Fcctoc15

TABLE OF CONTENTS Section 1

Introduction ................................................................................................................ 1‐1

Section 2

Executive Summary .................................................................................................... 2‐1

Section 3

Market and Environmental Legislation Status and Trends .......................................... 3‐1

3.1 3.1.1 3.1.2

3.2 3.2.1 3.2.2

3.3

Section 4 4.1 4.1.1 4.1.2 4.1.3 4.1.4

4.2 4.2.1 4.2.2 4.2.3 4.2.4 4.2.5 4.2.6

4.3

Section 5 5.1

Market Conditions ...................................................................................................................... 3‐1 Regional Changes in Transportation Fuel Demand ....................................................................................... 3‐1 Evolving Propylene Supply and Demand Situation ........................................................................................ 3‐7 Environmental Legislation and Regulations ............................................................................... 3‐10 Specifications for Transportation Fuels ....................................................................................................... 3‐10 Emissions from FCC Units ............................................................................................................................ 3‐12 Conclusion ................................................................................................................................ 3‐13

FCC Patent Analysis .................................................................................................... 4‐1 Global Patent Activities (2008‐2014) ........................................................................................... 4‐2 Annual Global Patent Counts ......................................................................................................................... 4‐2 Patent Counts for Global Regions .................................................................................................................. 4‐2 Patent Counts for Individual Companies ....................................................................................................... 4‐3 Patent Counts for Specific Application Categories ........................................................................................ 4‐5 Applications Covered by Patents of Specific Companies .............................................................. 4‐7 Representation of Patents from Major Companies by Application Groups .................................................. 4‐7 Group 1 Applications – FCC Product Yields and Qualities ........................................................................... 4‐10 Group 2 Applications – Energy and the Environment ................................................................................. 4‐12 Group 3 Applications – FCC Alternative Feed Sources ................................................................................ 4‐14 Group 4 Applications – FCC Catalysts and Additives ................................................................................... 4‐16 Group 5 Applications – FCC Operations....................................................................................................... 4‐17 Summary and Discussion .......................................................................................................... 4‐19

Patent Technology Themes ......................................................................................... 5‐1 Group 1 Applications – FCC Product Yields and Qualities ............................................................. 5‐1

5.1.1 Gasoline Yield ................................................................................................................................................ 5‐1 5.1.1.1 Process ................................................................................................................................................. 5‐1 5.1.1.2 Catalysts ............................................................................................................................................... 5‐2 5.1.2 Gasoline Reformulation ................................................................................................................................. 5‐3 5.1.2.1 Process ................................................................................................................................................. 5‐3 5.1.2.2 Catalyst ................................................................................................................................................ 5‐6 5.1.3 LCO Yield and Quality .................................................................................................................................... 5‐8 5.1.3.1 Process ................................................................................................................................................. 5‐8 5.1.3.2 Catalyst ................................................................................................................................................ 5‐9 5.1.4 Light Olefins Yield ........................................................................................................................................ 5‐10 5.1.4.1 Process and/or Hardware .................................................................................................................. 5‐10 5.1.4.2 Catalysts and Additives ...................................................................................................................... 5‐17

5.2 5.2.1 5.2.2 5.2.3

Group 2 Applications – Energy and the Environment ................................................................. 5‐22 Energy Management ................................................................................................................................... 5‐22 GHG Emissions ............................................................................................................................................. 5‐24 SNOX Emissions ............................................................................................................................................ 5‐26

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5.3 5.3.1 5.3.2 5.3.3

5.4 5.4.1 5.4.2

5.5 5.5.1 5.5.2 5.5.3 5.5.4 5.5.5 5.5.6

5.6

Section 6 6.1

Group 3 Applications – FCC Alternative Feeds ........................................................................... 5‐33 Resid Processing .......................................................................................................................................... 5‐34 Biofeeds ....................................................................................................................................................... 5‐39 Paraffinic Hydrocarbons .............................................................................................................................. 5‐43 Group 4 Applications – FCC Catalysts and Additives .................................................................. 5‐43 Catalyst Formulation/Preparation .............................................................................................................. 5‐43 Additives ...................................................................................................................................................... 5‐46 Group 5 Applications – FCC Operations ..................................................................................... 5‐47 Catalyst Management/Addition .................................................................................................................. 5‐47 Feed Injection .............................................................................................................................................. 5‐49 Catalyst Separation/Stripping ..................................................................................................................... 5‐50 Catalyst Regeneration/Cooling ................................................................................................................... 5‐53 Product Fractionation/Recovery ................................................................................................................. 5‐57 Process Control ........................................................................................................................................... 5‐57 Summary and Discussion .......................................................................................................... 5‐59

