Transcript Slide 1

Refining & Petrochemicals
Technology Solutions
through Integrated Optimisation
Matthew Lippmann
UOP LLC, A Honeywell Company
Iraq Refinery 2012
April 17-18
London, England
© 2012 UOP LLC. All rights reserved.
UOP 5794-1
Agenda
 Market Overview
 Why Integrate?
 Maximum Fuels to Maximum Petrochemicals
UOP 5794-2
Petrochemical Demand Soars
into the Future
Light Olefin Demand
Paraxylene Demand
10
years
20
20,000
10,000
 90 million MTA of incremental light
olefins needed over next 10 years
20
18
2020
20
10
12
20
08
06
04
02
2010
20
20
20
20
00
2000
20
98
96
94
1990
20
2020
19
2010
19
2000
19
1990
92
90
0
19
0
0
16
50
30,000
20
100
40
40,000
14
150
100%
Increase!
50,000
20
200
60
60,000
20
Propylene
Ethylene
19
250
70,000
MTA
Million
pX Demand, kMTA
MTA
Million
million tpa
300
 Annual demand growth of 6.7%
u
Additional Need for “On
Purpose” Propylene
Demand of pX Projected
to Double Over the
Next 10 Years!
UOP 5794-3
Ethylene Cracker Feedstock is
Variable by Region
100%
90%
80%
Percent
70%
60%
50%
40%
30%
20%
10%
0%
North
America
Ethane
South Europe
America
Propane
CIS &
Baltic
States
n-Butane
Middle Northeast Southeast
East/
Asia
Asia
Africa
Naphtha
Gasoil
Other
Source: CMAI 2011 World Ethylene Cost Study
Feedstock Selection Depends
on Regional Feedstock Availability
UOP 5794-4
Ethylene Production Costs are Increasing
Ethylene Cash Cost Curve
1,050
Ethylene CCOP $/MT
Middle East
850
North America
NE Asia
SE Asia
Refinery
Integration
Source: CMAI
2009 Curve:
February 10,
2010 Asia
Light Olefins
Market
Advisory
Service
(Graphical
Analysis)
2004 Curve:
2005 World
Light Olefins
Analysis
2009
Western Europe
650
450
2004
250
50
0
20
40
60
80
Feedstock Price
Increasing
100
120
140
160
Cumulative Ethylene Capacity (million tons)
Offset Higher Feedstock Costs through Proper Refinery
Integration
UOP 5794-5
Major Oil Companies Recognize
Value of Integration
Percent of Ethylene Capacity Integrated with a Refinery
by Same Company in Europe
90%
74%
39%
24%
BP
Shell
Total
ExxonMobil
Source: Morgan Stanley
Trend Towards More Integrated Complexes
is Increasing
UOP 5794-6
Why Integrate?
Secure reliable
feedstock supply
at reduced cost
Increase
product
valuation
Refinery
Processes
Other Advantages:
 Reduced Shipping Costs
 Reduced Tankage Costs
 Common Offsites / Utilities
 Common Maintenance / Admin
 Upgrade of byproduct streams
Petrochemical
Processes
Leverage Synergies to Maximize Product Values
Lowers Operating & Capital Costs
UOP 5794-7
What is Refinery-Petrochemical Integration?
Fuel Gas
Refinery
Processes
Light Naphtha/
LPG
$600/Te
$800/Te
$880/Te
Heavy Naphtha
Reformate
Distillate
$870/Te
$900/Te
UOP 5794-8
What is Refinery-Petrochemical Integration?
Fuel Gas
Refinery
Processes
$600/Te
Petrochemical
Processes
Light Naphtha/
LPG
$800/Te
C2=/C3=
$1,500/Te
$880/Te
Heavy Naphtha
BZ/pX
Reformate
Distillate
$870/Te
$1,200/Te
$900/Te
Refinery Optimization
UOP 5794-9
What is Refinery-Petrochemical Integration?
