Refinery / Petrochemical. Integration. Gildas Rolland
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1 Refinery / Petrochemical Integration Gildas Rolland 1
2 Global Middle Eastern Market 2 nd ~30% 10ppm Growing market for global Refined Product Demand +1.6% AAGR of worldwide refining capacity expansion by 2020 are expected in ME Sulfur Gasoline & Diesel Demand will be driven by Euro IV or Euro V fuel specification implementation Refined Product Demand Growth 1 AAGR, ME % Africa +1.9% CIS +1.1% 3 World +0.9% Asia +1.3% Source: HART Energy 2
3 Increase ME Refineries Conversion Rate (300) (250) (200) (150) (100) (50) Nelson Refinery Complexity Ranking Mbpd (Mtpy) 28 < > Number of Index Middle East Today Total of 53 Refineries with 8.6 Mbpd (430 Mtpy) capacity Avg. Nelson Index : 5.2 Index can vary widely from one refinery to the other Potential Upgrading Achieving greater competitiveness by: Increasing conversion rates Moving to production of higher-value products Source: Hart Energy, IEA 3
4 Mb/d Refining and Petrochemical Integration Incentives World Trend World demand index Polymer demand GDP*: Gross Domestic Product GDP* Gas prod. Oil prod. Source : Total Annual growth ~ 4 % ~ 3 % ~ 2 % ~ 1 % Crude Oil Demand by Sector Petrochemicals Transportation fuels 8% 13% World Polymers demand growth > Crude oil production growth Oil to be dedicated preferably to transportation fuels & Petrochemicals (where replacement by alternative energy sources is the most difficult) Crude oil demand share dedicated to petrochemicals increases Integration between Refining & Petrochemical required Residential/other ind. Power generation 4
5 Refining & Petrochemical Integration Incentives Middle Eastern Trend Refining Petrochemicals Mb/d % Regional share of global additional capacities Dem Oil Product Incremental Demand CDU New refinery project or expansions, condensate splitters HDS Desulfurization: Hydrotreating and HDS capacity UpG Upgrading: coking, visbreaking, hydrocracking, residue hydrocracking, FCC or RFCC % 7% 15% 17% Includes Africa Aromatics Olefins Lot of New Refinery projects or expansion, Regional demand among the highest (~3%/y) Increased product exports State-of-the-art & large scale plants Highly competitive Refining & Petrochemicals integration: Naphtha-based Steam Crackers Olefin oriented Fluid Catalytic Cracking (HS- FCC & (R)FCC) Source: HART Energy 5
6 Production of Petrochemicals Base Compounds Targeting Heavy Naphtha for Aromatics Production Targeting Light Olefins Production Propylene On Demand Olefins Production 6
7 VDU ADU Crude Oil How to Increase Naphtha Production? Atmospheri c Residue Vacuum Residue Selection of a Technology Providing Maximum Conversion and Potential for HN Production Naphtha Middle Distillate VGO Middle Distillate Residue Conversion Complex Selection of Light Crude to Maximize Straight Run Naphtha Naphtha VGO Fuel Oil Diesel HDT Partial Cracking of Middle Distillate Cut to Naphtha Aromatic Complex Naphtha VGO Hydrocracker Petrochemicals px Benzene Diesel Kero Diesel UCO Selection of Scheme/ Catalytic System for Naphtha Maximization Reliability is key for economics viability 7
8 Axens H-Oil RC Residue HydroCracking Vacuum Residue (VR) Feedstock Conversion into valuable products Naphtha, Diesel, VGO High Value Products VR Unconverted Residue (UCO) Low Sulfur & Stable Fuel Oil Feed for Coker, SDA, Boilers or Gasification UCO is a Liquid Fuel Various Options for UCO Outlet 8
9 HyK TM Technology: Best Solution for Top Quality Products & Flexibility FEED FEED FEED OR OR Diesel Kero Gr.III Lube Base Naphtha Diesel Kero Naphtha Adjustable Yields for max Profit Top Quality Products Euro V Diesel Jet Fuel A-1 CCR-ready Heavy Naphtha Gr. III Lube Base Maximum Selectivity From 65% Heavy Naphtha To 80% Middle Distillates 9
