A World of Solutions Crude to Chemicals Opportunities and Challenges of an Industry Game-Changer MERTC, Bahrain Daniel McCarthy, Executive Vice President Group President of Technology, CB&I January 23, 2017
Safe arbor Statement This presentation contains forward-looking statements regarding CB&I and represents our expectations and beliefs concerning future events. These forward-looking statements are intended to be covered by the safe harbor for forward-looking statements provided by the Private Securities Litigation Reform Act of 1995. Forwardlooking statements involve known and unknown risks and uncertainties. When considering any statements that are predictive in nature, depend upon or refer to future events or conditions, or use or contain words, terms, phrases or expressions such as achieve, forecast, plan, propose, strategy, envision, hope, will, continue, potential, expect, believe, anticipate, project, estimate, predict, intend, should, could, may, might or similar forward-looking statements, we refer you to the cautionary statements concerning risk factors and Forward-Looking Statements described under Risk Factors in Item 1A of our Annual Report filed on Form 10-K filed with the SEC for the year ended December 31, 2015, and any updates to those risk factors or Forward-Looking Statements included in our subsequent Quarterly Reports on Form 10-Q filed with the SEC, which cautionary statements are incorporated herein by reference. A World of Solutions 2
CB&I Overview A Leading Provider of Technology and Infrastructure for the Energy Industry ~40,000 employees Breadth of services from wellhead to polymers Recent technology portfolio expansions LC-Fining LC-Max LC-Slurry >99% conversion of crude Start up of world s largest PX unit (2,200 KTA) at Reliance AlkyClean (solid acid catalysis alkylation) - in operation E-Gas: Coke & Pitch world s largest gasification unit - 2017 start up at Reliance NET Power superheated CO 2 cycle - 50 MW demo unit in construction A World of Solutions 3
Lummus Technology is CB&I For more than 100 years, Lummus Technology has been recognized as one of the energy industry s leading providers of licensed process technology CB&I acquired Lummus Technology in 2007 and has been developing and expanding the technology portfolio for 10 years Our robust technology offering and legacy of excellence in engineering and construction are unmatched in the industry LUMMUS TECNOLOGY IS CB&I A World of Solutions 4
Recent Industry Trends Petrochemicals Ethylene growth rate continues to be 4-5% per year Percentage of ethylene from ethane increasing driven by North America Limited supply of ethane in most of GCC shift to liquid feeds Where will crackers be built? Gas crackers in North America Liquid crackers in Middle East and Asia Brent Crude Oil = $65/bbl US Natural Gas = $2.7/mmbtu US Ethane = $133/ton Cash Cost Mid East Ethane N America LPG N America Ethane W Europe LPG Mid East LPG/Naphth Rest of World China Coal Asia LPG N America Naphtha Asia Naphtha W Europe Naphtha A World of Solutions 5
Refined products landscape has changed ~1% growth in refined products Gasoline demand remains flat Increased supply of NGLs Distillate demand growth modest IMO sulfur specs for bunker fuel to be implemented 2020 fuel oil reduction Recent Industry Trends Refined Products Source: IEA A World of Solutions 6
Recent Industry Trends Oil Oil prices volatile (~ $45-55/Bbl) Multiple supply sources make oil prices unpredictable: OPEC initiatives to manage supply US tight oil resilient Canadian syncrude production flat Crude volatility +/- 100% Polymer volatility +/- 40% Greater petrochemical price stability drives advantage to monetize crude by conversion to petrochemical products A World of Solutions 7
