refining & petrochemicals technology solutions through integrated optimisation © 2012 uop llc....
TRANSCRIPT
Refining & PetrochemicalsTechnology Solutions
through Integrated Optimisation
Refining & PetrochemicalsTechnology Solutions
through Integrated Optimisation
© 2012 UOP LLC. All rights reserved.
Iraq Refinery 2012 April 17-18London, England
Matthew LippmannUOP LLC, A Honeywell Company
Matthew LippmannUOP LLC, A Honeywell Company
UOP 5794-1
Agenda
Market Overview Why Integrate? Maximum Fuels to Maximum Petrochemicals
UOP 5794-2
Light Olefin Demand
0
50
100
150
200
250
300
1990 2000 2010 2020
mill
ion
tp
a
Propylene
Ethylene
90 million MTA of incremental light olefins needed over next 10 years
Petrochemical Demand Soars into the Future
Paraxylene Demand
Demand of pX Projected to Double Over the
Next 10 Years!
0
10,000
20,000
30,000
40,000
50,000
60,000
70,000
1990
1992
1994
1996
1998
2000
2002
2004
2006
2008
2010
2012
2014
2016
2018
2020
pX
De
ma
nd
, kM
TA
10years
Mil
lio
n M
TA 60
40
20
0
Mil
lio
n M
TA
1990 2000 2010 2020
Annual demand growth of 6.7%
u
Additional Need for “On Purpose” Propylene
100% Increase!
UOP 5794-3
Ethylene Cracker Feedstock is Variable by Region
NorthAmerica
SouthAmerica
Europe CIS & BalticStates
MiddleEast/Africa
SoutheastAsia
NortheastAsia
100%
90%
80%
70%
60%
50%
40%
30%
20%
10%
0%
Ethane Propane n-Butane Naphtha Gasoil Other
Source: CMAI 2011 World Ethylene Cost Study
Feedstock Selection Depends on Regional Feedstock Availability
UOP 5794-4
Middle East
North America
NE Asia
SE Asia
Western Europe
1,050
850
650
450
250
500 20 40 60 80 100 120 140 160
Cumulative Ethylene Capacity (million tons)
2004
2009
Ethylene Cash Cost Curve
Source: CMAI2009 Curve: February 10, 2010 Asia Light Olefins Market Advisory Service (Graphical Analysis)2004 Curve: 2005 World Light Olefins Analysis
Ethylene Production Costs are Increasing
Feedstock Price Increasing
Refinery Integration
Offset Higher Feedstock Costs through Proper Refinery Integration UOP 5794-5
Major Oil Companies Recognize Value of Integration
24%
39%
74%
90%
BP Shell Total ExxonMobil
Percent of Ethylene Capacity Integrated with a Refinery by Same Company in Europe
Source: Morgan Stanley
Trend Towards More Integrated Complexes is Increasing
UOP 5794-6
Why Integrate?
Leverage Synergies to Maximize Product Values Lowers Operating & Capital Costs
Increase product
valuation
Secure reliable feedstock supply at reduced cost
Other Advantages: Reduced Shipping Costs Reduced Tankage Costs Common Offsites / Utilities Common Maintenance / Admin Upgrade of byproduct streams
PetrochemicalProcesses
RefineryProcesses
UOP 5794-7
$870/Te
Heavy Naphtha
Reformate
Distillate
RefineryProcesses
Fuel Gas$600/Te
$800/TeLight Naphtha/
LPG
$880/Te
$900/Te
What is Refinery-Petrochemical Integration?
UOP 5794-8
PetrochemicalProcesses
Light Naphtha/LPG
Heavy Naphtha
Reformate
Distillate
RefineryProcesses
Fuel Gas
C2=/C3
=
BZ/pX
$600/Te
$800/Te
$880/Te
$870/Te
$900/Te
$1,500/Te
$1,200/Te
Refinery Optimization
What is Refinery-Petrochemical Integration?
UOP 5794-9
PetrochemicalProcesses
Light Naphtha/LPG
Heavy Naphtha
Reformate
Distillate
RefineryProcesses
Fuel Gas
C2=/C3
=
$1,500/Te
Integrated Complex Optimization
Optimize Quantity and Quality of Intermediate Streams
Select the Right Technology Solutions for the Integrated Complex
BZ/pX
$1,200/Te
$600/Te
$870/Te
$900/Te
$800/Te
$880/Te
What is Refinery-Petrochemical Integration?
