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Refining and Petrochemical Integration Case Study
Ccile Plain
1
Axens P2 Services: Your Partner for Major Projects
Asia-Pacific Market Highlights
Case Study: Refinery and Petrochemical Integration
Objectives and Definitions
Project Execution
Conclusions
Agenda
2
Hydrographic Study and Marine Facility Design Petroleum Terminal Study
Project stage (Grassroots & running plants)
Added Value Activities
P2 Consulting Services
Site Location Evaluation
Feedstock & Product Market Analysis
Crude Opportunity
Commercial Excellence
Energy Efficiency GHG Mitigation
CO2 Credit Identification And Valorization
Risk Study & Environmental Impact Assessment
Oil Loss Reduction
Cost Estimation, Financial Analysis &
Risk Assessment
Linear Programming Services
Pre-feasibility Study
Feasibility Study
Conceptual Engineering Study
Integrated Process Solution 3
-60%
-40%
-20%
0%
20%
40%
60%
80%
100%
PROJECT PROGRESS
time
Start-up
PROJECT COST
ACCURACY
% Cost Estimation Accuracy
Pre-feasibility
Feasibility
Conceptual
Axens P2 BU
EPC CONTRACTOR Basic
Feed
Axens PL BU
Project Scope
P2 Scope of Work versus Cost Accuracy
4
Agenda
Axens P2 Services: Your Partner for Major Projects
Asia-Pacific Market Highlights
Case Study: Refinery and Petrochemical Integration
Objectives and Definitions
Project Execution
Conclusions
5
0.0
0.5
1.0
1.5
2.0
2.5
3.0
Axens & other sources
Market Structure 2010 vs. 2030
Other* = Kerosene ( Jet Kerosene), Refinery Gas, Petroleum Coke, NGL, Lubricants, Bitumen, Paraffin Wax, Refinery Losses,
2010-2030
AAGR
Other* 0.9%
LPG 0.4%
Naphtha 2.7%
Motor Gasoline 2.4%
Jet Kerosene 3.6%
On-road diesel 2.6%
Off-road diesel 1.2%
Fuel Oil 0.3%
Mbdoe
Incremental Demand 2010-2030
11.0%
15.6%
13.1%
3.7%
19.9%
14.8%
10.2%
11.7%
8.2%
13.8%
15.4%
5.3%
22.2%
17.6%
7.7%
9.9%
0%
20%
40%
60%
80%
100%
2010 2030
27.4 Mbdoe
39.2 Mbdoe
2010-2030 AAGR 1.8%
Oil Products Demand Asia Pacific 2030
6
Petrochemical Products Demand 2004-2020
60000
100000
140000
180000
2004 2009 2014 2019
2000
6000
10000
14000
18000
2004 2009 2014 2019
World Asia 000 MT 000 MT
Ethylene
Propylene
+ 154 %
+ 54 %
+ 55 % + 56 %
Growth in Asian ethylene demand is equal to the very high worldwide demand growth
Growth in Asian propylene demand is significantly larger than global demand growth
Ethylene
Propylene
7
Agenda
Axens P2 Services: Your Partner for Major Projects
Asia-Pacific Market Highlights
Case Study: Refinery and Petrochemical Integration
Objectives and Definitions
Project Execution
Conclusions
8
Project: Key Figures World scale Refining & Petrochemical Plant Configuration Study
20 bn$ Investment
Meet primary C2-C4 olefins demand
Heavy, sour Middle East crude input
3 Mt/y Naphtha Cracker Did you know? The project is one of the worlds most extensive integrated refining and
petrochemical complexes 300 000 bbl/day Crude Distillation
9
Key Project Objectives
Kick-off
meeting
Milestone I Milestone II
Project
accomplishment
Time
Project shall
capture demand growth for high value-added petrochemical specialties
be flexible and fit into existing refining system
meet future refined product demand and specifications
create opportunities for the development of a major industrial hub including new maritime infrastructures
10
020
40
60
80
100
C2 = C3 = C4 =
Steam Cracker
Refinery
% of demand Production Plant
5 Units
15 Units
8 Units 5 Units 6 Units
Total of 42 Process Units
C5 = 3 Units
Axens P2 ensured integration of facility.