Gap Analysis to Identify Technical Challenges & Business Opportunities ..................... 6‐1 Volatile Oil Prices and Shift in Crude Supply and Demand Fundamentals .................................... 6‐2

6.1.1 Processing Heavy, Aromatic Crudes .............................................................................................................. 6‐5 6.1.1.1 Current Technology Status ................................................................................................................ 6‐10 6.1.1.1.1 Commercial RFCC Processes ......................................................................................................... 6‐12 6.1.1.1.2 Commercial RFCC Catalysts........................................................................................................... 6‐14 6.1.1.2 R&D Works to Capture Future Business Opportunities .................................................................... 6‐19 6.1.2 Processing Paraffinic, Contaminant‐laden Tight Oil .................................................................................... 6‐21 6.1.2.1 FCC Metal Contaminants and Product Quality .................................................................................. 6‐21 6.1.2.1.1 Current Technology Status ........................................................................................................... 6‐22 6.1.2.1.2 R&D Works to Capture Future Business Opportunities ................................................................ 6‐24 6.1.2.2 Maintaining FCC Heat Balance .......................................................................................................... 6‐25 6.1.2.2.1 Current Technology Status ........................................................................................................... 6‐25 6.1.2.2.2 R&D Works to Capture Future Business Opportunities ................................................................ 6‐27 6.1.2.3 Lack of VGO Feedstocks ..................................................................................................................... 6‐28 6.1.2.3.1 Current Technology Status ........................................................................................................... 6‐29 6.1.2.3.2 R&D Works to Capture Future Business Opportunities ................................................................ 6‐29 6.1.2.4 Improving Octane Quality .................................................................................................................. 6‐30 6.1.2.4.1 Current Technology Status ........................................................................................................... 6‐30 6.1.2.4.2 R&D Works to Capture Future Business Opportunities ................................................................ 6‐31 6.1.3 Processing Dumbbell Crudes ....................................................................................................................... 6‐31 6.1.3.1 Current Technology Status ................................................................................................................ 6‐32 6.1.3.2 R&D Works to Capture Future Business Opportunities .................................................................... 6‐32 6.1.4 Processing Waxy Feeds ............................................................................................................................... 6‐33 6.1.4.1 Current Technology Status ................................................................................................................ 6‐34 6.1.4.2 R&D Works to Capture Future Business Opportunities .................................................................... 6‐35

6.2 6.2.1 6.2.2

6.3

Processing Biofeeds in FCCUs .................................................................................................... 6‐36 Current Technology Status .......................................................................................................................... 6‐37 R&D Works to Capture Future Business Opportunities .............................................................................. 6‐39 Changes to Product Demand and Fuel Specifications ................................................................ 6‐41

6.3.1 Global Gasoline and Diesel Imbalance ........................................................................................................ 6‐41 6.3.1.1 Maximize LCO Yield ........................................................................................................................... 6‐46 6.3.1.1.1 Current Technology Status ........................................................................................................... 6‐47 6.3.1.1.2 R&D Works to Capture Future Business Opportunities ................................................................ 6‐52