UOP 5794-10
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
Maximum Fuels to Maximum PetrochemicalsCase Study
UOP 5794-11
Integration Example: FCC Based Complex Case 1
Crude
VDU
PitchCSO
GasolineModeFCCUnit
CDU
Diesel
CCRPlatforming
Unit
Heavy Naphtha
Distillate
LCN HCN
LCO
Light Naphtha/LPG
Gasoline
F. G.
DelayedCoking
DistillateUnionfiningTM
Unit
UOP 5794-12
Integration Example Yields: FCC Based Complex Case 1
Low Severity FCC Unit(Fuels)
Case 1 Case 2
Pro
du
ct Y
ield
(W
t-%
)
Net
Op
era
tin
g M
arg
in (
$/B
BL
)
Net Margin =
Net MarginLess Capital
Fuel/CokeDistillate
GasolineLPG
50%
45%
40%
35%
30%
25%
20%
15%
10%
5%
0%
$22
$20
$18
$16
$14
$12
$10
$8
$6
$4
$2
$0
Product Values – Feedstock Cost – Variable Costs – Fixed Costs
= Net Margin – Capital Charges
Case 3 Case 4 Case 5
18%
41%
35%
6%
UOP 5794-13
Integration Example Yields: FCC Based Complex Case 1
Low Severity FCC Unit(Fuels)
Case 1 Case 2
Pro
du
ct Y
ield
(W
t-%
)
Net
Op
era
tin
g M
arg
in (
$/B
BL
)
Fuel/CokeDistillate
GasolineLPG
50%
45%
40%
35%
30%
25%
20%
15%
10%
5%
0%
$22
$20
$18
$16
$14
$12
$10
$8
$6
$4
$2
$0
Traditional Refinery Produces ~75% Transportation Fuels
18%
41%
35%
6%
Case 3 Case 4 Case 5
~75% Fuels
Net MarginLess Capital
Net Margin
UOP 5794-14
Integration Example: FCC Based Complex Case 1
Crude
VDU
PitchCSO
GasolineModeFCCUnit
CDU
Diesel
CCRPlatforming
Unit
Heavy Naphtha
Distillate
LCN HCN
LCO
Light Naphtha/LPG
Gasoline
F. G.
DelayedCoking
DistillateUnionfining
Unit
UOP 5794-15
Integration Example: FCC Based Complex Case 2
Crude
VDU
PitchCSO
MedSeverity
FCCUnit
CDUCCR
PlatformingUnit
Heavy Naphtha
Distillate
LCN HCN
LCO
Light Naphtha/LPG
Gasoline
C3=C3
=
Recovery
AromaticsComplex
Bz
pX
Raffinate
Diesel
DelayedCoking
DistillateUnionfining
Unit
UOP 5794-16
Integration Example Yields: FCC Based Complex Case 1
Low Severity FCC Unit(Fuels)
Case 1 Case 2 Case 3 Case 4
Pro
du
ct Y
ield
(W
t-%
)
Net
Op
era
tin
g M
arg
in (
$/B
BL
)
Net MarginLess
Capital
50%
45%
40%
35%
30%
25%
20%
15%
10%
5%
0%
$22
$20
$18
$16
$14
$12
$10
$8
$6
$4
$2
$0
Case 5
Delta Net Margin
Fuel/CokeDistillate
GasolineLPG
18%
6%
41%
35%
UOP 5794-17
Integration Example Yields: FCC Based Complex Case 2
Low Severity FCC Unit(Fuels)
Med SeverityFCC Unit
BTX Complex
Case 1 Case 2
Pro
du
ct Y
ield
(W
t-%
)
Net
Op
era
tin
g M
arg
in (
$/B
BL
)
Delta Net Margin
Net MarginLess
Capital
50%
45%
40%
35%
30%
25%
20%
15%
10%
5%
0%
$22
$20
$18
$16
$14
$12
$10
$8
$6
$4
$2
$0
FCC Severity and BTX Complex Converts 16% of Gasoline Into Higher Value Petrochemicals
Case 3 Case 4 Case 5
6%
Fuel/CokeDistillate
GasolineLPG
BTX C3=
21%
43%
11%9%
13%
3%+16% BTX + C3
=
41%
35%
18%
UOP 5794-18
Integration Example: FCC Based Complex Case 2
