GRASSROOTS FCC AND CYCLOFINES™

COMPLETE SUCCESSFUL FOUR YEAR

INAUGURAL CAMPAIGN

Authors:
Brian A. Cunninham - ExxonMobil Research and Engineering Company
Jacob J. Thiart - ExxonMobil Research and Engineering Company
Robert Peterson - KBR

Publication / Presented:
NPRA Paper AM-03-74 to be presented at 2003 NPRA Annual Meeting in San Antonio, TX

Date:
March 23-25, 2003
 Annual Meeting
March 23-25, 2003
Marriott Rivercenter Hotel
San Antonio, TX

AM-03-74 Grassroots FCC and Cyclofines™ Complete

Successful Four Year Inaugural Campaign

Presented By:

Brian A. Cunninham
Advanced Engineering
Associate
ExxonMobil Research
and Engineering
Company
Fairfax, VA

Jacob J. Thiart
FCC Licensing Group
Head
ExxonMobil Research
and Engineering
Company
Fairfax, VA

Robert Peterson
KBR
Houston, TX

National Petrochemical & Refiners Association 1899 L Street, NW 202.457.0480 voice

Suite 1000 202.429.7726 fax
Washington, DC www.npra.org
20036.3896
This paper has been reproduced for the author or authors as a courtesy by the National
Petrochemical & Refiners Association. Publication of this paper does not signify that the
contents necessarily reflect the opinions of the NPRA, its officers, directors, members, or staff.
Requests for authorization to quote or use the contents should be addressed directly to the
author(s)
 NPRA Paper AM-03-74

To be presented at the
2003 NPRA Annual Meeting in San Antonio, TX
March 23-25, 2003

Title
Grassroots FCC and Cyclofines™ Complete Successful Four Year Inaugural Campaign

Abstract
Advancements in technology were incorporated by the KBR/Mobil design team in ExxonMobil's
Altona Fluid Catalytic Cracking (FCC) unit, and resulted in a low cost, mechanically robust, and
operationally friendly FCC unit. The new FCC unit, which was brought on line in late 1997, has
improved the profitability of the Australian refinery by improving its conversion capability and
crude diet flexibility. Emissions from the new FCC unit have been controlled by a Cyclofines™
third stage separator (TSS) system, which is the first of a kind.

The grassroots Orthoflow™ FCC unit at ExxonMobil's Altona, Australia Refinery completed its
very successful first run after four years on line. The unit's operation met all objectives including
availability, capacity, and yields, through the end of the run, without any significant incidents or
major mechanical issues. The FCC regenerator has operated well in both full and partial
combustion modes.

The turnaround inspection showed key technology components of the unit, including the
ATOMAX-1TM feed nozzles, Closed Cyclones Riser Termination system, and CyclofinesTM third
stage separator, to be in excellent condition, with only minimal wear.

The Cyclofines™ third stage separator at Altona was the first grassroots application of the
Cyclofines™ technology, and proved to be extremely robust in operation and in mechanical
design. During its inaugural run the unit handled a wide range of catalyst loadings varying
between normal operation and high loading events -- including at least one large catalyst
carryover. After four years of service the Cyclofines™ unit showed no damage or measurable
wear. Following the turnaround, it was returned to service without any maintenance or repair.

The success of the inaugural campaign can be attributed to a collaborative team approach to
design and operation. Refinery personnel and technical specialists in both ExxonMobil and
KBR have supported design, start-up, and ongoing operation.

Authors
Brian Cunningham and Jacob Thiart, ExxonMobil Research and Engineering Company, Fairfax,
VA

Bob Peterson, KBR, Houston, TX

John Mullaly, Mobil Oil Australia, Altona, Australia

AM-03-74
Page 1
Background

ExxonMobil's Altona Refinery provides fuels and chemicals feed stocks to the Australia and
Asia Pacific markets. In 1994, a project was initiated to upgrade the capabilities and flexibility of
the refinery by retiring the small, aging Thermofor Catalytic Cracking (TCC) unit, which had
been in service since the 1950s, and replacing it with a larger, modern Fluid Catalytic Cracking
(FCC) unit. A new Kellogg Brown and Root (KBR) OrthoFlow™ FCC unit (Figure 1) was
constructed and started up in 1997, giving the refinery improved operating flexibility and
profitability. The FCC unit completed its inaugural run in late 2001, capping an extremely
successful 49.5 month run, characterized by high unit availability, high throughput, and yields
that exceeded plan. The FCC unit completed its inaugural run without any shutdowns for
mechanical work.

