Refinery Per to Chemical 2004

8/3/2019 Refinery Per to Chemical 2004

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Refinery

Petrochemical Integration



• Returns on refining assets fallen to inadequate

levels due to

- Low growth for major refined products

- Poor upgrading margins

- Increased competition



The drivers to these issues are:

• Refinery/ Petrochemical Integration

• Business diversification challenges (e.g. power

generation, retail marketing)• Process technology developments

• Regulatory issues



Growth Rate

• Global Petroleum demand is expected to

average 2.2% during next 10 years

• Global demand for major petrochemical

will grow twice as fast.



All the major petrochemical producing regions will be adding

petrochemical processing capacity to 2005

Petrochemical New Investment/additionMillion tons/ year

Ethylene 41.3

Benzene 10.5

Styrene 11.4

Poly-olefins+ 50.1

Para-xylene (PX) 11.1

Terephthalic Acid (PTA) 15.5

+ Polyolefins includes polypropylene, all grades of

polyethylene (including LDPE- 29.2 million tons/year,

LLDPE- 20.9 million tons/year and HDPE



WORLD ETHYLENE CAPACITY (MAY 1997)

1997 2000 % increase from 1997 to 2000

North America 28,732 31,619 10

South America 3365 3935 16.9

West Europe 19,786 20,046 1.3

East Europe 7568 8058 6.5

Africa 1255 1555 23.9

Middle East 4846 6611 36.4

Asia 17812 22573 26.7

Australia 505 505 -

TOTAL 83,869 94,902 13.2

Source: Japan Petrochemical Industry Association, Tokyo, May 1997



ASIAN ETHYLENE PRODUCTION CAPACITY

1991 1997 2000* 2005/10*

Japan 6150 7114 7478 8554

South Korea 1232 3720 4380 4380

China 2225 2338 4205 6723

Taiwan 745 960 1390 2365

East Asia Total 10,352 14,132 17,453 22,472

Singapore 400 960 1005 1760

Thailand 230 1130 1130 1730

Malaysia - 530 1010 1600

Indonesia - 550 715 2265

Philippines - - - 500Asean Total 630 3170 3860 7855

India 510 510 1260 3950

Asia Grand Total 11,492 17,812 22,573 34,277

*Few of the above planned projects may not materialize or may be postponed, especially those in

China and India.



Propylene demand continues to exceedgrowth in production from steam

crackers

Projects to produce additional

propylene from Refinery FCC units are

being considered.



World-scale steam cracker facilities

under construction cannot keep up withdemand

Result-

Refinery- based petrochemicals canplay a significant role in providing a

security of supply to petrochemicalprocessors



INDIAN SCENE….

Post Administered Pricing Regime (APR)-

• Allow world market prices for refined products to beapplied in India

• As product prices change, the refineries will be faced withthe need to improve allocation of their capital and optimize

crude oil selection strategies.• The products most in demand will be transportation fuels-

diesel and motor, meeting the stringent environmentalregulations

• Capacity increase and meeting specifications of fuels tomeet stringent regulations will be involve huge capitalinvestments

Refinery profits will squeeze

Alternative options to improve profitability need to belooked into



Benefits of Integration

• Advantage of Counter-seasonal trends in fuel/transport

demand vs. Petrochemical feedstock requirements.

• Integrated economics often reflect lower refinery values

for petrochemical feed-stocks.

• Many big products from the petrochemical operations can

be recycled back to the refinery at higher value.

• Competitive edge over stand-alone petrochemical

complexes

• Overall economics also improves from shared utilities,

transportation, maintenance and administrative functions.

• Finally, petrochemicals generally offer higher value,

better growth opportunities.



Profitability Cycles

• Petrochemicals often exhibit cyclicalprofitability (6-7 years cycles)

• Refining industry, cyclically differs in both

timing and severity compared to

petrochemicals

- Integration allows to temper thedownturns

in petrochemicals by the more stable

behavior of refining cycle.



Refinery/ Petrochemical integration also

brings other synergistic opportunities

- Energy optimization and cogeneration

- Recycling H2 from integrated

petrochemical complexes to refinery for

increased demand in hydroprocessing inreformulated products.



