A World of Solutions
Integrating Refinery with Petrochemicals:
Advanced Technological Solutions for Synergy and
Improved Profitability
Global Refining & Petrochemicals Congress
25th - 26th May, 2017
Mumbai, India
Anil K. Sarin
A World of Solutions
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. Forward-looking 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, 2016, 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.
1
Safe Harbor Statement
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▪ About CB&I
▪ Refining business scenario in India
▪ Considerations for refining & petrochemicals integration
▪ Indmax RFCC technology features
▪ ARDS technology features
▪ Olefins conversion technology features
▪ Refinery and petrochemical configurations/schemes
▪ Case study results and summary
PRESENTATION OUTLINE
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▪ Leading provider of technology and
infrastructure for the energy industry
▪ 125+ years of experience and expertise
in reliable solutions
▪ $19.3 billion backlog (Mar. 31, 2017)
▪ More than 40,000 employees worldwide
▪ Relentless focus on safety: 0.00 LTIR
(Mar. 31, 2017)
OVERVIEW
4
CB&I HISTORY
5
EXPERIENCE AND GLOBAL REACH
50+ years
75+ years
125+ years
70+ years
100+ years
75+ years
70+ years
6
DIVERSIFICATION ACROSS ENERGY INFRASTRUCTURE
7
Fabrication Services
▪ Fabrication & erection
▪ Process & modularization
▪ Pipe fitting and distribution
▪ Engineered products
▪ Specialty equipment
▪ Engineering
▪ Procurement
▪ Construction
▪ Commissioning
Engineering & ConstructionTechnology
▪ Licensed technology
▪ Proprietary catalysts
▪ Technical services
Capital Services
▪ Program management
▪ Maintenance services
▪ Remediation and restoration
▪ Emergency response
▪ Environmental consulting
BREADTH OF SERVICES
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▪ Process heavier opportunity crudes
▪ Upgrade bottom-of-the barrel
▪ Decrease bottoms while improving crude diet flexibility
▪ Reduce production of lower value products
▪ Polymers consumption in India
▪ 7.6 kg per Capita versus 35 (world average)
▪ Polymer imports continue to increase
▪ Make higher value petrochemical products (e.g., propylene, BTX)
▪ Improve energy efficiency
▪ Achieve economy of scale
REFINING BUSINESS SCENARIO IN INDIA
Need of the Hour:
Process heavier crudes and Maximize Petrochemicals Production
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▪ Units considered in integration
▪ Atmospheric Residue Hydro-desulfurization (ARDS) unit to upgrade the Atmospheric Residue (AR)
▪ Indmax FCC unit to convert treated AR to propylene
▪ Olefin Conversion Technology (OCT) unit to convert light olefins (C2, C4 and C5) from Indmax FCC to propylene
▪ OCT feed enhancement units – CD-DeIB®, CD Isomerization
▪ Objectives:
▪ Maximize propylene production from residue
▪ Essentially create a propylene “machine” using residue as a feedstock
▪ Meet product specifications and environmental emission requirements
CONSIDERATIONS FOR REF-PETCHEM COMPLEX
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▪ Process scheme and case studies considered in the present study
▪ Typical Integrated Process Scheme
▪ Brief description of technologies
▪ Block flow diagrams (Cases 1, 2)
▪ Optimization of ARDS and Indmax RFCC Units
▪ Optimization of Indmax RFCC and OCU
CASE STUDIES FOR REFINING AND
PETROCHEMICALS INTEGRATION
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TYPICAL ARDS/RFCC CONFIGURATION
Gasoline
LCO
CLO
Naphtha
Diesel
H2
Crude
Diesel and Lighter
RFCCARDS
ATM
Tower
Typical RFCC Feed Targets:
<15 ppm Ni + V
5 Wt % CCR
0.5 Wt % Sulfur
Light Gas to
Petrochemicals
Most common configuration in grassroots projects today