Fuel Gas
Refinery
Processes
$600/Te
Petrochemical
Processes
Light Naphtha/
LPG
$800/Te
C2=/C3=
$1,500/Te
$880/Te
Heavy Naphtha
BZ/pX
Reformate
Distillate
$870/Te
$1,200/Te
$900/Te
Integrated Complex Optimization
Optimize Quantity and Quality of Intermediate Streams
Select the Right Technology Solutions for the
Integrated Complex
UOP 5794-10
Maximum Fuels to Maximum Petrochemicals
Case Study
 400 KBPD FCC Based Complex
– Case 1: Traditional Fuels Refinery
– Case 2: Fuels Refinery with BTX Complex
– Case 3: Maximum Petrochemical Refinery
– Case 4: Integrated Refinery – Petrochemical Complex
– Case 5: Integrated Refinery – Petrochemical Complex
– No Fuels
UOP 5794-11
Integration Example:
FCC Based Complex Case 1
Light Naphtha/LPG
F. G.
Heavy Naphtha
Gasoline
CDU
CCR
Platforming
Unit
Distillate
LCN HCN
Crude
Distillate
UnionfiningTM
Unit
Gasoline
Mode
FCC
Unit
VDU
Delayed
Coking
Diesel
LCO
Pitch
CSO
UOP 5794-12
Integration Example Yields:
FCC Based Complex Case 1
$22
50%
Product Yield (Wt-%)
40%
Gasoline
LPG
$20
41%
$18
$16
35%
35%
$14
30%
$12
25%
20%
Net Margin = Product Values – Feedstock Cost –
Variable Costs – Fixed Costs
18%
$10
$8
15%
$6
10%
5%
$4
6%
Net Margin = Net Margin – Capital Charges
Less Capital
Net Operating Margin ($/BBL)
Fuel/Coke
Distillate
45%
$2
0%
$0
Low Severity
FCC Unit
(Fuels)
Case 1
Case 2
Case 3
Case 4
Case 5
UOP 5794-13
Integration Example Yields:
FCC Based Complex Case 1
$22
50%
Product Yield (Wt-%)
40%
Gasoline
LPG
$20
41%
$18
$16
~75% Fuels
35%
35%
$14
30%
$12
25%
20%
$10
Net Margin
18%
$8
15%
$6
10%
5%
$4
Net Margin
Less Capital
6%
Net Operating Margin ($/BBL)
Fuel/Coke
Distillate
45%
$2
0%
$0
Low Severity
FCC Unit
(Fuels)
Case 1
Case 2
Case 3
Case 4
Case 5
Traditional Refinery Produces ~75%
Transportation Fuels
UOP 5794-14
Integration Example:
FCC Based Complex Case 1
Light Naphtha/LPG
F. G.
Heavy Naphtha
Gasoline
CDU
CCR
Platforming
Unit
Distillate
LCN HCN
Crude
Distillate
Unionfining
Unit
Gasoline
Mode
FCC
Unit
VDU
Delayed
Coking
Diesel
LCO
Pitch
CSO
UOP 5794-15
Integration Example:
FCC Based Complex Case 2
Light Naphtha/LPG
C3=
Recovery
C3=
Heavy Naphtha
Gasoline
CDU
CCR
Platforming
Unit
Distillate
Aromatics
Complex
LCN HCN
Crude
Distillate
Unionfining
Unit
Med
Severity
FCC
Unit
VDU
Delayed
Coking
Raffinate
Bz
pX
Diesel
LCO
Pitch
CSO
UOP 5794-16
Integration Example Yields:
FCC Based Complex Case 1
$22
50%
Product Yield (Wt-%)
40%
Gasoline
LPG
$20
41%
$18
$16
35%
35%
$14
Delta
Net Margin
30%
$12
25%
$10
20%
18%
$8
15%
10%
5%
$6
Net Margin
Less
6%Capital
$4
Net Operating Margin ($/BBL)
Fuel/Coke
Distillate
45%
$2
0%
$0
Low Severity
FCC Unit
(Fuels)
Case 1
Case 2
Case 3
Case 4
Case 5
UOP 5794-17
Integration Example Yields:
FCC Based Complex Case 2
$22
50%
Product Yield (Wt-%)
40%
Fuel/Coke
Distillate
43%
Gasoline
LPG
BTX
C3=
$20
41%
$18
$16
35%
35%
$14
Delta
Net Margin
30%
$12
25%
20%
$10
21%
18%
$8
15%
10%
5%
Net Margin
Less
6%Capital
$6
13%
11%
9%
$4
3%