Obstacles that can deter investments in extending

refinery operations into petro-chemical operations

include:

• High capital costs of new petrochemical units

• Product/intermediate transfer costs between

refinery and petrochemical divisions• Refiners may see a higher rate of return in

other| business such as retail marketing

• In contrast to refiners, many chemical industryplayers prefer to make smaller acquisitions to

fit existing portfolios and minimize risks



•

The trend towards refinery/ petrochemicalintegration is clear as one of the options to

improve the profitability .

•

Already been implemented by – Exxon, Shell, Mobil, & BP



Some Grass root refineries in Asia are being

driven by petrochemical feedstock

considerations:

RIL, India

- Catalytic Reformer with 4 p-xylene units- FCC unit for high yield of C3, C4 and C5

olefins

•Aromatics complexes have been added to two ofthe four major Singapore refineries.



Broader outlook of refinery – petrochemicalsintegration

1. Energy Center Complex

2. Utilities Island integration



Crude/Feed stock

Fuels &

Lubricants

Hydrogen

Gasification

Complex

Petrochemical

Complex

Petrochemicals

Refinery

Complex

Power

Feed stock

Power

Steam

Figure 1- Energy Center Complex



UTILITY ISLANDS…..

COMBINED FACILITY FOR ELECTRIC POWER AND OTHER

UTILITY PRODUCTS

PRODUCTS AMENABLE TO INCLUSION IN UTILITY ISLAND

INCLUDE:

•Industrial gases (O2, N2, H2, CO, Syn gas)

• Thermal energy (steam or hot water)

• Electricity

• Cooling or chilled water

• Purified water (boiler-feed, deionized, ultra high purity)

• Instrument and clean dry air

• Process gas cleanup



Figure- 2A: Utilities Island integration

Petrochemicals

Refinery

Complex

Petrochemical

Complex

Utilities

Island

Fuel

Lubes

Power

Steam

gases- N2, O2, Air

etc.



The future of petrochemical integration into

the refinery cannot be characterized insimple terms. It must first be recognized

that petrochemical industry is a large

industry with many products and more

than 500 processes.



If an existing refining facility does not

already produce a sizable quantity ofpetrochemical products, can it ever

hope to achieve an acceptable return

on petrochemical projects?



Refiners produce a wide range of

chemical feedstocks depending on

crude type, refinery complexity, and

other operating conditions.

Typically a limited number of refinery

processes/ streams provide the

primary feedstocks to supportcompetitively sized petrochemical

production.



PETROCHEMICALS FROM REFINERY STREAMS

Petrochemical Stream Refinery Stream Alternative

Refinery Use

Base PetrochemicalsEthylene Naphtha and LPG Fuel gas

Propylene Refinery propylene (FCC

product)

Alkylation

Benzene, toluene,

xylenes (BTX)

Reformate Gasoline

blending

Downstream Derivatives

Ethylbenzene Dilute ethylene (FCC and

delayed coker off-gases)

Fuel gas

Polypropylene Refinery propylene (FCCproduct)

Alkylation

Isopropanol Refinery propylene (FCC

product)

Alkylation

Cumene Refinery propylene (FCC

product)

Alkylation

Contd…..



Oligomers Refinery propylene

(FCC and delayed

coker)

Alkylation

MEK Butylenes

(FCC and delayed

coker)

Alkylation, MTBE Production

MTBE Butylenes

(FCC and delayed

coker)

Alkylation, MTBE Production

Cyclohexane Reformate Gasoline blending

Ortho-Xylene Reformate Gasoline blending

Para-Xylene Reformate Gasoline blending

Normal paraffins Kerosene Refinery product

Naphthalene FCC light cycle oil Diesel blend-stock after

hydro-treating



REFINERY-GENERATED FEED-STOCKS AND

THEIR COMMON AND POTENTIAL USAGEFeed-Stock Derivatives

LPG (Propane,Butane)

Feedstock for:

Ethylene,Propylene, Butylenes by steam

cracking/dehydrogenation:

•Aromatics by aromizing

•Acid, aldehydes & ketones through oxidn.

Naphtha •Light and heavy for olefins and aromatics production,

depending upon the composition (steam

cracking/Reforming)

•Light naphtha to C5-stream

•Hydrogenation of benzene rich fraction (69-90°C) for

cyclohexane/ cyclohexene, which is feed stock for

fibre industry.