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6.3.1.2 Improving the Quality of LCO Coming from the FCCU ....................................................................... 6‐54 6.3.1.2.1 Current Technology Status ............................................................................................................ 6‐55 6.3.1.2.2 R&D Works to Capture Future Business Opportunities ................................................................ 6‐56 6.3.1.3 Flexibly Changing the Proportions of FCC Products ........................................................................... 6‐56 6.3.1.3.1 Current Technology Status ............................................................................................................ 6‐57 6.3.1.3.2 R&D Works to Capture Future Business Opportunities ................................................................ 6‐59 6.3.2 Increasingly Stringent Gasoline Standards .................................................................................................. 6‐60 6.3.2.1 Gasoline Sulfur Reduction .................................................................................................................. 6‐61 6.3.2.1.1 Current Technology Status ............................................................................................................ 6‐61 6.3.2.1.2 R&D Works to Capture Future Business Opportunities ................................................................ 6‐63 6.3.2.2 Gasoline Benzene Reduction .............................................................................................................. 6‐65 6.3.2.2.1 Current Technology Status ............................................................................................................ 6‐65 6.3.2.2.2 R&D Works to Capture Future Business Opportunities ................................................................ 6‐66 6.3.3 Surplus of Naphtha ...................................................................................................................................... 6‐66 6.3.3.1 Sending Naphtha to Second Riser ...................................................................................................... 6‐69 6.3.3.1.1 Current Technology Status ............................................................................................................ 6‐69 6.3.3.1.2 R&D Works to Capture Future Business Opportunities ................................................................ 6‐69 6.3.3.2 Oligomerization of Light Naphtha ...................................................................................................... 6‐70 6.3.3.2.1 Current Technology Status ............................................................................................................ 6‐70 6.3.3.2.2 R&D Works to Capture Future Business Opportunities ................................................................ 6‐73 6.3.3.3 Alkylation of Heavy Naphtha and Aromatics ..................................................................................... 6‐77 6.3.3.3.1 Current Technology Status ............................................................................................................ 6‐77 6.3.3.3.2 R&D Works to Capture Future Business Opportunities ................................................................ 6‐78 6.3.4 Increasing Demand for Propylene ............................................................................................................... 6‐78 6.3.4.1 Current Technology Status ................................................................................................................. 6‐80 6.3.4.2 R&D Works to Capture Future Business Opportunities ..................................................................... 6‐87 6.3.5 Increasing Demand for Butylenes ................................................................................................................ 6‐91 6.3.5.1 Current Technology Status ................................................................................................................. 6‐92 6.3.5.2 R&D Works to Capture Future Business Opportunities ..................................................................... 6‐93 6.3.6 Increasing Demand for BTX ......................................................................................................................... 6‐94 6.3.6.1 Current Technology Status ................................................................................................................. 6‐96 6.3.6.2 R&D Works to Capture Future Business Opportunities ..................................................................... 6‐97 6.3.7 Reducing Residual Fuel Oil Demand ............................................................................................................ 6‐98 6.3.7.1 Current Technology Status ................................................................................................................. 6‐98 6.3.7.2 R&D Works to Capture Future Business Opportunities ................................................................... 6‐100

6.4

Unit Design Advances to Improve Operational Efficiency for Higher Profitability ..................... 6‐102

6.4.1 Catalyst Management ................................................................................................................................ 6‐102 6.4.1.1 Catalyst/Additive Addition ............................................................................................................... 6‐102 6.4.1.1.1 Current Technology Status .......................................................................................................... 6‐103 6.4.1.1.2 R&D Works to Capture Future Business Opportunities .............................................................. 6‐103 6.4.1.2 Catalyst Rejuvenation ...................................................................................................................... 6‐104 6.4.1.2.1 Current Technology Status .......................................................................................................... 6‐104 6.4.1.2.2 R&D Works to Capture Future Business Opportunities .............................................................. 6‐105 6.4.1.3 Controlling Catalyst Activity and Selectivity ..................................................................................... 6‐106 6.4.1.3.1 Current Technology Status .......................................................................................................... 6‐106 6.4.1.3.2 R&D Works to Capture Future Business Opportunities .............................................................. 6‐109 6.4.2 Feed Injection ............................................................................................................................................ 6‐109 6.4.2.1 Current Technology Status ............................................................................................................... 6‐109 6.4.2.2 R&D Works to Capture Future Business Opportunities ................................................................... 6‐111 6.4.3 Catalyst Separation/Stripping .................................................................................................................... 6‐113 6.4.3.1 Current Technology Status ............................................................................................................... 6‐113 6.4.3.2 R&D Works to Capture Future Business Opportunities ................................................................... 6‐116

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6.4.4 Catalyst Regeneration/Cooling ................................................................................................................. 6‐119 6.4.4.1 Current Technology Status .............................................................................................................. 6‐119 6.4.4.2 R&D Works to Capture Future Business Opportunities .................................................................. 6‐121 6.4.5 Product Fractionation/Recovery ............................................................................................................... 6‐124 6.4.5.1 Current Technology Status .............................................................................................................. 6‐125 6.4.5.2 R&D Works to Capture Future Business Opportunities .................................................................. 6‐127 6.4.6 Process Control and Simulation ................................................................................................................ 6‐127 6.4.6.1 Current Technology Status .............................................................................................................. 6‐127 6.4.6.2 R&D Works to Capture Future Business Opportunities .................................................................. 6‐130