10 Aromatics Complex Blocks Functions ParamaX Suite 10
11 ParamaX Improvement Products & Technology Energy Efficiency in the Complex Raffinate Benzene Breakthrough on: Aromatics Extraction Adjustment of operating parameters Heavy Naphtha Catalysts, Xylene Isom., ) Molecular Sieve HDT Improvements Reforming on Technology (Eluxyl 1.15) PX Separation Transalkylation Integration between units Integration with Utility Network Xylenes Isom. Paraxylene Boost of the complex profitability Boost Aromatics Complex profitability Heavies 11
12 Axens Recent Award in China (1/2) Crude to PX Project Petrochemicals Feed 20 Mtpy of crude oil 60% Arabian Heavy 30% Arabian medium 10% Marlim World Largest Capacity! Product Requirement: 9 Mtpy of Heavy Naphtha for PX production Co-Production of gasoline, diesel & jet fuel meeting severe specifications Production of Group III Lube Base Oil Minimization of residue production 12
13 Axens Recent Award in China (2/2) Crude to PX Project Petrochemicals Vacuum Residue HCK & SDA (H- Oil RC & Solvahl ) 2 VGO HCK (for Lube Oil, for Naphtha production) (HyK ) Diesel HCK Aromatic Complex (ParamaX ) 13
14 Production of Petrochemicals Base Compounds Targeting Heavy Naphtha for Aromatics Production Targeting Light Olefins Production Propylene On Demand Olefins Production 14
15 A Propylene Sourcing: Catalytic Cracking Technologies Propylene Yield %wt HS-FCC Resid to Propylene High Olefins FCC DCC Heavy Resid Light Resid VGO High H content VGO HS-FCC, a new member to the family 15
16 Innovation towards Olefins HS-FCC Technology A design of catalytic system with ultra-low hydrogen transfer High selectivity towards olefins Proprietary Catalyst Reaction Conditions Maximum Propylene Yield High Severity for High Propylene and Butylene yields High reaction temperature High catalyst to oil ratio Down-flow technology Ultra-short residence time Unique Reaction System 16
17 HS-FCC A Worldwide Cooperation 17
18 Integration Benefits HS-FCC : Technology development 3 DFRs controled scale-up x300 X100 X bpd pilot at KFUPM Saudi Arabia 30 bpd Demonstration plant in Ras Tanura, KSA 3,000 bpd Semi-commercial unit in Mizushima, Japan 76,000 bpd Commercial unit 18
19 On Demand Alpha Olefins Production Co-monomer requirements: 1-butene and 1-hexene for polyethylene applications World demand index Polymer demand GDP*: Gross Domestic Product GDP* Gas prod. Oil prod. Source : Total Annual growth ~ 4 % ~ 3 % ~ 2 % ~ 1 % Sustained growth for LLDPE and HDPE demand 1-butene and 1-hexene AAGR ~ 5 % 1-butene and 1-hexene sourcing? 19
20 AlphaHexol TM Key Features Selective ethylene trimerization mechanism Similar to AlphaButol, backed by extensive industrial experience in homogeneous catalysis M = Metal L n = Ligand L n M + 3 C 2 H 4 L n M 1-hexene Polymer grade 1-hexene suitable for LLDPE & HPDE Efficient ethylene feed use Process simplicity and ease of operation High flexibility Mild operating temperature and pressure Carbon Steel Equipment 20
21 AlphaHexol TM Key Features Selective ethylene trimerization mechanism Similar to AlphaButol, backed by extensive industrial experience in homogeneous catalysis Polymer grade 1-hexene suitable for LLDPE & HPDE Efficient ethylene feed use Process simplicity and ease of operation High flexibility Mild operating temperature and pressure Carbon Steel Equipment M = Metal L n = Ligand L n M + 3 C 2 H 4 L n M Ethylene to 1-hexene yield > 85% 1-hexene 21
22 Conclusion Fuels demand growth lower than that of petrochemicals Axens at the forefront of Innovation with Advanced Solutions & Technologies which best integrate Refining & Petrochemicals 22
23 Thank you! And see you on Axens Blog axens.net/blog 23
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