Kerosene •n-paraffins for LAB, LAS etc.

•specialty chemicals, plasticizers and solvent

Contd….



Gas Oil • Feedstock for steam cracking to produce olefins

(commonly used in china).

• Gas oil from thermal conversion process- alpha

olefins for AOS.FCC off gases • Propylene, isopropanol, cumene, oligomers,

polypropylene, acrylic acid.

• Butylenes- MEK, MTBE, oligomers, pure

butene-1, alkyl phenols and additives, acrolein,

MMA acrylic acid.

• High octane, benzene free gasoline blending

component by alkylating benzene rich naphtha

with FCC- off gases and isobutene.

DCC•

Olefins

Kerosene from

thermal process

(visbreaking,

coking)

• n-paraffins, alpha olefins,

• aromatics – naphthalene

Contd….



Reformate • BTX

• C9+ aromatics from reformate and their

conversion,

Residues sludge,

coke etc.

Power (IGCC), steam, H2, Syn gas-chemicals,

High cetane, zero sulfur diesel, specialty linear

waxes, olefins, alcohols etc.

Petroleum Coke Use based on acetylene chemistry



Changing fuel specifications willhave an impact on the interfaces or

synergies of refining and

petrochemical operations.



Levels of Refining and Petrochemical

Integrations

• Forward Integration…

–

Utilization of refinery manufacturedproducts as petrochemical feedstock rather

than gasoline blending component.

• Backward Integration…

– Disposal of petrochemical by-products to

refinery applications, namely gasoline

blending.



Site-wide and System-wide Integration

• Side-wide integration…

– Petrochemical and refining operations are

integrated on one site.• System-wide integration…

– Products are traded between several

independent refinery and petrochemical sites.



Basic Petrochemical Plans

1.Steam cracker or olefins plant.

2.Aromatic Plant

Both unit obtain feedstocks from refining section.

– LPG, light or full range naphtha and unconvertedoil for steam cracker.

– Reformate for aromatics.

Alternatively these feedstocks are also availablefrom the market.



Alternatives for light naphtha

1. Feedstock for steam cracker

2. Feed stock for isomerisationunit



Alternatives for Reformate

1. Feedstock for Aromatics

2. Gasoline Blending Component



New Fuels Specification due to AOP

Before AOP AOP 200 AOP 2005

Sulphur ppm Max. 500 Max. 150 Max. 50

Benzene%v/v

Max. 5 Max. 1 Max. 1

Aromatics%v/v

- Max. 42 Max. 35

Olefins%v/v

- Max. 18 Max. 18



Changing Gasoline Specifications

Sulfur

Benzene

Aromatics

Olefins

Changing Gasoline Specifications

Sulfur

Benzene

Aromatics

Olefins



AOP will Affect…

• Recipe for gasoline blending

• Choice for feedstocks for steamcracking and aromatics unit.



•

Both steam crackers and aromaticsunits produce by-products inaddition to C2H4, C3H6 or aromatics.

• Some of these by-products return tothe refinery as gasoline blend stockscalled “Chemical Returns ”.



• Chemical returns from steam crackerinclude : pyrolysis gasoline, followingbenzene extraction

Pygas split - Light & heavy

• Chemical returns from aromatic unit

consists of C9 or C8 (xylenes)aromatics.



The fuel regulations being enacted will

change the blending values andopportunities for chemical returns aswell as the availability of light naphtha

as cracker feed.

This affect will be increased by the

fact that gasoline demand is expectedto increase at low pace than demandfor C2H4 and C3H6.



Qualities of typical gasoline blending components

Blending

Component

Benzene

Vol%

Sulphur

ppm

Olefins

vol%

Aromatics

Vol%

RON/MON

Reformate 1,0-10 1 0 60-75 99/98

FCC gasoline 0,7-1,0 100-2000 30-40 5-45 91-96 / 78-84

-light cut 0,9-1,5 15-300 20-55 1-2 98-96/80-82

-heavy cut 0,1-1,1 350-3500 2-14 40-60 91-96/78-84

Isomerisate 0 0 0 0 87-92/84-90

Alkylate 0 0 1 0 95/93

MTBE 0 0 1 0 111/96

Pyrolysis

gasoline

0-6 0-600 25-35 75-88 98/84

- light cut 0-6 0-50 55 5 96/80

-heavy cut <1 0-600 0 86 99/84

C9-Aromatics 0 0 0 100 105/93



There are four general refinery types

• Hydroskimmer refineries consisting only oftopping and reforming.