+16% BTX + C3=
Net Operating Margin ($/BBL)
45%
$2
0%
$0
Low Severity
FCC Unit
(Fuels)
Med Severity
FCC Unit
BTX Complex
Case 1
Case 2
Case 3
Case 4
Case 5
FCC Severity and BTX Complex Converts 16% of
Gasoline Into Higher Value Petrochemicals
UOP 5794-18
Integration Example:
FCC Based Complex Case 2
Light Naphtha/LPG
C3=
Recovery
C3=
Heavy Naphtha
Gasoline
CDU
CCR
Platforming
Unit
Distillate
Aromatics
Complex
LCN HCN
Crude
Distillate
Unionfining
Unit
Med
Severity
FCC
Unit
VDU
Delayed
Coking
Raffinate
Bz
pX
Diesel
LCO
Pitch
CSO
UOP 5794-19
Integration Example:
FCC Based Complex Case 3
Light Naphtha/LPG
C3=
Recovery
C3=
Heavy Naphtha
Gasoline
CDU
CCR
Platforming
Unit
Distillate
Aromatics
Complex
LCN HCN
Crude
Distillate
Unionfining
Unit
RxProTM
High C3=
FCC Unit
VDU
Delayed
Coking
LCO
Raffinate
Bz
pX
Diesel
LCO
Unicracking
Unit
Pitch
CSO
UOP 5794-20
Integration Example Yields:
FCC Based Complex Case 2
$22
50%
Fuel/Coke
Distillate
43%
Gasoline
LPG
BTX
C3=
$20
$18
Product Yield (Wt-%)
40%
$16
35%
30%
$14
Delta
Net Margin
$12
25%
$10
21%
20%
$8
15%
10%
5%
Net Margin
Less
Capital
$6
13%
11%
9%
$4
Net Operating Margin ($/BBL)
45%
$2
3%
0%
$0
Low Severity
FCC Unit
(Fuels)
Med Severity
FCC Unit
BTX Complex
Case 1
Case 2
Case 3
Case 4
Case 5
UOP 5794-21
Integration Example Yields:
FCC Based Complex Case 3
$22
50%
43%
BTX
C3=
$20
41%
40%
Product Yield (Wt-%)
Gasoline
LPG
Fuel/Coke
Distillate
$18
$16
35%
30%
$14
Delta
Net Margin
$12
25%
$10
21%
21%
20%
$8
15%
15%
$6
13%
10%
5%
Net Margin
Less
Capital
11%
9%
10%
6%
7%
+6% BTX + C3=
3%
0%
$4
Net Operating Margin ($/BBL)
45%
$2
$0
Low Severity
FCC Unit
(Fuels)
Med Severity
FCC Unit
BTX Complex
RxPro
FCC Unit
BTX Complex
LCO UC Unit
Case 1
Case 2
Case 3
Case 4
Case 5
RxPro FCC and LCO Unicracking Unit Shifts Product
Yields Towards BTX and C3=
UOP 5794-22
Integration Example:
FCC Based Complex Case 3
Light Naphtha/LPG
C3=
Recovery
C3=
Heavy Naphtha
Gasoline
CDU
CCR
Platforming
Unit
Distillate
Aromatics
Complex
LCN HCN
Crude
Distillate
Unionfining
Unit
RxPro
High C3=
FCC Unit
VDU
Delayed
Coking
LCO
Raffinate
Bz
pX
Diesel
LCO
Unicracking
Unit
Pitch
CSO
UOP 5794-23
Integration Example:
FCC Based Complex Case 4
C2=/C3=
Recovery
Light Naphtha/LPG
C2=/C3=
Steam
Cracker
Heavy Naphtha
PyGas
CDU
CCR
Platforming
Unit
Distillate
Aromatics
Complex
LCN HCN
Crude
Distillate
Unionfining
Unit
RxPro
High C3=
FCC Unit
VDU
Delayed
Coking
LCO
Raffinate
Bz
pX
Diesel
LCO
Unicracking
Unit
Pitch
CSO
UOP 5794-24
Integration Example Yields:
FCC Based Complex Case 3
$22
50%
C3=
$20
$18
$16
35%
30%
$14
Delta
Net Margin
$12
25%
$10
21%
20%
$8
15%
15%
10%
5%
$6
10%
Net Margin
Less
Capital
6%
$4
7%
Net Operating Margin ($/BBL)
BTX
41%
40%
Product Yield (Wt-%)
Gasoline
LPG
Fuel/Coke
Distillate
45%
$2
0%
$0
Low Severity
FCC Unit
(Fuels)
Med Severity
FCC Unit
BTX Complex
RxPro
FCC Unit
BTX Complex
LCO UC Unit
Case 1
Case 2
Case 3
Case 4
Case 5
UOP 5794-25
Integration Example Yields:
FCC Based Complex Case 4
$22
50%
C3=
BTX
C2=
$20
41%
$18
$16
35%
30%
$14
Delta
Net Margin
$12
25%
23%
20%
5%
$8
17%
15%
15%
10%
$10
21%
+4% C2=
10%
Net Margin
Less
Capital
6%
7%
8%
7%
$6
$4
4%
Net Operating Margin ($/BBL)
41%
40%
Product Yield (Wt-%)
Gasoline
LPG
Fuel/Coke
Distillate
45%
$2
0%
$0
Low Severity
FCC Unit
(Fuels)
Med Severity
FCC Unit
BTX Complex
RxPro
FCC Unit
BTX Complex
LCO UC Unit
Case 1
Case 2
Case 3
RxPro
FCC Unit
BTX Complex
LCO UC Unit
Steam Cracker
Case 4
Steam Cracker Integration Enables
Entry Into C2= Market
Case 5
UOP 5794-26
Integration Example:
FCC Based Complex Case 4
C2=/C3=
Recovery
Light Naphtha/LPG
C2=/C3=
Steam
Cracker
Heavy Naphtha
PyGas
CDU
CCR
Platforming
Unit
Distillate
Aromatics
Complex
LCN HCN
Crude
Distillate
Unionfining
Unit
RxPro
High C3=
FCC Unit
VDU
Delayed
Coking
LCO
Raffinate
Bz
pX
Diesel
LCO
Unicracking
Unit
Pitch
CSO
UOP 5794-27
Integration Example:
FCC Based Complex Case 5
C2=/C3=
Recovery
Light Naphtha/LPG
C2=/C3=
Steam
Cracker
Heavy Naphtha
PyGas
CDU
Raffinate
CCR
Platforming
Unit
Distillate
Aromatics
Complex
LCN HCN
Bz
pX
Crude
Hvy
Lt
Naph Naph
RxPro
High C3=
FCC Unit
VDU
Delayed
Coking
LCO
Full Conv
Distillate
Unicracking Unit
Pitch
CSO
UOP 5794-28
Integration Example Yields:
FCC Based Complex Case 4
$22
Fuel/Coke
Distillate
45%
Gasoline
LPG
41%
40%
Product Yield (Wt-%)
C3=
BTX
C2=
$18
$16
35%
30%
$20
$14
Delta
Net Margin
$12
25%
23%
$10
20%
15%
10%
5%
$8
17%
$6
Net Margin
Less
Capital
8%
7%
4%
0%
$4
Net Operating Margin ($/BBL)
50%
$2
$0
Low Severity
FCC Unit
(Fuels)
Med Severity
FCC Unit
BTX Complex
RxPro
FCC Unit
BTX Complex
LCO UC Unit
Case 1
Case 2
Case 3
RxPro
FCC Unit
BTX Complex
LCO UC Unit
Steam Cracker
Case 4
UOP 5794-29
Integration Example Yields:
FCC Based Complex Case 5
$22
50%
Gasoline
LPG
35%
30%
$20
+32%
BTX+C3=
+C2=
41%
40%
Product Yield (Wt-%)
C3=
BTX
C2=
$18
38%
31%
Delta
Net Margin
$16
$14
$12
25%
23%
$10
20%
15%
10%
5%
$8
17%
12%
11%
Net Margin
Less
Capital
8%
7%
8%
4%
$6
$4
Net Operating Margin ($/BBL)
Fuel/Coke
Distillate
45%
$2
0%
$0
Low Severity
FCC Unit
(Fuels)
Case 1
Med Severity
FCC Unit
BTX Complex
Case 2
RxPro
FCC Unit
BTX Complex
LCO UC Unit
Case 3
RxPro
FCC Unit
BTX Complex
LCO UC Unit
Steam Cracker
Case 4
RxPro
FCC Unit
BTX Complex
LCO UC Unit
Steam Cracker
(No Fuels)
Case 5
Converting 100% of Fuels Increases Petrochemical
Yields by 32 Wt-%
UOP 5794-30
Integration Example Yields:
FCC Based Complex Comparison
$22
50%
Gasoline
LPG
$20
41%
40%
Product Yield (Wt-%)
C3=
C2=
$18
38%
35%
30%
31%
Delta
Net Margin
25%
23%
20%
5%
$14
$12
Margin
Optimum
Identified
$10
$8
17%
15%
10%
$16
12%
11%
Net Margin
Less
Capital
8%
7%
8%
4%
$6
$4
Net Operating Margin ($/BBL)
Fuel/Coke
Distillate
45%
$2
0%
$0
Low Severity
FCC Unit
(Fuels)
Case 1
Med Severity
FCC Unit
BTX Complex
Case 2
RxPro
FCC Unit
BTX Complex
LCO UC Unit
Case 3
RxPro
FCC Unit
BTX Complex
LCO UC Unit
Steam Cracker
Case 4
RxPro
FCC Unit
BTX Complex
LCO UC Unit