6.5

Improving Energy Efficiency and Reducing CO2 Emissions ....................................................... 6‐131

6.5.1 Energy Management ................................................................................................................................. 6‐131 6.5.1.1 Current Technology Status .............................................................................................................. 6‐133 6.5.1.2 R&D Works to Capture Future Business Opportunities .................................................................. 6‐136 6.5.2 Carbon Capture ......................................................................................................................................... 6‐137 6.5.2.1 Current Technology Status .............................................................................................................. 6‐137 6.5.2.2 R&D Works to Capture Future Business Opportunities .................................................................. 6‐140

6.6

Increasingly Stringent Emissions Standards ............................................................................. 6‐143

6.6.1 SOX Emissions Reduction ........................................................................................................................... 6‐144 6.6.1.1 Current Technology Status .............................................................................................................. 6‐144 6.6.1.2 R&D Work to Capture Future Business Opportunities .................................................................... 6‐146 6.6.2 NOX Emissions Reduction .......................................................................................................................... 6‐147 6.6.2.1 Current Technology Status .............................................................................................................. 6‐147 6.6.2.2 R&D Works to Capture Future Business Opportunities .................................................................. 6‐148 6.6.3 PM Emissions Reduction ........................................................................................................................... 6‐150 6.6.3.1 Current Technology Status .............................................................................................................. 6‐150 6.6.3.2 R&D Works to Capture Future Business Opportunities .................................................................. 6‐151

6.7

Rising Catalyst Manufacturing Costs ....................................................................................... 6‐151

6.7.1 Use of Rare Earths ..................................................................................................................................... 6‐151 6.7.1.1 Current Technology Status .............................................................................................................. 6‐153 6.7.1.2 R&D Works to Capture Future Business Opportunities .................................................................. 6‐154 6.7.2 Improved Catalyst and Additive Manufacturing Efficiency ....................................................................... 6‐154 6.7.2.1 Current Technology Status .............................................................................................................. 6‐154 6.7.2.2 R&D Works to Capture Future Business Opportunities .................................................................. 6‐156

6.8

Section 7

Conclusion .............................................................................................................................. 6‐160

SWOT Analysis of FCC Technology............................................................................... 7‐1

7.1

Strengths .................................................................................................................................... 7‐2

7.2

Weaknesses ............................................................................................................................... 7‐6

7.3

Opportunities ............................................................................................................................. 7‐9

7.4

Threats ..................................................................................................................................... 7‐13

7.5

Conclusion ................................................................................................................................ 7‐28

Section 8 8.1

Predicting Technology Trends and identifying R&D Opportunities .............................. 8‐1 Focuses of Significant Patents (from 2000 to 2014) ..................................................................... 8‐2

8.1.1 Resid and Heavy Oil Processing ..................................................................................................................... 8‐2 8.1.1.1 Process and Hardware ......................................................................................................................... 8‐3 8.1.1.2 Catalysts and Additives ...................................................................................................................... 8‐14