• FCC-type refineries with FCC plant for VGO or

rasid cracking without additional hydrogen.

• Hydrocracker type refineries including ahydrocracker plant for VGO cracking withhydrogen addition.

• Complex or FCC/Hydrocracker type, are refineries

with both types of cracking units.



The reduction in aromatics content of

gasoline will have major impact onrefining-petrochemical synergies.

All other parameters also needs to beconsidered; these will limit theblending returns into gasoline pool

and restrict the availability of lightnaphtha as petrochemical feedstock.



Refinery types and aromatics content ingasoline

Hydroskimmer

Topping and Reforming units only

About 51% aromatics content in gasoline; 77% reformate

FCC type

Hydroskimming and additional FCC for VGO cracking without hydrogenaddition less than 35% aromatics content in gasoline; about 38% reformate

Hydrocracker type

Hydroskimming and additional Hydrocracker for VGO cracking with hydrogen

addition about 54% aromatics content in gasoline; 83% reformate.

Complex or FCC/HC typeHydroskimming plus FCC and HC units

About 45% aromatics content in gasoline; 60% reformate



Blend Stock Qualities

• Pyrolysis Gasoline quality parameters are similarto FCC gasoline.

• PG has favourable RON and acceptable MON.• Sulfur, olefins and aromatics content of PG exceed

future gasoline specs.

• Light PG is low in aromatics but olefins content is

extremely high; MON is insufficient.

• Reverse is true for heavy PG – high aromatics lowolefins.

Pyrolysis Gasoline (PG)



C-9 Aromatics

• C-9 aromatics are excellent gasoline blend stock

– High aromaticity.

– Negligible olefin content. – Octane comparable to reformate

• Aromaticity will limit the future usage as blends.



C9-aromatics will not substitute reformate

because of the fact that:

• The reformer produces “cheap” hydrogen.

• Reformate has the more satisfactory distillation

curve (C9-aromatics heavy end only).

• Reformate has a lower aromatics content.



• Reformate has added advantages over C-9 aromatics

– Naphtha reforming generates H2 as by-product. – Distillation range of reformate favourable to gasoline

blending.

– C9-aromatics production can be reduced by cutting

reformer feed TBP (140°C max.)

• One option to limit aromatics in gasoline is dilution with

MTBE, alkylate, isomerisate etc.



Impact of Diesel Quality

If only further sulfur reduction is involved,

there is likely no impact on petro-chemicals.



More stringent gasoline specifications will

change refining and petrochemical synergies,

as they will have an impact on

refinery/petrochemical interfaces.



Steam Cracker feed stock

• Increasing use of isomerisation will affect steam

cracker feed supply and quality.

– Unconverted oil (UCO) form hydrocracker

produces less ethylene than high quality naphtha.

• Ethane and LPG are other alternatives.• Condensate may emerge as real alternative.



Naphtha volume and quality will change

due to:

• Increasing light naphtha/isomerate requirements at

refinery site for aromatics dilution.

• And because of growing olefins demand while

fuel requirements are stable or relaxed.



Changing naphtha quality:

• will cause lower ethylene and propylene yields at the samethroughput, while pygas output will increase.

• changing naphtha quality will also cause higher aromaticscontent in pygas and larger heavy pygas volumes.

• due to more stringent gasoline specifications especially withrespect to aromatics.

• there will be lower blending values of pygas and C9-

aromatics.

• and a limiting of light pygas blending into gasoline due tohigh olefin content.



Synergies between FCC and olefin

production

Catalytic Cracking can be a supplementary

source for olefins.



• Generally FCC is designed to produce gasoline anddiesel. (Large pore zeolites)

• Medium pore zeolites over crack gasoline to propylene

and butylenes

- Pentasil family of molecular sieves areused for this application

- ZSM-5 structure most successful

- Product gases contain 5-7 wt% propylene

OLEFINS FROM FCC



Petro FCC

Targets producing petrochemical feedstocks rather than fuelproducts

• Based on new catalyst (Rx-Cat) to improve yield of propylene

and aromatics.