Refining and Petrochemical Integration
11
Optimization of refinery process configuration and steam cracker integration
Initial decision: Feed a stream cracker with naphtha from a refinery
Petrochemical production is a complex business which differs from refining
Development of different derivatives plant options with high-profile licensor partners in close collaboration with the client
Options ranked based on a preliminary cost estimate and financial analysis
Value-Addition with Petrochemical Derivatives
12
2012-2025 Motor Fuels Demand
& Future product specifications (Euro IV)
Light
Medium
Heavy
Export of excess to
region
Type of crude input to be studied was
predefined by customer
Identify intermediates that can be exchanged
between sites. Other investments?
Integration and Synergy Between Sites
13
Integrating a refinery with a steam naphtha cracker and petrochemical facilities offers the best ROI for
satisfaction of the C2-C4 demand
But how can the value and benefits of a new refinery be optimized?
Maximize conversion of residue to
transportation fuels
Heavier crude
processed
Best value for cracker feed, satisfy fast-growing gasoline demand and unprecedented crude-processing flexibility
Main targets for refinery
14
Multi-criteria site localization study
+ Three phase harbor implementation study
Geographic
localization
Harbor
Infrastructure
Harbor to
site transfer
Infrastructure
Most suitable location Shipping Channels
Jetties Storage facilities
Rail Road Waterways
Three potential sites Identified and ranked by
multi criteria considerations:
Social impact Local economics Environmental constraints
15
Axens P2 Services: Your Partner for Major Projects
Asia-Pacific Market Highlights
Case Study: Refinery and Petrochemical Integration
Objectives and Definitions
Project Execution
Conclusions
16
Phase 1b Steam Cracker and
Refinery integration
Phase 1a Conversion strategy
screening
Axens in-house tools and data
Phase 2
Petrochemical Intermediates & Value added
products
Consulting with petrochemical
licensors
Axens know-how and co-operation with
third party licensors
Phase 3
Process specifications
(Pre-basic design)
Class V cost estimation (+/- 50%)
Class IV cost estimation (+/- 30%)
Optimal communication environment ensured by dispatch of client task force to Axens head office
Project Technical Phases: Duration: 1 year
17
Phase 1a: Conversion Strategy Screening
0
0.5
1
1.5
2
Mbdoe
Coking
Cat. Cracking
Hyd. Cracking
Heavy Oil / Res. Fuel
Asia-Pacific Conversion Capacity
No single correct strategy. Conversion type is closely
related to the countrys future demand.
All options studied. Best two options were: Coker / MHC / DCC versus ARDS / RFCC
Distillates / Olefins versus Gasoline / Olefins
18
CAPEX Advantages: optimized yields, shared utility production OPEX Advantages: energy efficiency by utility consumption
Optimization with LP Model
Feedstock LPG, Naphtha, Distillates, HCK
Unconverted Oil
Refining capacity Domestic demand
Export market
Bottom-of-the-barrel Coker or Visbreaker
Maxi Diesel scheme
Petchem plant Ethylene production volume constraints
Phase 1b: Cracker and Refinery Integration
19
Typical Naphtha Steam Cracker
Products
Many different value added products can be produced (Hygiene, Automobile, Pharma, ) from precursors
Configuration study based on clients petchem strategy, petrochemical licensor know-how, local economics, trading and future market
Decision has major impact on future plant economics (ROI).
Phase 2: Value-added Products
20
Overall Design Basis Environment and safety Class IV Cost Estimates Financial and risk
analysis
Overall Plot Plan
General Project
Process Flow Diagrams Material & Utility
balances
Sized Equipment List Catalyst and Chemical
Consumption
Effluents, Waste and Environment
Flare Loading
Process
Infrastructure
Liquid Bulk handling Dry Bulk Export Container handling Jetty and Haul Road Gas Feeding Pipe
Utilities
Off-sites
Tankage Buildings
Fuel Gas Systems Power and Steam
Generation
Water Systems Plant Air
Phase 3: Process Specifications
Ready for FEED!
500 Documents
21
Highly complex and complete detailed feasibility study performed within tight schedule.
Project is currently in FEED phase
Successful collaborative project for Axens and Client (win win situation)
Axens is the ideal partner for Refining and Integrated studies because of its immediate access to a wealth of proprietary information.
Conclusions
22