After more than 12 years, a project between Saudi Aramco, King Fahd University of Petroleum and Minerals (KFUPM) and Nippon Oil has resulted in the groundbreaking development of high-severity fluid catalytic cracking (HS-FCC) technology. The new process converts low-value refinery gas-oils into high-value light olefins for use in integrated petrochemical processes and light olefins feedstock for alkylation to produce high-octane gasoline components. Propylene yields of four times greater than conventional FCC operations have been achieved in the pilot plant studies. In addition, the overall yield of these products increased to more than 70%, in comparison with less than 60% in conventional FCC processes (Figure 1).

“HS-FCC maximizes propylene production with a combination of new technology, operating conditions and a down-flow reactor,” said Yuichiro Fujiyama, manager of the Chemical Refinery Integration Group at Nippon Oil’s Fuel Research Laboratory in Yokohama, Japan. “A proprietary catalyst with high olefin selectivity was developed. Short contact time prevents secondary reactions such as hydrogen transfer and over cracking, which reduce propylene production.”

Mohammad H. Al-Tayyar, a process engineer in Saudi Aramco’s Research and Development Center’s Downstream and Strategic Program, said the HS-FCC process complements the growing trend of refinery and petrochemical integration. “The main features of the new process take into consideration the operations of conventional FCC units to maximize the production of petrochemical feedstock, allowing for more optimized refinery and petrochemical integration schemes. The HS-FCC technology comprises a down-flow reactor (downer), high reaction temperature (550°C to 650°C / 1,021°F to 1,201°F), short reaction contact time and high catalyst-to-oil ratio. By controlling reaction temperature, operations can elect to either optimize gasoline components or propylene production. A downer reactor system was selected instead of the riser reactor in conventional FCC units to minimize back mixing thereby reducing undesirable byproducts,” (Figure 2).

Christopher F. Dean, a refining consultant in Saudi Aramco’s Oil to Chemicals Research and Devel-opment Division and co-author of several HS-FCC patents, said optimum conditions should yield
high propylene.

“The 30-b/d demonstration plant achieved high propylene levels of greater than 20wt% with a very hydrotreated feedstock. Even higher propylene yields are expected at optimum catalyst and operating conditions,” he said.

Project evolution
The HS-FCC project is part of Saudi Aramco’s oil-to-chemicals research program, which is within the company’s Downstream and Strategic Research Program. The program focuses on pursuing research, development and technology implementation initiatives in areas relating to Saudi Aramco’s downstream operations and long-term strategic research interests. JCCP and JPEC led the project and prov-ided financing.

The project was designed in three phases, the first of which created a 0.1-b/d lab scale model used in initial process and catalyst testing at KFUPM.

During the second phase, a 30-b/d facility was constructed at Ras Tanura Refinery on the Gulf Coast in the eastern region of Saudi Arabia and operated successfully for more than a year. The data collected confirmed the importance of moving forward with a larger scale commercial unit.

In the third phase, issues relating to technical development and commercialization are being worked out as the process is scaled up to a 3,000-b/d semi-commercial unit. Nippon Oil has seven refineries in Japan. The company has chosen to install the unit at its Mizushima refinery because of the refinery’s existing facilities, land availability and opportunities to utilize the products most effectively. The detailed engineering design is under way, and the plant is expected to be operational by 2010.

A full-size commercial design package of up to 40,000 b/d also is being developed.
Saudi Aramco is funding the development of a customized model with a full-scale simulation that will allow for economic studies. This FCC program was modified from the traditional riser FCC simulation model to a quick low contact time down-flow reactor for the HS-FCC. Once the model has been fully tested, it will be demonstrated and used in various planned process studies.

“The key success factor for this project was the diversity of the team, cooperating on different levels and working cohesively to achieve our goals,” Al-Tayyar said.

Project origin
The project began with a Nippon Oil and JPEC study in 1994 on catalysts and operating conditions of HS-FCC.

“JPEC and the Japanese government were looking for a new item that was suitable for a joint research project with Saudi Arabia,” Fujiyama said. “PEC already had a relationship with KFUPM before we started Phase I. We needed Saudi Aramco when we started Phase II. The 30-b/d demo plant was too large to install in a university.”

Saudi Aramco was invited to participate in the project and for the second phase included providing land, utilities, engineering and operations support along with the feed from the adjacent Ras Tanura Refinery complex. The company realized this would be a unique opportunity to become involved and support a new technology that would have a direct global impact on the downstream industry.

“We enhanced the relationships between Aramco and Nippon Oil and between Saudi Arabia and Japan during the project,” Fujiyama said. “That was another goal and result of the project.”

“It was a great experience for me to participate in developing a new technology and to learn a new business model in approaching a development such as this,” Al-Tayyar said. “There were a lot of new factors that we learned together involving activities such as licensing, marketing and commercializing a new technology process, which allowed us to grow closer together.”

Nippon Oil’s role
Nippon Oil developed the proprietary catalyst and studied reaction conditions before Phase I.