- Lower HC partial pressure

- Slightly higher reactor outlet temperature

- Improved spent catalyst stripping

- Nearly eliminating post-riser, non-selective back-mixed

cracking

- High catalyst flux rates

Yi ld P



Yield Patterns

Component,

wt%

Traditional FCC Petro FCC

H2S, H2, C1 & C2

Ethylene

Propane

Propylene

Butanes

Butylenes

NaphthaDistillate

Fuel Oil

Coke

2.0

1.0

1.8

4.7

4.5

6.5

53.514.0

7.0

5.0

3.0

6.0

2.0

22.0

5.0

14.0

28.09.5

5.0

5.5

DEEP CATALYTIC CRACKING (DCC)



DEEP CATALYTIC CRACKING (DCC)

• DCC is an extension of FCC process to producemore propylene and butylenes.

• Propylene yields of 18-20% can be obtained

• Modes of operation- maximization of propylene

- maximization of iso-olefins

• Overall scheme is very similar to that of aconventional FCC



Typical Operation Conditions

DCC FCC Steam

Cracking

Temperature °F 1020-1100 920-1020 1400-1600

Cat./oil ratio 8-15 4-10 --

Dispersion steam

wt%

10-30 0-2 30-80

Pressure, psig 15-30 15-30 atm



DCC commercial trial (max C3=mode) yields

Wt% on feed DCC FCC SC

H2 0.3 0.1 0.6

Dry gas (C1-C2) 12.6 3.8 44.0

LPG (C3-C4) 42.3 27.5 25.7

C5

+ naphtha 21.5 47.9 19.3

Light cycle oil (400-630°F+) 7.9 8.7 4.7

Decant oil (630°F+) 7.3 5.9 5.7

Coke 8.1 6.1 -

Lt olefin yield (wt%)

C2=

C3=

C4=

5.7

20.4

15.7

0.9

8.2

13.1

28.2

15.0

4.1

TABLECOMPARISON OF DCC FCC SC N h h PONA



COMPARISON OF DCC vs. FCC vs. SC Naphtha PONAs

Component wt% DCC FCC SC

Paraffins

Olefins

Naphthenes

Aromatics

Total

14.3

32.4

5.0

48.3

100.0

28.6

35.3

9.8

26.3

100.0

3.5

13.3

4.1

79.1

100.0

Aromatics Breakdown

Benzene

Toluene

C8

C9

C10+

Total

1.9

9.4

15.612.1

9.3

48.3

0.6

2.4

6.712.5

4.1

26.3

37.1

18.9

13.55.4

4.2

79.1

TABLEDCC PRODUCT SLATE AND YIELD STRUCTURE



DCC PRODUCT SLATE AND YIELD STRUCTUREProcess DCC Type I DCC Type II FCC

Material Balance wt%

C2 MinusC3 and C4

Naphtha

LCO

DO

Coke

Loss

TOTAL

11.942.2

26.6

6.6

6.1

6.0

0.6

100.0

5.634.5

39

0

9.8

5.8

4.3

100.0

3.517.6

54.8

10.2

9.3

4.3

0.3

100.0

Light Olefin Yield, wt%

EthylenePropylene

Butylene

Isobutylene

Amylene

Isoamylene

6.121.0

14.3

5.1

--

--

2.314.3

14.7

6.1

9.8

6.8

0.84.9

8.1

2.3

--

--



Catalytic Pyrolysis Process (CPP)

It is a hybrid DCC- steam cracking system.

• Operated under more severe conditions than

DCC• Combined yield of C2-C4 is very high

• It is a petrochemical process designed to

make a range of olefins and aromatics.

CATALYTIC PYROLYSIS PROCESS TYPICAL



CATALYTIC PYROLYSIS PROCESS- TYPICAL

PRODUCT DISTRIBUTION

Product yield, wt%

Ethylene 22.78

Propylene & butylene 29.62C5+ naphtha 14.93

LCO 3.72

HCO 4.56

Coke 8.67

Conversion, wt% 91.72

(Feed: atm residue)



n-Paraffins from kerosene

• Kerosene prefractionation

- To tailor the kerosene to desired carbon range

• Hydrotreatment

To remove sulfur, nitrogen and olefins and

oxygenates which might poison the molexadsorbent

• Recovery of n-paraffins –

MOLEX PROCESS

Liquid phase separation of n-paraffins from branched

and cyclic compounds using adsorptive separation.



