Ax Ens

1

Refining-Petrochemical

Synergies & Opportunities

Christian Dupraz

2OAPEC Middle East 2010 – Manama, Kingdom of Bahrain - 25-27 October 2010

Agenda

• Refining & Petrochemical (R&P) synergies Facts & figures

• Axens portfolio for R&P integration :

• Refinery & Steam Cracker

• Refinery & ParamaX Suite for Aromatics

• Around (R)FCC: PetroRiserSM, FlexEneTM, Olicrack

• Olefins upgrading and purification

• APU: new way for BTX production

• Conclusion


Agenda








• Conclusion


0

100

200

300

400

500

600

700

800

900

1980 1990 2000 2010 2020 2030

World demand, index

Polymers

GDP

Crude oil

Avg

Growth

rate

1997-07

4.7%

3.9%

1.5%

Polymers demand growing much

quicker than crude oil production

0

100

200

300

400

500

600

700

800

900

1980 1990 2000 2010 2020 2030

World demand, index

Polymers

GDP

Crude oil

Avg

Growth

rate

1997-07

4.7%

3.9%

1.5%

Polymers demand growing much

quicker than crude oil production

Alternative routes to polymers not fast

enough to feed petchem growth

Feedstock from oil refining (LPG,

Naphtha, …)

EthaneRenewables

MethanolTo Olefins

100

200

300

400

500

Mt

Olefins & Aromatics feedstock

sources

86 %

85 %

82 %

1980 2005 2030

Alternative routes to polymers not fast

enough to feed petchem growth

Feedstock from oil refining (LPG,

Naphtha, …)

EthaneRenewables

MethanolTo Olefins

100

200

300

400

500

Mt

Olefins & Aromatics feedstock

sources

86 %

85 %

82 %

1980 2005 2030

Market Analysis

Source: Total Petrochemicals


Refining & Petrochemical Synergies

• Taking out total profit from low value crude oil to high value refined/petrochemical products

• Enhanced cost competitiveness

• Maximized margin by flow exchanges

• Economy of scale

• Optimized CAPEX/OPEX

• Increased flexibilities towards

• Crude price volatility

• Refined/ petrochemical market evolution

• Financial resistance to cyclic market

• Environmental benefits


R&P Flow Exchanges

Aromatics Complex

ParamaX

Steam

Cracker

CDU

VDU

FCC

Main Refining UnitsConcerned

Exchanged flows Petrochemical Units

Products

Refinery Off Gases

FCC C3/C4

Naphtha SR or cracked

Middle Distillates

VGO

Hydrocracker bleed

Reformate

Heavy Naphtha from

Maxi C3= FCC

Polyethylene

Polypropylene

…

Polystyrene

Polyethylene

terephthalate

…

Hydrogen

C4

Pygas

ReformingCCR

RFCC

Hydrocracker

Raffinate

Raffin.


R&P IntegrationKey Issues for Scheme Selection

• Geographical location and

targeted markets (local vs export)

• Flexibility window for feedstocks and

products

• Investment constraints


Agenda








• Conclusion


Case Study 1Feasibility Study

SITE LOCATION EVALUATION

MARKET STUDY / MARKET ANALYSIS

CRUDE SELECTION

MASS BALANCE MODELS

PROCESS SCHEME OPTIMISATION

COST ESTIMATION (UP TO CLASS IV)

FINANCIAL ANALYSIS &

PROJECT RISK ASSESSMENT

RISK STUDY &

ENVIRONMENTAL IMPACT

ASSESSMENT

Unit Local

Market

Export

LPG Kbd 2.2 -

Gasoline Kbd 4.8 -

Jet A1 Kbd 0.52 0.052

Lighting

Kerosene

Kbd 0.1 0

Diesel Kbd 12.5 Max

HSFO Kbd Min Min

PE Kt/y 300

PP Kt/y 300

PVC Kt/y 120

Minimized Investment


Case Study 1Refinery + Steam Cracker

VDU

VBU

HDSKero & GO

Steam

CrackerTHU

HD1-HD2

PVC

PE

PP

NHT Isom.

