Maximize Vacuum Residue Conversion and Processing Flexibility with the UOP Uniflex Process

Transcription

1 Maximize Vacuum Residue Conversion and Processing Flexibility with the UOP Uniflex Process Hans Lefebvre UOP LLC, A Honeywell Company XVIII Foro de Avances de la Industria de la Refinación 11 and 12, July, 2012 Mexico City, Mexico 2012 UOP LLC. All rights reserved. UOP

2 Gas & Oil Price ($/MMBTU) $/MMBTU Impact of Global Crude Oil and Natural Gas Prices Natural Gas Crude Oil Oil Price ($/BBL) Natural gas price has not risen as quickly as crude oil This favours upgrading because heavy fuel oil competes with gas, whereas transportation fuels are linked to crude oil price This offers an increased residue conversion margin uplift Delta The widening differential favours Hydrogen Addition, rather than Carbon Rejection, due to: Increased product values 5 Decreased H 2 manufacturing costs Source: BP Statistical Review of World Energy 2011 UOP

3 Million Barrels Per Day History In 1970, 80, 90 Fuel Oil was 50, 40, 30% of Distillates Demand Global Oil Product Demand (Heavy Fuel Oil and Distillates) Middle Distillates Light Distillates Heavy Fuel Oil Source: BP Statistical Review of World Energy By 2010 fuel oil had declined to only 15% By 2020 fuel oil is likely to be only 10% of distillates demand UOP

4 Thousand barrels Per Day Mexico s Oil Market Refined Product Imports into Mexico Source: Pemex Statistical Yearbook Diesel VGO Vacuum Residue Base Case Gasoline + Diesel Benefits of Adding Conversion Gas Diesel VGO Vacuum Residue Base Case+ FCC Gas Diesel VGO Coke Base Case+ FCC+ Coker Pemex s strategy is to reduce imports of gasoline and diesel by expanding capacity and increasing residue conversion capability Source: Business Plan of Petróleos Mexicanos and Subsidiary Entities June 1, 2010 Dominant crude varieties in Mexico have high sulfur and high residue content Addition of residue conversion with Delayed Coking increase a refineries yield of + Diesel High yield of Pet Coke UOP

5 Distillation UOP s Heavy Oil Upgrading Processes Hydrotreating & Reforming Distillates Distillate Hydrotreating Crude Oil Vacuum Gas Oil FCC or Hydrocracking Transportation Fuels: Gasoline, Jet Fuel, Diesel Vacuum Residue Residue Conversion UOP Solutions for Residue Conversion Residues: Heavy Fuel Oil, Pitch, Coke UOP RCD Unionfining Process UOP/FWUSA Solvent Deasphalting FWUSA SYDEC Delayed Coking Process UOP/FWUSA Visbreaking UOP Uniflex Process UOP

6 Yield, vol % Uniflex Process Commercial Experience 25 years R&D 15 years commercial operation High conversion Petro-Canada Montreal Unit Commercial Performance 85% 94% 90% Conversion Distillate VGO Pitch Many UOP improvements in the last 5 years UOP

7 Uniflex Process Commercial Experience Commercial Operations: 5000 BPD unit operated for 15 years in Montreal Processed wide range of feedstocks Excellent design correlations allowing accurate scale-up Very high reliability / availability demonstrated (97+%) UOP Enhancements: Completed UOP Schedule A design Petro-Canada Montreal Unit with improvements Single train design: parallel reactors, common separation More efficient heat integration High conversion of HVGO Integrated pilot plant matches with commercial performance Analytical modeling supports optimization UOP

8 Uniflex Process Thermal Cracking of Asphaltenes Heavier, higher sulfur feeds have higher reactivity Wide boiling range containing olefins, aromatics, S, N Further hydroprocessing is required Benefits from a combination of: 1. Thermal cracking to shorter chain lengths 2. Catalyst inhibits coke through: Hydrogenation of free radicals formed in thermal cracking Physically hinders growth of coke precursors. Archipelago Model of Asphaltenes, Carbon # = 313, MW = 4705 Source: M. Gray, Univ of Alberta UOP