The primary drivers for changing technology from TCC to FCC were to increase gasoline
producing capacity, provide refinery crude diet flexibility, and to decrease fuel oil production.
The Altona refinery configuration limited the refinery feed diet to a small number of crudes.
Acceptable crudes needed to be low in both sulfur and heavy metals, and contain limited high
boiling range material. In addition, local pipeline crude sources were in decline, and raw
material feedstock costs were projected to increase. Conversion to FCC technology increased
the refinery's crude diet flexibility, while accomplishing the other yield objectives.

Plot space limitations at the Altona refinery put a premium on minimizing the footprint of the
proposed FCC unit, and the tight refining margins in Australia dictated that the project minimize
investment cost. The KBR Orthoflow™ FCC technology was an excellent fit for these
objectives. The stacked configuration of the Orthoflow™ FCC unit not only requires less plot
space than side-by-side alternatives, but also reduces total installed cost, since the stacked
reactor / regenerator can be transported in a single piece, and can be erected on site in a single
lift.

The Altona Refinery is located in a suburb of Melbourne, adjacent to a residential area that has
grown around it. The new Orthoflow™ FCC unit had to meet new environmental performance
standards for the area, which required particulate emissions from the FCC unit stack of less
than 100 mg/Nm3.

In addressing environmental concerns during the early phases of the project, the team looked
for novel and cost effective ways to meet the stringent emissions limits. The newly developed
Cyclofines™ TSS technology for particulate emissions control was an excellent fit for this
application, and Altona became the first commercial application of the Cyclofines™ TSS
technology. In addition, the low NOx emissions that are characteristic of the Orthoflow™ FCC
unit's counter current regenerator design, further reduced the environmental impact of the new
FCC unit.

Technology Features of the Altona OrthoFlow™ FCC unit

The Altona Orthoflow™ FCC was equipped with a number of reaction specific advances,
including the patented ATOMAX-1™ feed injection system, riser reactor technology, and
Closed Cyclone Riser Termination technology.

The Orthoflow™ catalyst regenerator uses countercurrent contacting, employing a unique spent
catalyst distributor, and multiple pipe grid air distributors for optimum catalyst regeneration.

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In addition, the Orthoflow™ FCC unit utilizes a stacked reactor / regenerator, which minimizes
plot space, and requires a simpler support structure than a side-by-side unit.

The Orthoflow™ unit design addresses a number of common mechanical trouble areas by using
fewer expansion joints, pipe grid air distributors, a completely external riser, cold wall cyclone
plenum chambers, and unrestrained cyclone support systems. These features come with
unmatched cold wall and refractory lining experience.

The value of the advanced process and mechanical features were proven by excellent yields
throughout the run, along with robust operation, and a minimal number of mechanical issues
uncovered during the first turnaround.

Features of the Cyclofines™ Third Stage Separator (TSS)

The Cyclofines™ Third Stage Separator (TSS) is an advanced small cyclone tertiary cyclone
system developed for control of fine particulate emissions.

ExxonMobil Research and Engineering Company (EMRE, formerly Mobil Technology Company)
and KBR jointly developed the CyclofinesTM (TSS) as part of a long-standing FCC technical
alliance. CyclofinesTM technology represents a major step forward in TSS technology,
employing improved small diameter cyclones to achieve net fine particle capture efficiency
better than the other cyclonic systems available on the market. The first grassroots commercial
CyclofinesTM TSS was constructed for ExxonMobil's Altona FCC unit (Figure 2).

In developing the CyclofinesTM TSS system, studies showed that small, horizontally mounted,
and lightly loaded cyclone systems were often troubled by cyclone vortices that extended
beyond the cyclone barrels. In these cases, while the individual cyclones could operate at high
capture efficiencies, in-situ performance was less than expected, due to re-entrainment of
collected particles from the cyclones located higher in the vessel back into the cyclones located
directly below (1,2). This theory was supported by inspection observations from older small
horizontal cyclone TSSs that had been in operation for several years. In these older TSSs, we
found a swirling erosion pattern cut into the refractory wall opposite the solids discharge,
indicating the presence of the vortex outside of the cyclone barrel.

Vertical cyclones may suffer from a similar but less severe problem. Catalyst discharging from
these cyclones will be thrown outwards towards the extending vortices of adjacent cyclones
where it may then be re-entrained.

These important factors were considered in the design of the Cyclofines™ TSS cyclone system.
The cyclones are designed to be mounted vertically and include containment of the vortex
inside the individual cyclone bodies. Actual measurement of the vortex size in full-scale test
cyclones at expected operating conditions allowed the design team to establish the design
parameters of the Cyclofines™ TSS cyclones with greater confidence.