Crude
VDU
PitchCSO
MedSeverity
FCCUnit
CDUCCR
PlatformingUnit
Heavy Naphtha
Distillate
LCN HCN
LCO
Light Naphtha/LPG
Gasoline
C3=
AromaticsComplex
Raffinate
Diesel
DelayedCoking
DistillateUnionfining
Unit
C3=
Recovery
Bz
pX
UOP 5794-19
Integration Example: FCC Based Complex Case 3
Crude
VDU
PitchCSO
RxProTM
High C3=
FCC Unit
CDUCCR
PlatformingUnit
Heavy Naphtha
Distillate
LCN HCN
LCO
Light Naphtha/LPG
Gasoline
C3=C3
=
Recovery
AromaticsComplex
Bz
pX
Raffinate
Diesel
LCOUnicracking
UnitDelayedCoking
DistillateUnionfining
Unit
UOP 5794-20
Integration Example Yields: FCC Based Complex Case 2
Low Severity FCC Unit(Fuels)
Med SeverityFCC Unit
BTX Complex
Case 1 Case 2
Pro
du
ct Y
ield
(W
t-%
)
Net
Op
era
tin
g M
arg
in (
$/B
BL
)
Delta Net Margin
Net MarginLess
Capital
50%
45%
40%
35%
30%
25%
20%
15%
10%
5%
0%
$22
$20
$18
$16
$14
$12
$10
$8
$6
$4
$2
$0
Case 3 Case 4 Case 5
Fuel/CokeDistillate
GasolineLPG
BTX C3=
21%
43%
11%9%
13%
3%
UOP 5794-21
Integration Example Yields: FCC Based Complex Case 3
Low Severity FCC Unit(Fuels)
Med SeverityFCC Unit
BTX Complex
Case 1 Case 2 Case 3
Pro
du
ct Y
ield
(W
t-%
)
Net
Op
era
tin
g M
arg
in (
$/B
BL
)
Delta Net Margin
Net MarginLess
Capital
50%
45%
40%
35%
30%
25%
20%
15%
10%
5%
0%
$22
$20
$18
$16
$14
$12
$10
$8
$6
$4
$2
$0RxPro
FCC UnitBTX ComplexLCO UC Unit
RxPro FCC and LCO Unicracking Unit Shifts Product Yields Towards BTX and C3
=
21%
43%
11%9%
13%
3%
Fuel/CokeDistillate
GasolineLPG
BTX C3=
21%
41%
10%
6%
15%
7%
Case 4 Case 5
+6% BTX + C3=
UOP 5794-22
Integration Example: FCC Based Complex Case 3
Crude
VDU
PitchCSO
RxProHigh C3
=
FCC Unit
CDUCCR
PlatformingUnit
Heavy Naphtha
Distillate
HCN
LCO
Light Naphtha/LPG
Gasoline
C3=C3
=
Recovery
AromaticsComplex
Raffinate
Diesel
LCOUnicracking
UnitDelayedCoking
DistillateUnionfining
Unit
LCN
Bz
pX
UOP 5794-23
Integration Example: FCC Based Complex Case 4
Crude
VDU
PitchCSO
CDUCCR
PlatformingUnit
Heavy Naphtha
Distillate
Light Naphtha/LPGC2
=/C3=
AromaticsComplex
Raffinate
Diesel
C2=/C3
=
Recovery
PyGas
SteamCracker
DelayedCoking
LCO
DistillateUnionfining
Unit
LCOUnicracking
Unit
RxProHigh C3
=
FCC Unit
HCNLCN
Bz
pX
UOP 5794-24
Integration Example Yields: FCC Based Complex Case 3
Low Severity FCC Unit(Fuels)
Med SeverityFCC Unit
BTX Complex
Case 1 Case 2 Case 3
Pro
du
ct Y
ield
(W
t-%
)
Net
Op
era
tin
g M
arg
in (
$/B
BL
)
Delta Net Margin
Net MarginLess
Capital
50%
45%
40%
35%
30%
25%
20%
15%
10%
5%
0%
$22
$20
$18
$16
$14
$12
$10
$8
$6
$4
$2
$0RxPro
FCC UnitBTX ComplexLCO UC Unit
Fuel/CokeDistillate
GasolineLPG
BTX C3=
41%
10%
6%
15%
7%
Case 4 Case 5
21%
UOP 5794-25
Integration Example Yields: FCC Based Complex Case 4
Low Severity FCC Unit(Fuels)
Med SeverityFCC Unit
BTX Complex