Steam Cracker
(No Fuels)
Case 5
UOP’s Extensive Technology Portfolio Can Optimize
Configuration to Client Needs
UOP 5794-31
Evaluating the Appropriate Conversion
Technology
Nat Gas
H2
H2 Plant
Plant
H2
Off Gas
SR Naphtha
Steam
Cracker
CDU
Olefins
Crude Oil
Vacuum Unit
UnicrackingTM
Unit
Aromatics
Aromatics
Complex
Complex
Aromatics
Heavy Oils
Delayed
Coking Unit
Coke
UOP 5794-32
Evaluating the Appropriate Conversion
Technology
Nat Gas
H2
H2
H2 Plant
Plant
Off Gas
SR Naphtha
Steam
Cracker
Olefins
Crude Oil
RCD
UnionfiningTM
Unit
Aromatics
Aromatics
Complex
Complex
Aromatics
Heavy Oils
RFCC Unit
LCO
UnicrackingTM
Unit
Coke
UOP 5794-33
Evaluating the Appropriate Conversion
Technology
Feed
Streams
(KMTD)
Product
Streams
(KMTD)
Delayed Coking/
Unicracking
Complex
RCD/RFCC
Complex
Delta
Crude Oil
30
30
0.0
Natural Gas
0.7
1.0
0.3
Olefins
15.4
16.1
0.7
Aromatics
4.5
4.1
(0.4)
Offgas
5.3
5.4
0.1
Heavy Oils
3.2
3.3
0.1
Coke
1.6
0.9
(0.8)
RCD/RFCC Complex Provides Higher Liquid Yields
Offsetting Higher Capital and Operating Expense
UOP 5794-34
Evaluating the Appropriate
Operating Severity
Nat Gas
H2
H2
H2 Plant
Plant
Naphtha/LPG
SR Naphtha
Steam
Cracker
Off Gas
Olefins
Crude Oil
RCD
Unionfining
Unit
RFCC Unit
HDT
Severity
Aromatics
Aromatics
Complex
Complex
Aromatics
Heavy Oils
LCO
UnicrackingTM
Unit
Coke
UOP 5794-35
Hydrotreating Severity Improves
Olefin Yields
FCC C3= Yield (Lb/BBL FF)
Commercial FCC C3= Yields vs Feed Contaminants
Operating Units
40
Hydrotreated Resid
35
Hydrotreating
Severity
30
25
Straight Run Resid
20
10
20
30
40
FCC Feed Ni + V (wppm)
Increased RCD Severity Increases Olefin Yields,
Generates Additional SC Feedstock
UOP 5794-36
Worlds Largest Process
Licensing Organization
Refining
 UOP Fluid Catalytic Cracking Process
 UOP LCO-XTM Process
 UOP UnicrackingTM Process
 UOP Distillate UnionfiningTM Process
 UOP SelectFiningTM Process
 UOP MeroxTM Process
 UOP PenexTM Process
 UOP CCR PlatformingTM Process
 UOP HF Alkylation Process
 UOP RCD UnionfiningTM Process
 UOP UniflexTM Process
Hydrogen
 UOP PolybedTM PSA System
 UOP PolysepTM Membrane System
Aromatics
 UOP ParexTM Process
 UOP IsomarTM Process
 UOP TatorayTM Process
 UOP SulfolaneTM Process
 UOP MX SorbexTM Process
 UOP Q-MaxTM Process
Olefins
 UOP/HYDRO MTO Process
 Total Petrochemicals/UOP Olefins
Cracking Process
 UOP OleflexTM Process
 UOP MaxEneTM Process
 UOP Propylene Recovery Unit
Having the Best
Technology Solutions is
Not Enough
UOP 5794-37
Capture Integration Opportunities
Project Objectives
UOP Capabilities
• Minimize energy consumption
and environmental footprint
• CapEx/ OpEx Targets
• Fuels/Petrochemical
Product Slate
• Rapid Project
Implementation
• Catalyst and Adsorbent
Technology
• Process Technology
• Technical Services
• Optimization Services
• Field Operating Services
Integration
Opportunities
Realized
UOP offers unmatched capability to
deliver customized, integrated solutions
UOP 5794-38
UOP 5794-39