PETRO-CHEMICALS FROM COKER

DISTILLATES

Available from coking operations in refinery

• Excellent starting for host of chemicals,especially detergents

Fig 1 Coker Distillates: Typical utilization pattern using LAOP-Process



Linear Hydrocarbons

Coker DistillatesDistillation

Coker Distillates(C10-C18)

LAOP Process

Reactive Separation

RaffinateAromatics forcarbon black Feed Stock fornaphthaleneBlending w ithstraight run

refinery streamsAromatic solventfor pesticides

n-Paraffins

Alpha Olefin SulphonatesSecondary alkyl sulfatesPoly alpha olefinsLinear alkyl benzeneFatty alcohols, acids and estersFatty amines & amidesFatty ketones

Olefins

Paraffin OilSec-alcoholsChlorinaed paraffinsOlefins

Fig.1 Coker Distillates: Typical utilization pattern using LAOP-Process

USES OF n-PARAFFIN



USES OF n PARAFFIN

Chlorinated paraffins

Secondary alkane sulfonate

SolventOlefins

n-PARAFFINS

DEHYDROGENATION

(PACOL)

INTERNAL OLEFINS

ALKYLATIONBENZENE

LAB

RESID PROCESSING……



RESID PROCESSING……

• Currently the primary goal of an Indian refinery is:

• To upgrade as much crude as possible into saleable fuel

products.

• Maximizing overall profitability.

• current options:-

– Carbon rejection (coking, deasphalting)

– Hydrogen addition (resid hydroprocessing) (needs

additional hydrogen)

These options leave behind undesired hydrogen-deficient

material rich in carbon, sulfur, metals etc.



OTHER OPTIONS…..

The ability to convert this unmarketable

material to produce electricity, clean lighter

fuels and petrochemicals permits therefinery to increase its profitability



The refiner can choose among three electric-

power-generation methods:

• Circulating-fluidized beds (CFB)

• Boilers with flue gas desulfurization (FGD)

• Integrated gasification combined cycle (IGCC)



Primary factors affecting the selection for

power generation need balancing

- Environmental issues

- Efficiency- Economics while preserving strategic options

for future investments.

RESIDUE CONVERSION



RESIDUE CONVERSION

GASIFICATION

• Gasification

Power, hydrogen

Syn gas petro-chemicals

• Offers an alternative to handle high sulfur and metal

containing residues in a refinery with value addition

• Alternative economically attractive option for many of

the problems associated with changing scenario in thepetroleum refining industry

• Great advantage in co-generation and petro-chemicals

via syn gas

GASIFICATION



• FLEXIBLE PROCESS

CAN HANDLE WIDER FEED STOCKS INCLUDING

RESIDUES AND COKE

• MEETS ENVIRONMENTAL

REGULATIONS

• WIDE RANGE OF PRODUCTS

- ELECTRICITY

- HYDROGEN

- CHEMICALS



COGENERATION……

THE SEQUENCIAL PRODUCTION OF ELECTRIC POWER

AND USEFUL THERMAL ENERGY AND PRODUCTS

During past 20 years more than 100,000 MW of cogeneration

capacity has been built and now supplies over 13% of total

power generation is US.

By 2015 it is expected that natural gas combined – cycle units

will supply roughly 25% of total electricity generated in US.

The driver behind cogeneration is the increase in efficiency

compared to conventional non-integrated power generation.

COMPARISON OF ELECTRICAL GENERATION



OPTIONS

CFB FGD IGCC

Sulfur-removal

experience

95% 95% +98%

Merchantablesulfur

No No Yes

Oxygen/ nitrogen

byproduct No No Yes

Hydrogen

byproduct

Cost. $/kw

No

900

No

700

Yes

800-1,000

COMPARISON OF TYPICAL EMISSIONS, LB/MW-HR



@ 100% CAPACITY

Natural gas

combined

cycle

Coke gasif.