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8.1.2 Biofeeds and Fischer‐Tropsch Feeds ........................................................................................................... 8‐27 8.1.2.1 Biofeeds .............................................................................................................................................. 8‐28 8.1.2.1.1 Process and Hardware ................................................................................................................... 8‐28 8.1.2.1.2 Catalysts ........................................................................................................................................ 8‐32 8.1.2.2 Fischer‐Tropsch Feeds ........................................................................................................................ 8‐33 8.1.3 Gasoline Yield and Quality ........................................................................................................................... 8‐33 8.1.3.1 Gasoline Yield ..................................................................................................................................... 8‐33 8.1.3.1.1 Process and Hardware ................................................................................................................... 8‐37 8.1.3.1.2 Catalysts and Additives .................................................................................................................. 8‐39 8.1.3.2 Octane Quality ................................................................................................................................... 8‐41 8.1.3.2.1 Process and Hardware ................................................................................................................... 8‐43 8.1.3.2.2 Catalysts and Additives .................................................................................................................. 8‐46 8.1.3.2.2.1 Catalysts ................................................................................................................................. 8‐47 8.1.4 Gasoline Reformulation ............................................................................................................................... 8‐49 8.1.4.1 Gasoline Sulfur Reduction .................................................................................................................. 8‐49 8.1.4.1.1 Process and Hardware ................................................................................................................... 8‐50 8.1.4.1.2 Catalysts and Additives .................................................................................................................. 8‐53 8.1.4.2 Gasoline Olefins Reduction ................................................................................................................ 8‐61 8.1.4.2.1 Process and Hardware ................................................................................................................... 8‐61 8.1.4.2.2 Catalysts ........................................................................................................................................ 8‐64 8.1.5 Light Olefins Yield ........................................................................................................................................ 8‐66 8.1.5.1 Process and Hardware ....................................................................................................................... 8‐67 8.1.5.2 Catalysts and Additives ...................................................................................................................... 8‐79 8.1.6 LCO Yield and Quality .................................................................................................................................. 8‐91 8.1.6.1 Improving LCO Yield ........................................................................................................................... 8‐91 8.1.6.1.1 Process and Hardware ................................................................................................................... 8‐92 8.1.6.1.2 Catalysts and Additives .................................................................................................................. 8‐94 8.1.6.2 Improving LCO Quality ....................................................................................................................... 8‐98 8.1.6.2.1 Process and Hardware ................................................................................................................... 8‐98 8.1.6.2.2 Catalyst and Additives ................................................................................................................... 8‐99 8.1.7 FCC Operations .......................................................................................................................................... 8‐100 8.1.7.1 Catalyst Management/Addition ....................................................................................................... 8‐100 8.1.7.2 Feed Injection ................................................................................................................................... 8‐105 8.1.7.3 Catalyst Separation and Disengagement ......................................................................................... 8‐106 8.1.7.4 Catalyst Stripping ............................................................................................................................. 8‐109 8.1.7.5 Catalyst Regeneration/Cooling ........................................................................................................ 8‐110 8.1.7.6 Process Monitor, Control, and Simulation ....................................................................................... 8‐114 8.1.8 Energy Management and CO2 Emissions ................................................................................................... 8‐116 8.1.8.1 Energy Management ........................................................................................................................ 8‐116 8.1.8.2 GHG Emissions Reduction ................................................................................................................ 8‐120 8.1.9 SOX, NOX, and PM Emissions ...................................................................................................................... 8‐123 8.1.9.1 Process and Hardware ..................................................................................................................... 8‐123 8.1.9.2 Catalysts and Additives .................................................................................................................... 8‐129 8.1.9.2.1 SOX Emissions Reduction ............................................................................................................. 8‐133 8.1.9.2.2 NOX Emissions Reduction ............................................................................................................ 8‐136 8.1.9.2.3 Combined SOX and NOX Emissions Reduction ............................................................................. 8‐140 8.1.9.2.4 CO Promoters with or without NOX Removal .............................................................................. 8‐141 8.1.9.2.5 PM Emissions Reduction ............................................................................................................. 8‐143 8.1.10 Catalyst Manufacturing ......................................................................................................................... 8‐147 8.1.10.1 Efficient Manufacturing to Lower Production Costs ........................................................................ 8‐147 8.1.10.2 Methods of Preparing Improved Catalysts and Additives ................................................................ 8‐148 8.1.10.3 Analysis and Testing of Catalysts ..................................................................................................... 8‐151

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8.2 8.2.1 8.2.2

8.3

Analysis of Patenting Trends, and Predictions ......................................................................... 8‐152 Processes and Hardware (5 predictions)................................................................................................... 8‐152 Catalysts and Additives (5 predictions) ..................................................................................................... 8‐157 Conclusion .............................................................................................................................. 8‐163

Section 9

Strategic Analysis and Recommendations ................................................................... 9‐1

9.1

Recommendations for Global Refiners Operating FCC Units (15 recommendations) .................... 9‐2

9.2

Recommendations for FCC Technology Providers (15 recommendations) .................................. 9‐26

9.3

Conclusion ................................................................................................................................ 9‐65

Section 10

References ............................................................................................................ 10‐1

Section 11

Index ..................................................................................................................... 11‐1

11.1

Company/Institution ................................................................................................................ 11‐1

11.2

Subject ..................................................................................................................................... 11‐6

Section 12

Appendix: List of Patents (2000‐2014) ................................................................... 12‐1

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LIST OF TABLES Table 2-1 2-2 2-3 3.1-1 3.1-2 3.2-1 3.2-2 3.2-3 4.2-1 6.1-1 6.1-2 6.1-3 6.1-4 6.1-5 6.1-6 6.1-7 6.1-8 6.1-9 6.1-10 6.2-1 6.2-2 6.3-1 6.3-2 6.3-3 6.3-4 6.3-5 6.3-6 6.3-7 6.3-8 6.3-9 6.3-10 6.3-11 6.3-12 6.3-13 6.3-14 6.3-15 6.3-16 6.3-17 6.3-18 6.3-19 6.3-20

