Refining & Petrochemicals Technology Solutions through Integrated Optimisation © 2012 UOP LLC. All...

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


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


UOP 5794-9


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


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



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%


~75% Fuels

Net MarginLess Capital

Net Margin

UOP 5794-14


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


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


Unit

UOP 5794-16



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



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


6%

Fuel/CokeDistillate

GasolineLPG

BTX C3=

21%

43%

11%9%

13%

3%+16% BTX + C3

=

41%

35%

18%

UOP 5794-18


Crude

VDU

PitchCSO

MedSeverity

FCCUnit

CDUCCR

PlatformingUnit

Heavy Naphtha

Distillate

LCN HCN

LCO

Light Naphtha/LPG

Gasoline

C3=

AromaticsComplex

Raffinate

Diesel

DelayedCoking


Unit

C3=

Recovery

Bz

pX

UOP 5794-19


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


Unit

UOP 5794-20




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


Fuel/CokeDistillate

GasolineLPG

BTX C3=

21%

43%

11%9%

13%

3%

UOP 5794-21




BTX Complex


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


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


Unit

LCN

Bz

pX

UOP 5794-23


Crude

VDU

PitchCSO

CDUCCR

PlatformingUnit

Heavy Naphtha

Distillate

Light Naphtha/LPGC2

=/C3=

AromaticsComplex

Raffinate

Diesel

C2=/C3

=

Recovery

PyGas

SteamCracker

DelayedCoking

LCO


Unit

LCOUnicracking

Unit

RxProHigh C3

=

FCC Unit

HCNLCN

Bz

pX

UOP 5794-24




BTX Complex


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


Fuel/CokeDistillate

GasolineLPG

BTX C3=

41%

10%

6%

15%

7%

Case 4 Case 5

21%

UOP 5794-25




BTX Complex


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


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


Crude

VDU

PitchCSO

CDUCCR

PlatformingUnit

Heavy Naphtha

Distillate

Light Naphtha/LPGC2

=/C3=

AromaticsComplex

Raffinate

Diesel

C2=/C3

=

Recovery

PyGas

SteamCracker

DelayedCoking

LCN HCN


Unit

LCOUnicracking

Unit

RxProHigh C3

=

FCC Unit LCO

Bz

pX

UOP 5794-27


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




BTX Complex


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


RxProFCC Unit


Steam Cracker

23%

41%

7%

17%

8%

4%

Fuel/CokeDistillate

GasolineLPG

BTX C3=

C2=

UOP 5794-29




BTX Complex


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


RxProFCC Unit


Steam Cracker

RxProFCC 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



BTX Complex


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


RxProFCC Unit


Steam Cracker

RxProFCC 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


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)


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

Refining & Petrochemicals Technology Solutions through Integrated Optimisation © 2012 UOP LLC. All...

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Transcript of Refining & Petrochemicals Technology Solutions through Integrated Optimisation © 2012 UOP LLC. All...