Combined cycle

Coke

circulating

fluid bed

Coke

boiler

FGD &

SCR*

SO2 0.0 0.5 3.7 3.6

NOx 0.3 0.4 0.9 1,5

CO 0.2 0.3 1.5 NA

VOC 0.02 0.07 0.08 NA

Particulates 0.05 0.07 0.2 0.2

CO2 820 1,930 2,170 2,120

Solid waste 0.00 9.1 350 190

*Fuel gas desulfurization and selective catalytic reduction. The solid wastes from a

coke gasifier contain only the feed metals plus some carbon.



PETRO-CHEMICALS FROM

REFINERY COKE

• Valuable material for producing petrochemicals

• Excellent source for high purity acetylene which

is a useful starting material for host of petro-

chemicals such as acrylonitrile, vinylchloride,acrylic monomer etc.

PETRO-CHEMICALS FROM REFINERY COKE



CRUDEOIL

REFINERY GASOLINE, DISTILLATE, ETC

REFINERY

CALCIUMCARBIDE

PLANT

PETROCHEMICAL

PLANT

ELECTRICUTILITY

RES. & COMM. POWERTO COMMUNITY

COKEACETYLENE

OR

CARBIDE

PETROCHEMICALPRODUCTS

POWER

CaCN 2HCNMgACRYLONITRILEVINYL CHLORIDE PLASTICSACRYLIC MONOMERACETYLENE BLACKCHLORINATED SOLVENTSACETALDEHYDE

ACETIC ACIDACETIC ANHYDRIDEACETYLENE CHEMICALS

FROM REPPE CHEMISTRY

Figure -12: Fuel power relationship between refinery, utility plant, carbide plant, and petrochemical plant

and petrochemical plant.

I i R fi / A i l



Integrating Refinery/ Aromatic complex

Case study by Chem Systems, NY.

Existing refineries

- North America (USGC)

- Western Europe (Roterdam)- Asia (Singapore)

C E ) Figure 1: Stand-alone USGC petrochemical plants, 1996



N o n e n

e s + T e t r a m e r

P a r a x y l e n e 6

C u m e n e

P r o p y l e n e 5

P o l y p r o p y l e n e

P h e n o l

I s o p r o p a n o l

N a p h t h a l e n e 4

S t y r e n e

P a r a x y l e n e 3

N o r m a l P a r a f f i n s

E t h y l e n e 2

E t h y l e n e 1

M E K

M T B E

O c t e n e s

B T X

c y c l o h e x a n e

B e n z e n e

Very Poor

Very Attractive

R e t u r n o n C a p i t a l E m p l o y m e d ( R O C

1 Naphtha Plus LPG feedstock

2 Naphtha feestock only

3 Orto-Xylene co-produced; adsorption/isomerization technology

4 Chemical grade

5 Polymer grade

6 Selective toluene disproportionation technology

Marginally Attractive



BaseRefinery

Base

Refinery

Integrated

Integrated

R e t u r n o n

C a p i t a l E m p l o y e d

1995 2005

Figure 2: Integrated Refinery / Aromatics Plants, USGC



Integrated

Refinery/Aromatic

Complex

Incremental Cash Return

R e t u r n o n C a

p i t a l E m p l o y e d

Figure 3: Comparison of Refinery / Aromatics Return, USGC

BaseRefinery



Results of Study

Refinery/ petrochemical integration can generatehigher profitability in all three regions withbenefits attributed to:

• Reduced capital investment and working capitalbecause of efficient utilization of existing

infrastructure• Reduced fixed costs because of shared services

• Optimization of overall refinery product yields

• Higher value of transfer streams and products



POWER GENERATION INTEGRATION

WITH HYDROGEN PLANT…….

It is profitable to integrate power generation with

other products say H2

.

The cost of power is substantially reduced.



POWER GENERATION INTEGRATION WITH H2 PLANT

POWER(MW)

HEAT RATE(BTU/KHW)

CAPITAL($/KW)

POWER($/KW)

Stand Alone 40 6500 800 $0.038

Integrated 41 5300 700 $0.031

*Additional benefit – 20% reduction in environmental emissions chargeable to power

Base Case: 80 MMSCFD H2 and $2.50/MMBTU

Refinery Per to Chemical 2004

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Transcript of Refinery Per to Chemical 2004