PTQ Q1 2026 Issue

Catalyst emissions normalised to the unit design emission value

Date

Empirical correlation

PM by opacity estimation

Date

1st regenerator

2nd regenerator

Total

(kg/kg)

(kg/kg)1

(kg/kg)

11/12 13/12

0.34 0.30

0.48 0.42

11/12 13/12

0.40 0.34

0.32 0.28

0.34 0.30

Table 2

1 Catalyst emissions normalised with the emission design value per unit.

Reactor catalyst losses to slurry oil obtained with ash content analysis

Table 1

Reactor catalyst losses to slurry oil obtained with empirical correlations

Date

SLR ashes by balance and analysis (wt%)

Ash in SLR calculated

by blend (kg/kg)1

Date

Reactor (kg/kg)

12/12 TK 205

0.104

0.45

11/12 13/12

0.35 0.54

1 Ash in slurry normalised to the reactor emissions design value.

Table 4

Table 3

• Cyclones in the reactor disengager were replaced. • Cyclones in the first regenerator were changed from a 4x1 configuration to a 2x2 configuration. Based on these bespoke technological improvements, the following parameters are analysed: • Reduction of catalyst emissions as particulate material through the CO boiler. • Reduction of catalyst emissions as ash in the slurry oil waste stream. • Reduced consumption of medium-pressure steam. • Increase in residual feed processing capacity and its impact on the performance of the unit, as well as on the yields of slurry oil and dry gas. • Evaluation of new unit operating constraints. To carry out a comparative analysis without interference, process simulator results calibrated using data from the unit test run discussed in the following section will be rep- resented for comparison under equivalent conditions. Performance results Between December 11, 2024 and December 14, 2024, a three-day test run was carried out on the RFCC unit with the following considerations: • Design throughput with a resid blend coming from the vacuum distillation unit. Feedstock properties and operating conditions differ from the previous operation, which is why iso-conditions were required to carry out the impact assessment. First, the calibration of a thermodynamic simulator using test run data from two different software was performed. Then, the model response to changing the feedstock and operat- ing conditions was evaluated against the response from a pre-revamp period, followed by a comparison of the results with the real-time data of that period. The result of the catalyst emissions reduction through the CO boiler was analysed by the following alternative methods: u Catalyst emissions simulated with empirical equa- tions : According to the correlation model, based on • First day at lowest severity. • Last day at highest severity.

operational data and analysis of the equilibrium catalyst, the average emitted losses of the double-stage cyclones of the first regenerator and the external cyclones of the sec- ond regenerator for 13/12 and 11/12 are estimated (see Table 1 ). v Catalyst emissions estimated with the opacity meter: Catalyst entrainment is obtained with the opacity meter and estimation of the total catalyst emissions in the CO boiler stack (see Table 2 ). Nevertheless, the opacity measure for the period 2022- 2023, on average, is equivalent to 1.31 kg/kg, correspond- ing to a comparative reduction of 45% to 65%. Reduction of catalyst emissions: SLR stream The result of the catalyst emissions as ash in the slurry oil (SLR) stream is analysed by three alternative methods: u Catalyst emissions simulated with empirical equations : According to the correlation model and the LD2 operation estimations provided by Axens, the average emitted losses of the reactor cyclones for 13/12 and 11/12 are estimated based on operational data and analysis of the equilibrium catalyst (see Table 3 ). v Catalyst emissions calculated with ash content in SLR stream : With the analysis of ash in the blended tanks, the density of the slurry and the average flow rate of the sam- pling period are obtained (see Table 4 ). The value obtained in the blend is similar to that obtained by the operating correlations of LD2 and the reactor cyclones. Compared to the unit design, the ash content in the SLR at the end of the 2023 period is in the order of 1.5 times, higher associated with the end-of-life cycle. After the tech- nological modifications, a reduction of 45% to 65% com- pared to the original design is obtained.  Total catalyst losses by catalyst inventory mass bal- ance : By evaluating the catalyst inventory of the unit, which includes the total inventory variation, catalyst injection rate, and catalyst discharge rate, the total catalyst losses are obtained, i.e. the sum of the losses through the CO boiler and the ash in the slurry.

PTQ Q1 2026