9 Uniflex Process Reactor Achieves High Conversion Products and Catalyst Optimal design for high conversion Upflow High temperature and moderate pressure Efficient utilization of reactor volume Low gas voidage High product vaporization Intense liquid backmixing Near isothermal Asphaltene management Nano-scale dispersed catalyst Solubility control techniques Feed, H 2 and Catalyst UOP

10 Uniflex Process with HVGO Recycle Makeup H 2 Recycle H 2 Recycling Benefits: Slurry Reactor HHPS CHPS HVGO is difficult to process in HT, HC and FCC units Uniflex converts HVGO to valuable products C 4 - Diesel Vacuum Column LVGO HVGO Catalyst Stripper/ Fractionator Pitch HVGO Recycle Vacuum Residue UOP

11 Volume% Crude & Vacuum Distillation Simple Integration into Existing Refineries Crude Oil Distillates Vacuum Gas Oil Existing Hydrocracking, MHC or FCC New Distillate Hydrotreating Diesel Pool Vacuum Residue UOP Uniflex Yield Comparison Distillate VGO Coke (Wt-%) Distillate VGO Pitch (Wt-%) Uniflex Integration Benefits >55% yield of diesel: 2x Delayed Coking Simple stand-alone hydrotreater produces reformer feed and Euro V diesel ½ VGO yield of Delayed Coking often allows VGO to be processed in existing units -40 Delayed Coking Uniflex UOP CONFIDENTIAL UOP

12 Low Value Fuels Indicative Yields (Wt %) High Value Products Maximizing and Diesel in an FCC Refinery Basis: Maya Crude Gas Gas Diesel VGO Vacuum Residue Gas Diesel Diesel Diesel VGO VGO VGO Pitch Coke Vacuum Residue -60 Base Case Base Case+ FCC Base Case+ FCC+ Coker Base Case+ FCC+ Uniflex Uniflex increases transportation fuel yields by 10 Wt-% when compared to the Coker case UOP

13 Uniflex Benefits Commercially Proven Low-value Feed High Conversion High-value Products Step Change Margin Increase So what else is new and different that makes the above even more compelling? The answer is higher prevailing crude oil prices UOP

14 Uniflex Process Residue Upgrading Economics Indicative Annual Cash Revenues / Costs ($ Billion) Pitch VR H 2 Cash Operating Cost 0.5 Product Revenue Cash Margin The value-added margin is high given low value feed and high value products UOP

15 Uniflex Process Pitch Product Can be handled in: Liquid form for nearby uses Solidified for offsite markets Feed Catalyst Pitch End Uses include: Cement Kilns Fluidized Bed Boilers Conventional Boilers Gasification Delayed Coking UOP

16 GRM ($/bbl of Crude Oil Processed) Global Average Gross Refining Margins 3 8 $/bbl over the last 20 years Indicative margin (GRM) after installation of a Uniflex complex ~10 16 $/bbl 3 8 $/bbl Low-quality and low-value feed (typically Vacuum Residue) High conversion to high quality products Source of Historical Global Indicator Margin (GIM): BP Uniflex complex DOUBLES your refinery margins UOP

17 Vacuum Distillation DAO VGO NRL in Pakistan to Construct 2 nd Uniflex Unit & Diesel VGO Lubes Stock Unicracking Atm Resid Unconverted Oil Lubes Lubes Lubes Extract Distillate from Crude Vacuum Resid Uniflex Distillate Unionfining & Diesel Vacuum Resid Solvent Deasphalting (Existing) SDA Pitch Pitch to Cement Plant Increases margins by $150 million/year UOP

18 Uniflex Benefits... The Time is Now: Falling fuel oil demand Rising clean distillates demand High prevailing crude oil prices Low cost of hydrogen production Uniflex is a highly compelling technology, maximizing the use of existing facilities to minimize capital cost, while offering a new commercially proven industry benchmark in Residue Conversion UOP

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20 Uniflex Benefits... The Time is Now: Falling fuel oil demand Rising clean distillates demand High prevailing crude oil prices Low cost of hydrogen production Uniflex is a highly compelling technology, maximizing the use of existing facilities to minimize capital cost, while offering a new commercially proven industry benchmark in Residue Conversion UOP