BT Extraction

Kero

GO

Fuel Oil

VGO

CDU

FG

C2/C3/C4

HN

LN

Raffinate

WN

Jet

Diesel

Kero

GO

KeroHCKHCK Bleed

C5

PyOil

Pygas

C4=

C3=

C2=

Gasoline

Naphtha

HN + LN

VBU GO

VBU Res

FRNAR

GO SR

Benzene

PVC

PE

Comonomer

LPG

HDT

Pygas

C4 to SMR

to SMR

NaCI + HCI

C4

SHUFRAC

PP

Tol

C7-

C8+

Blend

VR

SHU

FRAC

GO

C3

C2


Case Study 1Overall Mass Balance

23%

PURCHASES Kt/y Kbd wt%

Crude Blend 26 3538 75 95%

Hexene 27 0.5 1%

Sodium Chloride 138 4%

Hydrochloric acid 8 0%

Total 3711 100%

SALES Kt/y Kbd wt%

LPG 68 1.3 2%

Mogas 91 65 1.7 2%

Mogas 95 129 3.3 4%

Jet A1 29 0.7 1%

Automotive Diesel Oil 1592 35.1 53%

Heavy Fuel Oil 396 7.4 13%

Sulphur 19 1%

Polyethylene 300 10%

Polypropylene 213 7%

PVC 120 4%

Benzene 59 1.1 2%

Total 2990 100%


Agenda








• Conclusion


High

C3= FCC

CDU

Case Study 2Refinery with High C3= FCC + ParamaX

Benzene

Toluene

Paraxylene

SR Naphtha

Propylene

Naphtha

Bleed

HCGO

VGO

Kero

Coke

Aromatic Complex

ParamaX

Delayed

Coker

Hydro

cracker

VDU

Naphtha

LPG

Diesel


Aromatics Complex Blocks FunctionsParamaX Suite


Agenda



• Refinery & steam Cracker





• Conclusion


Ethylene

Propylene

Ethylene

Propylene

Benzene

ParaxyleneNaphtha

HDT &

Splitter

MIDDistillate

HDT

Steam

Cracker

High

C3=

FCC

Pygas

&

Petro FCC

Naphtha

HDT

Butadiene

Extrac.

C4 HDT

VDU

150 000bpsd

KERO

HDT

DieselCoke

Butadiene

Delayed

Coker

C2

C3

HCC

UCO

LPG

Kero

Diesel

CDU

LPG

Naphtha SR

Heavy

Naphtha

VGO

Kero

Aromatic

Complex

ParamaX

LPG

Raffinate HDT Pygas

C5 Recycle

LCGO

Naphtha

HCGO

Heavy

Naph.

Light

Naph

+Kero.

LPG

LPG

Pygas

C4

C4 recycle

Case Study 3Refinery + ParamaX + High C3= FCC + Steam Cracker

Naphtha


Axens Technologies Around FCC (1)

Source: Nexant Oct. 08 + CEH SRI July. 09

2008 Production

~ 74 Million tons (Mt)

On purpose production• Metathesis

• Olefins cracking

• MeOH to propylene

• C3 dehydrogenation

From Refineries (FCC)

From Steam crackers

58%

34%

8%

Main RiserResid

PetroRiserLCN

720-740°C

660°C

550°C

C/O 8590°C

C/O 12

R2R Unit

Resid to Propylene Technology Suite


Axens Technologies Around FCC (2)

FlexEneTM

LPG ex FCCSelective cracking

Oligomerisation

C4 olefins + 15 ~ 20 %

Propylene

OlicrackTM

Up to + 50%

Propylene

FCC or

Resid FCC

R2R Olicrack

Coker

Steam Cracker

Alternative fuel

units

C4 Cut

C5 Cut

C6 Cut Ethylene

Propylene

C3=/C2= ratio > 3- 4

FCC or

Resid FCC

R2R Olicrack

Coker

Steam Cracker

Alternative fuel

units

C4 Cut

C5 Cut

C6 Cut Ethylene

Propylene

C3=/C2= ratio > 3- 4

FCC or

Resid FCC

R2R Olicrack

Coker

Steam Cracker

Alternative fuel

units

C4 Cut

C5 Cut

C6 Cut Ethylene

Propylene

C3=/C2= ratio > 3- 4


Agenda








• Conclusion


MAPDSelective

Hydrogenation

MAPDSelective

Hydrogenation

C3=

C4

Ethylene

Propylene

1-Butene

MEK

Octenes

MTBE, ETBE

TAME, TAEE

C5-C10

Pygas

PygasSelective

Hydrogenation

GHU1

PygasSelective

Hydrogenation

GHU1

C5 Etherification

CatacolC5 Etherification

Catacol

PygasHydrodesulfurization

GHU2

PygasHydrodesulfurization

GHU2

Dimerization

AlphaButolDimerization

AlphaButol

Isobutane

Dehydro.