Configuration Analysis: Cracker Strategy The ethylene cracker is the heart of the petrochemical production center Feedstock flexibility is required (ethane VGO) Optimal utilization of C 4 s depends on local economics Control of propylene to ethylene ratio OCT (Olefins Conversion Technology) provides lower cost conversion flexibility to produce propylene / ethylene / butylenes A World of Solutions 8
OCT Maximum Flexibility Ethylene Feed Recycle Ethylene Lights Purge Propylene Product OCT Treater Reactor Feed eater OCT Reactor Deethylenizer Depropylenizer C 4 Feed C 4 Recycle C 4 Plus 100 kta Ethylene 200 kta Butene 300 kta Propylene A World of Solutions 9
A World of Solutions Crude to Chemicals
Change in Mindset in OTC Traditional CRUDE Chemicals Fixed Barrels Transportation Fuels OTC CRUDE Chemicals Fixed Qty. In KTA Transportation Fuels (Optional) A World of Solutions 11
owever There are challenges Polynuclear aromatics Lowest olefin yields igh coking rate Residue Extreme coking rate Contains asphaltenes that are difficult to vaporize Solids (asphaltenes and coke) will form during vaporization and cracking Asphaltenes are soluble in aromatics and insoluble in paraffins Coke is insoluble in both O C 3 C 2 C 2 C 2 N N S S A World of Solutions 12
Crude Cracking via eavy Oil Processing Scheme (OPS) Direct crude cracking can be achieved using eavy Oil Processing Scheme (OPS) Lummus patented the OPS 4 units were designed and commissioned Elimination of CDU and/or VDU with multi-stage OPS Lowest investment solution Crude Storage Storage Naphtha eaters AGO eaters VGO eaters Number of OPS stage dependent on crude gravity Dilution Steam Dilution Steam Dilution Steam Residue Naphtha Cut AGO Cut VGO Cut A World of Solutions 13
What are the Challenges? Typically the heaviest material (residue) must be removed before cracking 900 Condensate 800 Pen.Lt.Crude 5% Arab Light 20% 700 Arab VY 30+% Residue Crude residue fraction much larger 600 TBP Temperature, C 500 400 300 200 100 0 0 10 20 30 40 50 60 70 80 90 100 Vol% Distilled A World of Solutions 14
Summary of Direct Crude Cracking CB&I OPS technology successfully employed for condensates and extra light crudes Potential large volume of residue to be sold For most crudes an intermediate step is essential Mainly a niche application Miracle of hydrogen addition A World of Solutions 15
The Miracle of ydrogen Addition Raw VGO 18 wt% ydrocracked VGO 32 wt% 0% 5% 10% 15% 20% 25% 30% 35% Ethylene Yield / wt% ydrocracking of Residue and Distillates Provides the most efficient route to feeding the Ethylene Cracker in terms of Feed Flexibility AND Conversion Yield >2.0 MM MTA of Ethylene can be produced from 140,000 200,000 BPSD of AL Crude depending on flowscheme A World of Solutions 16
A World of Solutions Crude to Chemicals Configurations Matching the Refinery & the Chemicals
Minimum Investment ydrocracking - No Fuels SFO - No Residue Upgrading - ydrocracking to produce cracker feed - Produce SFO - Maximum petrochemicals / No fuels production Ethylene 2,000 KTA Minimum Investment; No Resid Upgrader; No Fuels; Sell SFO Naphtha, C2, LPG Propylene Crude (Arab Light), BPD 195,000 Ethylene, KTA 2,000 Crude 195,000 BPD Atm. Tower Kero/Diesel ISOCRACKING ydrogen Naphtha, C2, LPG Ethylene Cracker Complex + Olefins Conversion Technology Butene-1 Butadiene Propylene, KTA 1,480 Butadiene, KTA 357 Euro VI Diesel, BPD 0 Fuel Oil, BPD 54,000 Anode Coke, KTA 0 2 Required, MMSCFD 167 % Required 2 from Cracker 39 Natural Gas Required, KTA 596 Vac. Tower MTBE Benzene Chemical Yield on Crude, % 58 Total Project Cost, MM$ 6,954 %IRR 14.6 3%S SFO Mixed Xylenes SFO 54,000 BPD Py. Oil Notes 1. All cases includes ydrocracker + Olefins Conversion Technology 2. All cases produces MTBE, Butene-1, Benzene, Xylenes 3. 3% SFO priced at $21/Bbl less than crude 5. %IRR based on 70 / 30 debt / equity ratio A World of Solutions 18
