Refinery / Petrochemical Integration Gildas Rolland 1
Global Middle Eastern Market 2 nd ~30% 10ppm Growing market for global Refined Product Demand +1.6% AAGR 2014-2035 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, 2014-2035 4 ME 2 +1.6% Africa +1.9% CIS +1.1% 3 World +0.9% Asia +1.3% Source: HART Energy 2
Increase ME Refineries Conversion Rate (300) (250) (200) (150) (100) (50) 6 5 4 3 2 1 0 Nelson Refinery Complexity Ranking Mbpd (Mtpy) 28 < 4.0 4.1-8.0 8.1-10.1 > 10.1 11.1 8.2 6.2 20 4.2 4 5.2 5.4 Number of Refineries @ Index 1 6.9 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
Mb/d Refining and Petrochemical Integration Incentives World Trend 900 800 700 600 500 400 300 200 100 0 World demand index Polymer demand 1980 1990 2000 2010 2020 2030 GDP*: Gross Domestic Product GDP* Gas prod. Oil prod. Source : Total Annual growth 1980-2030 ~ 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
Refining & Petrochemical Integration Incentives Middle Eastern Trend Refining 2014-2019 Petrochemicals 2012-2020 4 Mb/d 3 2 1 0 25% Regional share of 2014-2019 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 100 80 60 40 20 0 7% 7% 15% 17% 2012 2020 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
Production of Petrochemicals Base Compounds Targeting Heavy Naphtha for Aromatics Production Targeting Light Olefins Production Propylene On Demand Olefins Production 6
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
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
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
Aromatics Complex Blocks Functions ParamaX Suite 10
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
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
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
Production of Petrochemicals Base Compounds Targeting Heavy Naphtha for Aromatics Production Targeting Light Olefins Production Propylene On Demand Olefins Production 14
A Propylene Sourcing: Catalytic Cracking Technologies Propylene Yield %wt 25 23 21 19 17 15 13 11 9 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
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
HS-FCC A Worldwide Cooperation 17
Integration Benefits HS-FCC : Technology development 3 DFRs controled scale-up x300 X100 X8.5 1996-2001 2001-2004 2007-2013 2014 0.1 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
On Demand Alpha Olefins Production Co-monomer requirements: 1-butene and 1-hexene for polyethylene applications 900 800 700 600 500 400 300 200 100 0 World demand index Polymer demand 1980 1990 2000 2010 2020 2030 GDP*: Gross Domestic Product GDP* Gas prod. Oil prod. Source : Total Annual growth 1980-2030 ~ 4 % ~ 3 % ~ 2 % ~ 1 % Sustained growth for LLDPE and HDPE demand 1-butene and 1-hexene 2010-2015 AAGR ~ 5 % 1-butene and 1-hexene sourcing? 19
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
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
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
Thank you! And see you on Axens Blog axens.net/blog 23