Dimerization

DimersolDimerization

Dimersol

C6-C10

n-Butane

Lin. - Olefins

C4/C5Olefins

Hydrogenation

C4/C5Olefins

Hydrogenation

C5

Hydration

Ste

am

Cra

ck

er

Advanced

Pygas

Upgrading

APU

Advanced

Pygas

Upgrading

APU

C2

LPG

C6-C10

To Motor Gasoline Pool

C4 AcetylenesSelective

Hydrogenation

C4 AcetylenesSelective

Hydrogenation

ButadieneMaximum Butadiene

Max B=1Hydrogenation


C4Etherification

Catacol

C4Etherification

Catacol

ButadieneSelective

Hydrogenation

ButadieneSelective

Hydrogenation

Maximum Butenes

2-Butenes



IB= Purification

IsopureIB= Purification

Isopure

Isobutylene

C5=

Skeletal Isomerization

Iso-5

Skeletal Isomerization

Iso-5

C9-C10

C4/C5

Butadiene

Extraction

Benzene

TolueneC8 Aromatics

to Aro. Complex

Oligomerization

α-Select/ α-HexolOligomerization

α-Select/ α-Hexol

C6-C8Extraction

Sulfolane

Morphylane

Extraction

Sulfolane

Morphylane

Super-

FractionationSuper-

Fractionation

Purification

MultibedPurification

Multibed

Oligomerization

Selectopol

Polynaphtha

Oligomerization

Selectopol

Polynaphtha

OlefinsHydrogenation

OlefinsHydrogenation

Solvents

Removal of

Arsenic & Mercury

RAM II

1-Hexene

Condensates

Sulfur

Removal

OATS

Sulfur

Removal

OATS

Axens Technologies for Olefins Upgrading


Olefins Purification

Typical contaminants

• CO2

• H2O

• Other oxygenates

• Sulfurs compounds

• NH3, amine

• Arsine

• Phosphine

• Mercury

• …

Products

• Feedstock Olefin

upgrading units

• Polymer grade ethylene

• Polymer grade propylene

Axens’ high performance adsorbents

AxSorb & AxTrap

AxSorb 531

AxSorb 970

AxSorb 911

AxTrap 191

AxSorb 980


Agenda








• Conclusion


New technology developed by SK, Korea

Concept validated by industrial trial

• SK Refinery

Commercial agreement signed in July 2005

Axens selected as exclusive licensor for its

strong position in

• Pygas hydrogenation

• Aromatics production

Advanced Pygas Upgrading (APU)


• Hydrocracking of paraffins

• Ring opening on naphthenes

• Hydrodealkylation of heavy

aromatics

APU Main Reactions


• Cracking of non aromatics

• high purity BTX left, recovered by distillation

• High quality C2-C4 for co-cracking produced

• Maximization of ethylene & propylene yields

• Hydrodealkylation of Heavy Aromatics

• Conversion of heavy pygas fractions, C9-C10

• Additional production of BTX

• Mixed xylenes quality improved

APU Main Benefits


1st Stage

Hydro.

C5s

C11+ (opt.)

C6 – C10

2nd Stage

Hydro.

FG +

H2SFG

APUBTX

FG +

LPG

Hydrogen

Fuel Gas (FG)

Ethylene

Propylene

Butadiene

C4 Olefins

Steam

Cracker

recycle to steam cracker furnaces

C5+ (Pygas)

C6+

APU Integration into Cracker

H2H2

H2


Agenda








• Conclusion


Conclusion

Integrating Refining & Petrochemical presents

synergies realizable with Axens’ portfolio :

• Full range of technologies from residue

conversion to olefins / aromatics maximization

• Full range of products : catalysts &

absorbents

• Full range of associated services : tech

service, consulting…

29

Refining-Petrochemical

Synergies & Opportunities

Date post:	04-Apr-2015
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