Title Worldwide Fuel Specifications FCCU Regenerator Emission Targets Internal and External Factors Facing FCC Units in Future Refinery Operations Global Slurry Oil Consumption, 2008 Worldwide Installed Steam Cracking Capacity in 2013 Worldwide Fuel Specifications IMO Bunker Fuel Sulfur Limits FCCU Regenerator Emission Targets Application Directions for FCC Patents from Major Companies US Crude Imports by Country of Origin 2005-2014 2014 US Refinery Coking Capacity by Refinery Region N2 Distribution in FCC Products from Processing Various Feeds Summary of Commercially Available RFCC Processes Summary of Commercially Available RFCC Catalysts and Additives Summary of Common Contaminant Metals in Tight Oil and Potential Processing Problems FCC Catalysts and Additives Applicable for Tight Oil Processing Operational and Hardware Adjustments for Maintaining FCC Heat Balance Options Available to Maintain FCC Heat Balance when Processing Tight Oil and Potential Concerns Fractions of Waxy Crudes Compared to Other Sources Summary of Biofeeds Potentially Useful for FCC Summary of Renewable FCC Technologies US Refined Product Exports, 2005-2014 Shift in Gasoline-to-Diesel Demand Ratio by Region Global Trades of Light Distillates (Gasoline & Naphtha) Global Trades of Middle Distillates (Gasoil & Kerosene) Impact of Operation on LCO Production Summary of Various Process and Catalyst Technologies that Maximize FCC LCO Production Summary of Various Catalyst Technologies that Maximize FCC LCO Production Worldwide Diesel Specifications Worldwide Gasoline Specifications Benzene Concentration in Gasoline vs. Propylne Modes of Operation Comparison of Properties of Tight Oil and Other Global Crudes Incremental Enhancement Augmentation of Diesel Production Olefin Oligomerization Catalyst Patents Olefin Oligomerization Process Patents Aromatics Alkylation Process Patents Impact of Design Adjustments on FCCU in High Olefin Mode Options to Enhance Propylene Yield from FCC Summary of Commercially Available Processes for Maximizing Light Olefins Summary of Commercially Available FCCU Catalysts and Additives for Olefin Production Applications for FCC Slurry Oil

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Page 2-5 2-6 2-10 3-5 3-9 3-12 3-12 3-13 4-9 6-4 6-7 6-11 6-12 6-15 6-22 6-23 6-26 6-26 6-34 6-37 6-39 6-42 6-44 6-45 6-46 6-49 6-50 6-51 6-55 6-60 6-65 6-68 6-72 6-75 6-76 6-78 6-82 6-83 6-83 6-86 6-99

Table 6.4-1 6.4-2 6.4-3 6.4-4 6.4-5 6.4-6 6.4-7 6.4-8 6.4-9 6.5-1 6.5-2 6.5-3 6.5-4 6.6-1 6.6-2 6.6-3 6.6-4 6.6-5 6.7-1 6.7-2 6.8-1 7-1 7.1-1 7.1-2 7.1-3 7.2-1 7.2-2 7.2-3 7.4-1 8.1-1 8.1-2 8.1-3 8.1-4 8.1-5 8.1-6 8.1-7 8.1-8 8.1-9 8.1-10 8.1-11 8.1-12 8.1-13 8.1-14 8.1-15