Case 1 Case 2 Case 3 Case 4
Pro
du
ct Y
ield
(W
t-%
)
Net
Op
era
tin
g M
arg
in (
$/B
BL
)
Delta Net Margin
Net MarginLess
Capital
50%
45%
40%
35%
30%
25%
20%
15%
10%
5%
0%
$22
$20
$18
$16
$14
$12
$10
$8
$6
$4
$2
$0RxPro
FCC UnitBTX ComplexLCO UC Unit
RxProFCC Unit
BTX ComplexLCO UC Unit
Steam Cracker
Case 5
Steam Cracker Integration Enables Entry Into C2
= Market
23%
41%
7%
17%
8%
4%
21%
41%
10%
6%
15%
7%
Fuel/CokeDistillate
GasolineLPG
BTX C3=
C2=
+4% C2=
UOP 5794-26
Integration Example: FCC Based Complex Case 4
Crude
VDU
PitchCSO
CDUCCR
PlatformingUnit
Heavy Naphtha
Distillate
Light Naphtha/LPGC2
=/C3=
AromaticsComplex
Raffinate
Diesel
C2=/C3
=
Recovery
PyGas
SteamCracker
DelayedCoking
LCN HCN
DistillateUnionfining
Unit
LCOUnicracking
Unit
RxProHigh C3
=
FCC Unit LCO
Bz
pX
UOP 5794-27
Integration Example: FCC Based Complex Case 5
Crude
VDU
PitchCSO
CDUCCR
PlatformingUnit
Heavy Naphtha
Distillate
Light Naphtha/LPGC2
=/C3=
AromaticsComplex
Raffinate
Full ConvDistillate
Unicracking Unit
C2=/C3
=
Recovery
PyGas
SteamCracker
LtNaph
HvyNaph
DelayedCoking
LCO
RxProHigh C3
=
FCC Unit
LCN HCNBz
pX
UOP 5794-28
Integration Example Yields: FCC Based Complex Case 4
Low Severity FCC Unit(Fuels)
Med SeverityFCC Unit
BTX Complex
Case 1 Case 2 Case 3 Case 4
Pro
du
ct Y
ield
(W
t-%
)
Net
Op
era
tin
g M
arg
in (
$/B
BL
)
Delta Net Margin
Net MarginLess
Capital
50%
45%
40%
35%
30%
25%
20%
15%
10%
5%
0%
$22
$20
$18
$16
$14
$12
$10
$8
$6
$4
$2
$0RxPro
FCC UnitBTX ComplexLCO UC Unit
RxProFCC Unit
BTX ComplexLCO UC Unit
Steam Cracker
23%
41%
7%
17%
8%
4%
Fuel/CokeDistillate
GasolineLPG
BTX C3=
C2=
UOP 5794-29
Integration Example Yields: FCC Based Complex Case 5
Low Severity FCC Unit(Fuels)
Med SeverityFCC Unit
BTX Complex
Case 1 Case 2 Case 3 Case 4
Pro
du
ct Y
ield
(W
t-%
)
Net
Op
era
tin
g M
arg
in (
$/B
BL
)
Delta Net Margin
Net MarginLess
Capital
50%
45%
40%
35%
30%
25%
20%
15%
10%
5%
0%
$22
$20
$18
$16
$14
$12
$10
$8
$6
$4
$2
$0RxPro
FCC UnitBTX ComplexLCO UC Unit
RxProFCC Unit
BTX ComplexLCO UC Unit
Steam Cracker
RxProFCC Unit
BTX ComplexLCO UC Unit
Steam Cracker(No Fuels)
Case 5
Converting 100% of Fuels Increases Petrochemical Yields by 32 Wt-%
41%
7%
17%
8%
4%
31%
38%
8%11%
12%
Fuel/CokeDistillate
GasolineLPG
BTX C3=
C2=
+32% BTX+C3
=
+C2=
23%
UOP 5794-30
Integration Example Yields: FCC Based Complex Comparison
Low Severity FCC Unit(Fuels)
Med SeverityFCC Unit
BTX Complex
Case 1 Case 2 Case 3 Case 4
Pro
du
ct Y
ield
(W
t-%
)
Net
Op
era
tin
g M
arg
in (
$/B
BL
)
Delta Net Margin
Net MarginLess
Capital
50%
45%
40%
35%
30%
25%
20%
15%
10%
5%
0%
$22
$20
$18
$16
$14
$12
$10
$8
$6
$4
$2
$0RxPro
FCC UnitBTX ComplexLCO UC Unit
RxProFCC Unit
BTX ComplexLCO UC Unit
Steam Cracker