ydroprocessing Residue ydrocracking offers maximum conversion and crude flexibility LC-SLURRY SDA Pitch LC-FINING LC-MAX Slurry Catalyst eavy South American VR (amaca) Pellet Catalyst Russian VR Middle Eastern VR Canadian eavy VR Conversion A World of Solutions 19
LC-FINING No Fuels LSFO - LC-FINING as Residue Upgrading - ydrocracking to produce cracker feed - Produce LSFO - Maximum petrochemicals / No fuels production LC-FINING; No Fuels; Sell LSFO Ethylene 2,000 KTA Crude (Arab Light), BPD 162,000 Crude 162,000 BPD Atm. Tower Kero/Diesel Vac. Tower ISOCRACKING Naphtha, C2, LPG ydrogen Naphtha, C2, LPG Ethylene Cracker Complex + Olefins Conversion Technology Propylene Butene-1 Butadiene MTBE Benzene Mixed Xylenes Ethylene, KTA 2,000 Propylene, KTA 1,493 Butadiene, KTA 358 Euro VI Diesel, BPD 0 Fuel Oil, BPD 25,000 Anode Coke, KTA 0 2 Required, MMSCFD 251 % Required 2 from Cracker 26 Natural Gas Required, KTA 777 Chemical Yield on Crude, % 70 Total Project Cost, MM$ 7,995 %IRR 22.4 1%S LSFO VGO Py. Oil LC-FINING 1%S LSFO 25,000 BPD Notes 1. All cases includes ydrocracker + Olefins Conversion Technology 2. All cases produces MTBE, Butene-1, Benzene, Xylenes 3. 3% SFO priced at $21/Bbl less than crude 5. %IRR based on 70 / 30 debt / equity ratio A World of Solutions 20
LC-FINING With Fuels LSFO - LC-FINING as Residue Upgrading - ydrocracking to produce cracker feed - Produce LSFO - Fuels production LC-FINING With Fuels; Sell LSFO Ethylene 2,000 KTA Crude 227,000 BPD Atm. Tower Kero/Diesel Vac. Tower LC-FINING + T VGO ISOCRACKING Naphtha, C2, LPG ydrogen Naphtha, C2, LPG Py. Oil Ethylene Cracker Complex + Olefins Conversion Technology Propylene Butene-1 Butadiene MTBE Benzene Mixed Xylenes Euro V / VI Diesel 74,500 BPD Crude (Arab Light), BPD 227,000 Ethylene, KTA 2,000 Propylene, KTA 1,469 Butadiene, KTA 347 Euro VI Diesel, BPD 74,500 Fuel Oil, BPD 20,000 Anode Coke, KTA 0 2 Required, MMSCFD 379 % Required 2 from Cracker 18 Natural Gas Required, KTA 1,011 Chemical Yield on Crude, % 49 Total Project Cost, MM$ 8,910 %IRR 24.4 1%S LSFO 1%S LSFO 20,000 BPD Notes 1. All cases includes ydrocracker + Olefins Conversion Technology 2. All cases produces MTBE, Butene-1, Benzene, Xylenes 3. 3% SFO priced at $21/Bbl less than crude 5. %IRR based on 70 / 30 debt / equity ratio A World of Solutions 21
LC-FINING With Fuels LSFO - LC-FINING as Residue Upgrading - ydrocracking to produce cracker feed - Produce LSFO - Fuels production Two Train Cracker LC-FINING With Fuels; Sell LSFO - Two Train Cracker Crude 400,000 BPD Atm. Tower Kero/Diesel Vac. Tower VGO ISOCRACKING Naphtha, C2, LPG ydrogen Naphtha, C2, LPG Py. Oil Ethylene Cracker Complex + Olefins Conversion Technology Ethylene 4,000 KTA Propylene Butene-1 Butadiene MTBE Benzene Mixed Xylenes Crude (Arab Light), BPD 400,000 Ethylene, KTA 4,000 Propylene, KTA 2,805 Butadiene, KTA 774 Euro VI Diesel, BPD 94,265 Fuel Oil, BPD 36,935 Anode Coke, KTA 0 2 Required, MMSCFD 665 % Required 2 from Cracker 22 Natural Gas Required, KTA 1,872 Chemical Yield on Crude, % 57 Total Project Cost, MM$ 14,173 %IRR 33.0 1%S LSFO LC-FINING + T 1%S LSFO 36,935 BPD Euro V / VI Diesel 94,265 BPD Notes 1. All cases includes ydrocracker + Olefins Conversion Technology 2. All cases produces MTBE, Butene-1, Benzene, Xylenes 3. 3% SFO priced at $21/Bbl less than crude 5. %IRR based on 70 / 30 debt / equity ratio A World of Solutions 22
LC-FINING + Delayed Coking: No Fuels/No Fuel Oil Anode Coke - LC-FINING + DCU - ydrocracking to produce cracker feed - Produce anode coke - Maximum petrochemicals / No fuels production Crude 138,000 BPD Atm. Tower Kero/Diesel ISOCRACKING Naphtha, C2, LPG ydrogen Naphtha, C2, LPG Ethylene Cracker Complex + Olefins Conversion Technology Ethylene 2,000 KTA Propylene Butene-1 Butadiene LC-FINING + Delayed Coking; No Fuels; Produce Anode Coke Crude (Arab Light), BPD 137,689 Ethylene, KTA 2,000 Propylene, KTA 1,481 Butadiene, KTA 373 Euro VI Diesel, BPD 0 Fuel Oil, BPD 0 Vac. Tower LCGO/CGO MTBE Benzene Mixed Xylenes Anode Coke, KTA 194 2 Required, MMSCFD 282 % Required 2 from Cracker 24 Natural Gas Required, KTA 794 Chemical Yield on Crude, % 83 VGO Py. Oil Total Project Cost, MM$ 8,492 %IRR 21.4 LC-FINING Delayed Coking Anode Coke UCO Anode Coke 194 KTA Notes 1. All cases includes ydrocracker + Olefins Conversion Technology 2. All cases produces MTBE, Butene-1, Benzene, Xylenes 3. 3% SFO priced at $21/Bbl less than crude 5. %IRR based on 70 / 30 debt / equity ratio A World of Solutions 23