The Altona CycloFinesä TSS was built using vertically mounted, small diameter cyclones, which
incorporate a proprietary solids outlet device to prevent the undesired re-entrainment. The
diameter of the TSS vessel containing the cyclones and plenum is approximately 7.6 m (or 25

AM-03-74
Page 3
ft). This was based on a future expansion case, which involves the addition of a catalyst cooler
to the FCC unit, and results in a 200+% increase in the flue gas volume handling capacity of the
TSS. The TSS was designed to maintain particulate emissions below 100 mg/Nm3 even in the
expansion case. To handle the increased volume, both the number of cyclones and their gas
handling capacity would increase, yet the barrel size would remain the same. Figure 3 is a
simplified layout drawing of the internal plenum and cyclone arrangement for the Altona
Cyclofines™ TSS.

Performance of Altona OrthoFlow™ FCC and CycloFines™ TSS units during First
Campaign

OrthoFlow™ FCC Performance

The Altona FCC unit was designed to operate at a fresh feed rate of 23,000 BPD, and over a
range of conversions from 48 to 82 LV% conversion. The unit reached the design rate shortly
after start-up, and has averaged above design rate since then (Figure 4). The unit has operated
near or above the top end of the design conversion rates, with the combined impact of
increasing refinery gasoline and LPG yields significantly (Figure 5).

During the first run of the Altona FCC unit, it operated nearly continuously, with close to 100%
availability. Short oil outages occurred as the result of non-FCC equipment and events (steam
system problems, etc.). The only FCC generated shutdowns were as the result of an operator
generated trip, and when a problem developed with one of the catalyst (circulation controlling)
plug valves. These oil outs were brief, and the unit was returned to service without incident.
None of the oil outages required removing the catalyst from the unit or opening the main FCC
vessels.

The successful operation of the FCC unit was due in part to good collaboration between the
operating and technical personnel in the refinery, and technical support staff from ExxonMobil's
Asia Pacific and USA offices, and from KBR's USA office.

CycloFines™ TSS Performance

The Altona Cyclofines™ TSS was subjected to a wide range of catalyst loads as the result of
normal operations and upset conditions in the FCC unit. Base line stack opacity normally ran
between 7% and 12%. The Cyclofines™ also proved itself capable of dealing with the wide
range of loads presented, without damage or forcing the shutdown of the FCC unit under
conditions that might have caused the shutdown of other units. Three abnormal catalyst loss
incidents occurred which resulted in overloading of the Cyclofines™ unit.

Catalyst Loss Incident 1

Shortly after the start-up of the FCC unit, the main air blower shut down due to a plugged inlet
strainer on the steam turbine. When the unit was re-streamed a day later, it was found that one
of the three air distributors was plugged. This resulted in a massive catalyst entrainment
problem most likely due to a second stage dipleg being sealed in an unfluidized area of the
catalyst bed.

AM-03-74
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The problem persisted for approximately 5 hours during which time, the loss rates from the
regenerator exceeded 3.5 metric tons per hour. This represents a severe test of the robustness
of the Cyclofines™ TSS design.

Figure 6 is a plot of the actual plant data from this period of time. The loss rate was determined
by the weight gain in the Fourth Stage Separator (FSS) hopper, while the TSS performance can
be inferred from the opacity measurements at the stack.

These data clearly show that the CycloFines™ TSS handled the large catalyst surges without
plugging or loss of performance. Any plugging in the third stage separator would have resulted
in flooded cyclones accompanied by a large increase in opacity. Over the 5 hour period of the
upset, the opacity remained nearly constant and even decreased slightly, clearly indicating
sustained performance during the upset.

Towards the end of the upset, the FSS hopper reached its maximum holding capacity, which did
result in a flooded FSS cyclone, and a rapid increase in opacity. The underflow from the third
stage separator was stopped as soon as the problem was determined, and the opacity returned
to normal.

Following the second start up, a preliminary dust survey was conducted to determine gross TSS
efficiency. The survey results showed that the Altona CycloFinesä TSS was operating with a
capture efficiency of 90%, which easily met required levels of performance (19 mg/Nm3 actual
vs. 50mg/Nm3 from the TSS).

Stack tests conducted later in the year as part the refinery's compliance testing, also confirmed
the preliminary results. The particulate emissions were measured as 45 mg/Nm3. The average
particle size of the collected particulate was 2.9 microns with almost nothing larger than 10
microns. These results are very encouraging, since they include the material not collected by
the Fourth Stage Separator -- a conventional large diameter cyclone used to clean the TSS
underflow. Fourth stage efficiencies are around 90%, and would account for the presence of
the small number of 10 micron size particles in the stack sample.