Title Summary of Commercially Available FCC Feed nozzles Summary of Commercial Separators and Disengagers Offered by Licensors Summary of Commercial Strippers Offered by Licensors Regenerator Configuration Options Differences Between Partial and Full Regeneration Modes Summary of Commercial FCC Regenerators Offered by Licensors FCC Gas Plant Revamp Opportunities Summary of Commercially Available Advanced Control Systems Summary of Commercially Available FCC Process Modeling and Simulation Systems Sources of Inefficiency in Fluid Catalytic Cracking Summary of Technology Options for Improving FCCU Energy Efficiency Most-likely FCC Unit Capture Method Summary of Ongoing CCU Projects Worldwide FCCU Regenerator Emissions Targets Hardware Options for Emissions Reduction Effect of Operational Variables on FCC SOX Emissions Summary of SOX Reducing Catalysts and Additives Summary of NOX Reducing Catalysts and Additives Effect of Rare Earth Content and Prices on Overall FCC Catalyst Costs Low Rare-Earth FCC Catalyst Offerings Summary of FCC Patent Gap Analysis Internal and External Factors Facing FCC Units in Future Refinery Operations US Gasoline Blending Pool Components Properties Estimated Utility Consumption and Capital Costs for FCC vs. Hydrocracker Average Energy Consumption for US Refinery FCCUs and Hydrocrackers, 2005 FCC LCO Quality vs. EU and North American Diesel Specs Steam Cracker Product Yields Based on Feedstock Average CO2 Emissions from Sources within a 250K-b/d US Refinery Biofuels Demand Growth by Region, 2013-2018 Current Process and Hardware Solutions to Crack Resid and Heavy Oil A Comparison of Current FCC Process and Hardware Solutions to Produce Gasoline A Comparison of Current FCC Catalyst and Additive Solutions to Produce Gasoline A Comparison of Current FCC Process Solutions to Increase Gasoline octane A Comparison of Current FCC Catalyst and Additive Solutions to Increase Gasoline Octane A Comparison of Current FCC Catalyst and Additive Solutions to Lower FCC Gasoline Sulfur A Comparison of Current FCC Procecss and Hardware Solutions to Lower FCC Gasoline Olefins Content A Comparison of Current FCC Catalyst and Additive Solutions to Lower FCC Gasoline Olefins Content A Comparison of Current and Potential Process and Hardware Solutions to Produce Propylene A Comparison of Current FCC Process Solutions to Produce LCO A Comparison of Current FCC Catalyst and Additive Solutions to Produce LCO Improvements In FCC Productivity and Energy Efficiency Potential Methods to Reduce FCCU CO2 Emissions A Comparison of Current Process and Hardware Solutions to Reduce FCC Emissions A Comparison of Current and Potential Catalyst and Additive Solutions to Reduce Emissions

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Page 6-110 6-114 6-115 6-120 6-120 6-121 6-126 6-127 6-129 6-132 6-134 6-139 6-142 6-143 6-144 6-145 6-145 6-148 6-153 6-154 6-160 7-1 7-3 7-5 7-5 7-7 7-7 7-9 7-24 8-3 8-34 8-39 8-42 8-46 8-54 8-61 8-64 8-67 8-92 8-95 8-117 8-120 8-123 8-130

Table 9.1-1 9.1-2 9.1-3 9.1-4 9.2-1 9.2-2 9.2-3 9.2-4 9.2-5 9.2-6

Title Market and Environmental Challenges Facing FCC Refineries in Various Global Regions US Refinery Coking Capacity and FCC Capacity Capable of Processing Light Tight Oil, 2014 Effect of FCCU Modifications on Key Gasoline Reformulation Targets SWOT Analysis for Global Refiners Operating FCC Units Catalysts and Additives Offered by Major FCC Catalyst Suppliers Summary of Commercially Available FCC Catalysts Summary of Commercially Available FCC Additives Processes, Hardware, and Internals Offered by Major FCC Technolgy Suppliers Processes Technologies Offered by Major Refining Technolgy Suppliers SWOT Analysis for FCC Technology Providers

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Page 9-3 9-7 9-8 9-26 9-32 9-33 9-34 9-36 9-37 9-64

LIST OF FIGURES Figure 2-1 2-2 2-3 2-4 2-5 2-6 3.1-1 3.1-2 3.1-3 3.1-4 3.1-5 4.1-1 4.1-2 4.1-3 4.1-4 4.1-5 4.2-1 4.2-2 4.2-3 4.2-4 4.2-5 4.2-6 4.2-7 4.2-8 4.2-9 4.2-10 4.2-11 6-1 6.1-1 6.1-2 6.3-1 6.3-2 6.3-3 6.3-4 7.5-1 9-1 9-2 9.1-1 9.1-2 9.1-3 9.1-4 9.1-5