“During that phase, Nippon Oil had an idea to use a down-flow reactor and designed a lab-scale pilot plant,” Fujiyama said. “It was installed at KFUPM during Phase I, and Nippon Oil researchers went to KFUPM to perform the pilot plant study.”

Before designing the 30-b/d-plant, Nippon Oil studied the configuration of the catalyst circulation system of the HS-FCC using a cold flow model. The catalyst circulation system is critical technology in the design of an FCC. Nippon Oil then sent researchers to jointly operate the plant at Ras Tanura.

Saudi Aramco’s role
Saudi Aramco’s main involvement occurred during the second phase of the project, ensuring a natural scale-up progression from the laboratory scale at KFUPM to a commercial unit at a refinery complex. Saudi Aramco also participated in the experimental set-up. Different runs in the downer-type pilot plant and the demonstration plant using different catalysts and feeds such as hydrotreated vacuum gas oil (VGO), untreated VGO and hydrotreated residue (fuel oil) were carried out. Saudi Aramco also continues to be an active participant in the licensing, marketing and commercialization activities.

Meeting the challenges
There were challenges along the way, Fujiyama said, as the partners collaborated on various phases of the project.

“FCC is a fluidization process; it is the first time a Japanese petroleum company has developed such a process,” he said. “In a fluidization process, catalyst moves. Scale-up is more difficult than with a fixed bed process.

“It was also challenging to initiate a joint research project with Saudi Arabia. The situation and culture were completely different.”

Al-Tayyar said his experience with the process was beneficial as well as educational.

“I would personally consider my interactions with the Japanese as enriching and constructive. I have learned a lot about the Japanese culture and their unique way of doing business,” he said. “I also observed how quickly our Japanese colleagues were able to acclimate easily and smoothly to Saudi Arabian culture. Moreover, these interactions allowed me to foster great friendships with the team that continue to grow stronger with each day of progress.”

Fujiyama said the project is significant to the industry and the companies involved.

“The HS-FCC commercial unit will be the first application of fluidized down-flow reactor technology,” he said.

Combined expertise
Nippon Oil has experience developing FCC auxiliary equipment and processes such as magnetic separation of FCC catalyst. However, the development of the HS-FCC is the first full FCC technology development by Nippon Oil and Japan. This is also the first major technology development of a refinery process by Saudi Aramco and Saudi Arabia.

In recognition of these achievements, the consortium received the prestigious Japanese Noguchi Memorial Award on May 17, 2007, for “fundamental or applied research in the area of petroleum alternatives, residual oil upgrading technology in petroleum refining and developments in utilization of light oil, thereby rendering outstanding service in promoting technological progress in the petroleum industry.”

It was the first time the award was presented to organizations outside of Japan.

“The award came as a pleasant surprise,” said Saudi Aramco’s Research and Development Center Manager Omar S. Abdul-Hamid, emphasizing the significance the center placed on technology that integrates refining and petrochemical manufacturing.

Like most initiatives the team faced several challenges, one of which was the language barrier.

“The alliance members represent diverse countries ranging from Saudi Arabia, Japan, France and the United States,” Al-Tayyar said. “It was a major challenge to conduct design reviews and agreement meetings with this diverse multilingual group. However, this diversity also enriched the experience of working on this type of project.”

Moving ahead
A conventional FCC licensor and engineering contractor have been invited to participate in the commercial application of HS-FCC and to develop a design package for the 40,000-b/d-plant. Nippon Oil, Saudi Aramco, JCCP and KFUPM are the HS-FCC core technology owners. The licensor will be able to sell the commercial HS-FCC in other countries.

Saudi Aramco is interested in selecting this process wherever the technology may be applicable in their existing or grass-root refineries.

To strengthen and sustain their relationship of mutually beneficial cooperation, further cooperation is under way on “Advanced Hydrocracking Catalyst Technology for Saudi Arabian Heavy Feed,” a project JCCP will be implementing in Saudi Arabia with the research center of Saudi Aramco and Nippon Oil as its partners.

As for lasting impressions from his work on this project, Fujiyama, who lived in Saudi Arabia during Phase II to operate the 30-b/d-plant, said, “I was really impressed when I saw the start-up of the 30-b/d-plant, which we designed. Also, living in Saudi Arabia was a rare experience for a Japanese.”

“I believe that we, as a team, have set a new precedent of high standard cooperation for similar projects. The great respect, appreciation and cooperation that we have for each other has been apparent throughout my personal involvement in the project,” Al-Tayyar said. “Although we are a very diverse group, we have still managed to find commonalities to aid us in moving forward. It is a great opportunity to be involved in such a project with such a dynamic talented group of individuals.”

Fujiyama had advice for anyone embarking on similar projects.

“At the start of a project, it is very difficult to get others interested,” he said. “The person who drives the project must have determination to do everything by himself. After times goes on, the person will find brothers. At that time, he has to share the work with the brothers; he must not try to keep everything in his hands.”