A second round of tests was conducted the following year. The three tests conducted
confirmed the CycloFines™ TSS efficiency to be 90-91% as originally predicted, and in
agreement with the surveys following initial start-up. Outlet loadings during these tests were in
the range of 7.3 - 10.3 mg/Nm3, well below the target range. During this test program, the FCC
unit experienced an emergency shutdown. The use of torch oil during the restart led to
increased catalyst fines production, resulting in a slight increase in loadings to the TSS for the
second test. By the start of the third test, the inlet loadings approached the levels of the first
test.

Catalyst Loss Incident 2

Midway through the first run of the Altona FCC, a sudden rapid increase in stack opacity was
observed. The problem was traced to an internal failure in the primary steam distributor for the

AM-03-74
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catalyst stripper. This failure occurred suddenly and resulted in a rapid increase in catalyst fines
generation through attrition. The stack opacity from the very fine material increased until the
primary stripping steam rate was decreased.

Stack testing close to the time of the upset indicated that losses to the stack were as high as
490 mg/Nm3 (Figure 7) for a short period of time. The unit was kept on line and operating
smoothly, and was returned to design performance by adjusting operations and taking
advantage of the secondary stripping steam distributor.

The Cyclofines™ unit operated as expected, capturing all the coarse material, but also as
expected it did not capture the large volume of very fine material generated by a large
unconstrained high velocity steam jet in the catalyst stripper bed. The unit operated
successfully for more than two years in this condition.

Catalyst Loss Incident 3

Approximately one year before the end of the run, an increase in catalyst losses from the
regenerator cyclone system (Figure 7) was noted. Prior to this, the baseline losses were 0.3
tonnes/day. Losses rapidly increased to approximately 5 tonnes/day. Analysis showed that the
losses were full range particle size material as indicated by an average particle size (APS) of
approximately 45 microns in the Cyclofines™ fines catch. At the same time the APS of the
catalyst in the circulating inventory increased from 74 to 85 micron.

This resulted in increased stack opacity and circulation problems, due to the loss of fines and
the concentration of the larger particles in the equilibrium catalyst (E-Cat). To manage the
losses the regenerator superficial velocity was constrained. The Cyclofines™ TSS unit handled
the increase in catalyst load and the upset conditions without problems with opacity, and loss
rates returning to normal. Stack testing during this period did show an increase in stack losses,
until the problem was isolated and addressed.

These observations indicated that the root cause of the problem was the regenerator second
stage cyclones, most likely dipleg plugging. This conclusion was borne out by turnaround
inspection findings, as discussed below.

Turnaround Findings

The Orthoflow™ FCC unit performed well throughout its first run, and there were no significant
surprises uncovered during the first turnaround. Wear to the cyclones, catalyst transfer lines,
catalyst circulation control plug valves, and other normal wear areas was as expected.

· The cyclones in both the reactor and regenerator were in good mechanical condition with
only minimal wear. No repairs were required.
· The disengager vessel was clean with only minor coke deposits in the dome.
· The ATOMAX-1™ feed injectors were in good condition, with minimal tip erosion. The
nozzles were upgraded during the turnaround to ATOMAX-2™ technology, as planned.

AM-03-74
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Condition of Cyclofines™ Third Stage Separator (TSS)

Turnaround inspections revealed no significant damage or wear in the unit, and no repairs were
required prior to re-streaming of the unit. The cyclone elements were in "as new" condition
(Figure 8), with machining marks still evident. There was no plugging of any of the elements, or
an indication of uneven flow patterns. There was some superficial cracking in some of the
vessel refractory, which did not require repair.

Regenerator Secondary Cyclone Dipleg Plugging

Inspection of the regenerator cyclones revealed that one of the secondary cyclone diplegs had
indeed plugged, although it was not with refractory as initially suspected. The plugging appears
to have been caused by catalyst depositing around the bottom of the dustbowls and within the
diplegs, restricting the dipleg openings, and one dipleg was completely plugged (Figure 9, 10).

The deposits, which formed in the dustbowl area, were extremely hard and refractory like in
external appearance. A cross section of the deposit revealed a grain, similar to growth rings in a
tree, suggesting the deposit had formed over a considerable period of time. The outside
surface was rough, appearing to have been scoured and pitted by the circulating gas in the
cyclone.

The nature of the deposits changed somewhat from the dust bowl area to the area inside the
diplegs. The deposits found in diplegs looked like a solidified liquid, which had been flowing
down the dipleg pipe (Figure 11). These deposits also had the appearance of being formed in
layers. However, unlike the deposits in the dust bowls, they were soft and easily crumbled
returning to a powder of E-Cat fines.