Title Regional Light Distillates Consumption, 2010-2014 Regional Middle Distillates Consumption, 2010-2014 Regional Light vs. Middle Distillates Consumption Ratio, 2005-2014 Regional Fuel Oil Consumption, 2005-2014 A FCC Perpetual Profit Cycle Interworking of Patent, GAP, and SWOT Analysis to Help Future FCC Operations Regional Light Distillates Consumption, 2010-2014 Regional Middle Distillates Consumption, 2010-2014 Regional Light vs. Middle Distillates Consumption Ratio, 2005-2014 Regional Fuel Oil Consumption, 2005-2014 Product Yields from Various Steam Cracker Feedstocks, wt% Annual Global Counts of Issued FCC Patents, 2008-2014 Regional Counts of Issued FCC Patents, 2008-2014 Company Counts of Issued FCC Patents, 2008-2014 Applications for 2008-2014 Issue Dates Categorical Distributions of Catalyst and Additive Patents, 2008-2014 Issue Dates Distributions of Patents from Major Companies across the Applications Groups Company Patent Counts for Group 1 Applications with Issue Dates during 2008-2014 Company Distributions of Patent Coverage over Group 1 Application Categories, Issue Dates 2008-2014 Company Patent Counts for Group 2 Applications with Issue Dates during 2008-2014 Company Distributions of Patent Coverage over Group 2 Application Categories, Issue Dates 2008-2014 Company Patent Counts for Group 3 Applications with Issue Dates during 2008-2014 Company Distributions of Patent Coverage between Group 3 Application Categories, Issue Dates 2008-2014 Company Patent Counts for Group 4 Applications with Issue Dates during 2008-2014 Company Distributions of Patent Coverage between Group 4 Application Categories, Issue Dates 2008-2014 Company Patent Counts for Group 5 Applications with Issue Dates during 2008-2014 Company Distributions of Patent Coverage Among Group 5 Application Categories, Issue Dates 2008-2014 Factors Influencing FCC Technological Advancements Worldwide Crude API Gravity Projections, 2010-2035 Worldwide Crude Sulfur Content Projections, 2010-2035 Effects of FCC Catalyst Formulation on Reactions, Product Mix Foster Wheeler's Zero Gasoline Refinery Method for Producing Diesel from FCC Naphtha and Olefins Potential Routes for Converting Naphtha to Diesel Turning Threats into Opportunities for FCC Technology An FCC Perpetual Profit Cycle Interworking of Patent, GAP, and SWOT Analysis to Help Future FCC Operations US Refinery Major Process Upsets, 2010-2014 Causes of FCCU Upsets at US Refineries, 2010-2014 Failed Hardware/Equipment Causing FCCU Upsets at US Refineries, 2010-2014 Effects of FCCU Upsets at US Refineries, 2010-2014 Net Profit Loss due to Unplanned FCC Shutdown

x Copyright Š Hydrocarbon Publishing Company, Inc. All Rights Reserved.

Page 2-2 2-2 2-3 2-4 2-12 2-12 3-2 3-2 3-3 3-6 3-8 4-2 4-3 4-4 4-6 4-7 4-8 4-10 4-11 4-12 4-13 4-14 4-15 4-16 4-17 4-18 4-19 6-2 6-6 6-6 6-51 6-71 6-71 6-73 7-29 9-1 9-2 9-20 9-21 9-22 9-23 9-24

Figure 9.2-1 9.2-2 9.2-3 9.2-4 9.2-5 9.2-6 9.2-7 9.2-8 9.2-9 9.2-10 9.2-11 9.2-12 9.2-13 9.2-14 9.2-15 9.2-16 9.2-17 9.2-18

Title Distribution of Patents from Major Companies across Application Groups, 2008-2014 UOP Patents by FCC Application, 2008-2014 Sinopec Patents by FCC Application, 2008-2014 Grace Patents by FCC Application, 2008-2014 ExxonMobil Patents by FCC Application, 2008-2014 Albemarle Patents by FCC Application, 2008-2014 Petrobras Patents by FCC Application, 2008-2014 Saudi Aramco Patents by FCC Application, 2008-2014 BASF Patents by FCC Application, 2008-2014 INTERCATJM Patents by FCC Application, 2008-2014 Shell Patents by FCC Application, 2008-2014 Major Patent Holders (Refiners), 2008-2014 Major Patent Holders (Catalyst Suppliers), 2008-2014 Major Patent Holders (Process Developers), 2008-2014 Licensing Companies FCC Completed Projects, 1998-2014 Licensing Companies FCC Future Projects, 2015 and beyond FCC Completed and Future Projects, 1998 and beyond Licenser Market Share of FCC Completed and Future Projects, 1998 and beyond

xi Copyright Š Hydrocarbon Publishing Company, Inc. All Rights Reserved.

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