LC-Slurry with Fuels ULSFO - LC-Slurry - ydrocracking to produce cracker feed - Petrochemicals with fuels production Crude 246,500 BPD Atm. Tower Kero/Diesel Vac. Tower VGO LC-Slurry + T ISOCRACKING Naphtha, C2, LPG ydrogen Naphtha, C2, LPG Py. Oil Ethylene Cracker Complex + Olefins Conversion Technology Ethylene 2,000 KTA Propylene Butadiene Benzene MTBE Mixed Xylenes Euro V / VI Diesel 106,000 BPD LC-Slurry With Fuels; Produce ULSFO Crude (Arab Light), BPD 246,515 Ethylene, KTA 2,000 Propylene, KTA 1,489 Butadiene, KTA 326 Euro VI Diesel, BPD 106,000 Fuel Oil, BPD 8,500 Anode Coke, KTA 0 2 Required, MMSCFD 417 % Required 2 from Cracker 16 Natural Gas Required, KTA 992 Chemical Yield on Crude, % 45 Total Project Cost, MM$ 9,285 %IRR 25.0 ULSFO 0.1%S ULSFO 8,500 BPD Notes 1. All cases includes ydrocracker + Olefins Conversion Technology 2. All cases produces MTBE, Butene-1, Benzene, Xylenes 3. 3% SFO priced at $21/Bbl less than crude 5. %IRR based on 70 / 30 debt / equity ratio A World of Solutions 24
Configuration Analysis: Refinery Strategy Crude Flexibility: design balances light and heavy crudes Opportunity of low cost crudes without excessive CAPEX Residue upgrading depends on: Quantity / quality of transportation fuels & fuel oil Power/hydrogen strategy Gasification provides flexibility where natural gas has limited availability Middle of the barrel processing objectives ydrogen production strategy Middle of the barrel processing depends on desired product slate: Lubes Gasoline vs. Jet vs. Diesel Aromatics igh quality / quantity of cracker feed igh on-stream factor: match refining to petrochemicals A World of Solutions 25
Analysis of Crude to Chemicals Complexes: Case Studies Minimum Investment; No Resid Upgrader; No Fuels; Sell SFO LC-FINING With Fuels; Sell LSFO - Two Train Cracker LC-FINING + Delayed Coking; No Fuels; Produce Anode Coke LC-Slurry With Fuels; Produce ULSFO LC-FINING; No Fuels; Sell LSFO LC-FINING With Fuels; Sell LSFO Crude (Arab Light), BPD 195,000 162,000 227,000 400,000 137,689 246,515 Ethylene, KTA 2,000 2,000 2,000 4,000 2,000 2,000 Propylene, KTA 1,480 1,493 1,469 2,805 1,481 1,489 Butadiene, KTA 357 358 347 774 373 326 Euro VI Diesel, BPD 0 0 74,500 94,265 0 106,000 Fuel Oil, BPD 54,000 25,000 20,000 36,935 0 8,500 Anode Coke, KTA 0 0 0 0 194 0 2 Required, MMSCFD 167 251 379 665 282 417 % Required 2 from Cracker 39 26 18 22 24 16 Natural Gas Required, KTA 596 777 1,011 1,872 794 992 Chemical Yield on Crude, % 58 70 49 57 83 45 Total Project Cost, MM$ 6,954 7,995 8,910 14,173 8,492 9,285 %IRR 14.6 22.4 24.4 33.0 21.4 25.0 Notes 1. 3%S SFO 1%S LSFO 1%S LSFO 1%S LSFO Anode Coke 0.1%S ULSFO 2. 3. 4. 5. All cases includes ydrocracker + Olefins Conversion Technology All cases produces MTBE, Butene-1, Benzene, Xylenes 3% SFO priced at $21/Bbl less than crude %IRR based on 70 / 30 debt / equity ratio A World of Solutions 26
Summary CB&I/CLG has a complete technology portfolio to upgrade ANY crude to chemicals in the most cost effective manner OPS technology successfully implemented for condensate / low residue crudes, but limited by crude slate ydrocracking provides optimum cracker feed quality LC-FINING / LC-Slurry with or without fuels has good economics Best economics achieved with world scale cracker and refinery capacity A World of Solutions 27
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