RxProFCC Unit
BTX ComplexLCO UC Unit
Steam Cracker(No Fuels)
Case 5
UOP’s Extensive Technology Portfolio Can Optimize Configuration to Client Needs
23%
41%
7%
17%
8%
4%
31%
38%
8%11%
12%
Margin Optimum Identified
Fuel/CokeDistillate
GasolineLPG
C3=
C2=
UOP 5794-31
Nat GasH2 Plant
Coke
Olefins
Aromatics Complex
Aromatics
H2
Off Gas
Heavy Oils
H2 Plant
Crude Oil
CDUSteam
Cracker
Vacuum UnitUnicrackingTM
Unit
AromaticsComplex
DelayedCoking Unit
SR Naphtha
Evaluating the Appropriate Conversion Technology
UOP 5794-32
Nat GasH2 Plant
Olefins
Aromatics Complex
Aromatics
H2
Off Gas
Heavy Oils
H2 Plant
Crude Oil
SteamCracker
RCDUnionfiningTM
Unit
AromaticsComplex
Coke
LCOUnicrackingTM
Unit
RFCC Unit
SR Naphtha
Evaluating the Appropriate Conversion Technology
UOP 5794-33
Delayed Coking/Delayed Coking/Unicracking Unicracking
ComplexComplexRCD/RFCCRCD/RFCCComplexComplex DeltaDelta
FeedStreams(KMTD)
Crude Oil 30 30 0.0
Natural Gas 0.7 1.0 0.3
ProductStreams(KMTD)
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)
Evaluating the Appropriate Conversion Technology
RCD/RFCC Complex Provides Higher Liquid Yields Offsetting Higher Capital and Operating Expense
UOP 5794-34
Nat GasH2 Plant
Olefins
Aromatics Complex
Aromatics
H2
Off Gas
Heavy Oils
H2 Plant
Crude Oil
SteamCracker
RCD Unionfining
Unit
AromaticsComplex
Coke
LCOUnicrackingTM
Unit
RFCC Unit
SR Naphtha
Evaluating the Appropriate Operating Severity
HDT
Severity
Naphtha/LPG
UOP 5794-35
Commercial FCC C3= Yields vs Feed Contaminants
Operating Units
10
FCC Feed Ni + V (wppm)
20 30 40
40
35
30
25
20
Hydrotreated Resid
Straight Run Resid
Hydrotreating Severity Improves Olefin Yields
Increased RCD Severity Increases Olefin Yields, Generates Additional SC Feedstock
Hydrotreating Severity
UOP 5794-36
Worlds Largest Process Licensing Organization
Refining Aromatics
Olefins
Hydrogen
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
UOP ParexTM Process UOP IsomarTM Process UOP TatorayTM Process UOP SulfolaneTM Process UOP MX SorbexTM Process UOP Q-MaxTM Process
UOP PolybedTM PSA System UOP PolysepTM Membrane System
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 EnoughUOP 5794-37
Capture Integration Opportunities
UOP offers unmatched capability to UOP offers unmatched capability to deliver customized, integrated solutions deliver customized, integrated solutions
• Catalyst and Adsorbent Technology
• Process Technology
• Technical Services
• Optimization Services
• Field Operating Services
• Minimize energy consumption and environmental footprint
• CapEx/ OpEx Targets
• Fuels/Petrochemical Product Slate
• Rapid Project Implementation
Project Objectives UOP Capabilities
IntegrationOpportunities
Realized
UOP 5794-38
UOP 5794-39