It was concluded that the deposits in the dust bowls and diplegs were the result of:
· The cyclone diplegs were very lightly loaded, as the result of low superficial velocity in
the regenerator. This led to low dipleg flux rate, and very little scrubbing action in the
dipleg.
· The presence of a high level of fines as the result of an attrition source in the catalyst
stripper. This led to poor flow properties of the catalyst in the diplegs.

Stripping Steam Distributor Failure

The failure in the stripping steam distributor, the one item that had the largest impact on ongoing
operation, was apparently the result of an undetected fabrication flaw (Figure 12).

AM-03-74
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Conclusions

The grassroots Orthoflow™ FCC unit at ExxonMobil's Altona, Australia Refinery completed its
very successful first run after four years on line. The unit's operation met all objectives including
availability, capacity, and yields, through the end of the run, without any significant incidents or
major mechanical issues.

The Cyclofines™ third stage separator at Altona was the first grassroots application of the
Cyclofines™ technology, and proved to be extremely robust in operation and in mechanical
design. During its inaugural run the unit handled a wide range of catalyst loadings varying
between normal operation and high loading events.

The turnaround inspection showed key technology components of the Altona Orthoflow™ FCC
and Cyclofines™ TSS units to be in excellent condition, with only minimal wear.

The Altona Orthoflow™ FCC and Cyclofines™ TSS units have proven themselves to be reliable
workhorse units during their inaugural four year run. While a few minor problems did develop
during this run, they were less common and less severe than the problems typically observed
on most new units, and did not force premature shutdown of the FCC unit.

Opacity monitoring and stack testing after the turnaround have shown that after repairing the
small problems encountered during the first run (stripping steam distributor failure and
unplugging the cyclone diplegs), the particulate emissions have returned to baseline levels.

References

1. Chitnis, G.K., Schatz, K.W., and Bussey, B.K.; "Improved High Efficiency Third Stage
Separator for Separation of Fines from Fluid Catalytic Cracking Flue Gas"; Fifth World
Congress of Chemical Engineering, July 14-18, 1996, San Diego, California.
2. Raterman, M., Chitnis, G.K., Holtan, T., and Bussey, B.K.; "A Post Audit of the New
Mobil/M.W.Kellog Cyclofines™ Third Stage Separator"; 1998 NPRA Annual Meeting, Paper
AM-98-19, San Francisco, California.

AM-03-74
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Figure 1 - The Altona Orthoflow™ FCC Unit

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Figure 2 - Altona Cyclofines ™ Third Stage Separator

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Figure 3 - Altona Cyclofines™ Third Stage Separator Arrangement

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 Figure 4 - Altona FCC Throughput History for First Run Cycle

33
Avg. FCC Throughput (KBD)

31
29
27
25
23
21
19
17
15
98

00
99

01
7

1
-0
-9

-9
n-

n-
b-

b-
ct

ct

ct
Ju

Ju
Fe

Fe
O

O
Figure 5 - Altona FCC Cracked LPG and Cracked Gasoline Production Pre/Post
Implementation of Orthoflow™ FCC Project

16

14

12
Product Rate (KBD)

10 Decommissioning
of TCC and Start-
8 up of FCC

0
1992 1993 1994 1995 1996 1997 1998 1999 2000 2001

Cracked LPG Production Cracked Gasoline Production

AM-03-74
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 Figure 6 - Altona FCC Unit Operation During First Restart

80
4 Stack Opacity Flow to 4th Stage 70
Flow to Fourth Stage,

60
3
Tons / hour

50

Opacity
40
2
30

20
1
10

0 0
8:00 14:0
TIME

Figure 7 - Altona FCC Unit Stack Emissions Test Results

500 50
Stack Emissions (mg/Nm3)

450 Dipleg 45
Impact of
400 Plugging 40
Stripping Steam
350 Failure 35

% Opacity
300 30
250 25
200 20
150 15
100 10
50 5
0 0
May-96 Sep-97 Feb-99 Jun-00 Nov-01 Mar-03

mg/Nm3 Opacity

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Figure 8- Interior View of Altona Cyclofines™ Cyclone After Four Year Run

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 Figure 9 - Regenerator Secondary Cyclone Dipleg Plugging

Figure 10 - Samples of Regenerator Secondary Cyclone Dust Bowl Deposits

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 Figure 11 - Samples of Regenerator Secondary Cyclone Dipleg Deposits

Figure 12 - Catalyst Stripping Steam Distributor Failure Due to Mechanical Flaw

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