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INDMAX RFCC: MOTHER UNIT FOR REFINERY &
PETROCHEMICAL INTEGRATION
Ultra Low Sulfur
Gasoline
Indmax
RFCC
Unit CDAlky
Gasoline
HDSCDHydro / CDHDS
ARDS
Ether/ Dimer
Technologies
OCU/
Reverse OCU
LPR
Ethylene
RecoveryEthylene
PRUC3s
Dry gas
Propylene
IsomerizationC4s
Alkylate
C5s
Slurry Oil to Coker Unit
Naphtha HDS+
BTX ExtractionBenzene,
Toluene, Mixed
Xylenes
C4 LPG
C3 LPG
MTBE/ ETBE/ TAME/ Dimers
LCO product
Maximize
flexibility to
address
market
changes
Maximize
Propylene,
Ethylene,
Butylenes
and BTX
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Features of Indmax RFCC Technology
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INDMAX FCC TECHNOLOGY FOR RESIDUE TO
PETROCHEMICALS
Advanced
Hardware
Well Tested
Process Parameters
& Concepts
Indmax
Catalyst
Indmax FCC
CB&I is the exclusive licensor worldwide
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INDMAX FCC TECHNOLOGY FEED/PRODUCT
FLEXIBILITY
Flexible Design Deals with Fluctuating Marketplace
Ind
ma
x F
CC
Un
it
Feeds from ARDS/ VRDS
Butylenes
Alkylation Feed
Ethylene and Propylene
High Octane Gasoline
BTX
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▪ Selective Cracking
▪ Achieves higher bottoms conversion
▪ Achieves high quantities of light Olefins
▪ Superior coke and dry gas selectivity at high reactor
temperatures
▪ Drawbacks of ZSM-5 eliminated
▪ Excellent Metals Tolerance
▪ Lower vanadium deactivation
▪ Suppresses dehydrogenation impact of nickel
INDMAX CATALYST
INDMAX FCC HARDWARE TECHNOLOGY FEATURES
Direct-Coupled Cyclones
Spent Catalyst
Distributor
MSOTM
Air Grids
Micro-JetTM
Feed Injectors
ModGridTM
Stripper
Internals
18
Trouble free start-up in Dec
2015. Continued smooth
operation to date!
SUCCESSFUL START-UP: INDMAX FCC UNIT AT
IOCL PARADIP REFINERY
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INDMAX FCC TECHNOLOGY EXPERIENCE
▪ Asia Confidential
▪ IOCL Paradip
▪ IOCL Guwahati
▪ IOCL Bongaigoan
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INDMAX RFCC FEED TARGETS
Property Desirable for Indmax RFCC ARDS
Sulfur
Avoid Flue Gas De-
sulphurisation in the Indmax
RFCC
0.5 Wt %
Max.
CCRDetermines catalyst cooling
requirements
3-6 Wt %
Max.
Nickel and
Vanadium
Determines RFCC catalyst
consumption2-50 ppm
Crackability
A combination of hydrogen
content, boiling range and
viscosity that promotes
vaporization and cracking
ARDS is preferable for preparing good feed for
RFCC/Indmax RFCC (feeds from heavy crude oils)
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OPTIMIZATION OF ARDS AND INDMAX RFCC UNITS
▪ Optimization of ARDS
▪ Extent of feed desulfurization
▪ Metals (nickel & vanadium) removal
▪ Simplification to fractionation/gas plant
▪ Effective Use of ARDS – Indmax RFCC Synergies
▪ Ensuring the sulfur trade-offs between feed/products
▪ Utilizing the higher metal tolerance capabilities of Indmax catalyst
▪ Indmax catalyst & FCC hardware – lower delta coke advantage
▪ Patented Light Feed Injection Technology for ARDS naphtha feed processing
ARDS & Indmax RFCC Synergies Capital &
Operating Cost Savings
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OPTIMIZATION OF RHDS AND INDMAX FCC UNITS
▪ Potential savings of ARDS (~30,000 BPSD) and Indmax RFCC optimization
▪ U.S. $11-$12 million Capital Costs of ARDS unit
▪ U.S. $5-$6 million per year Operating Costs of ARDS unit
▪ No capital/operating cost increase in the Indmax RFCC unit
▪ No flue gas treating unit
▪ No catalyst cooler
▪ No feed preheater
▪ Lower Indmax catalyst make-up (0.15-0.3 lb/bbl)
Higher the Throughput Improved Capital &
Operating Cost Savings
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RHDS PLANT REFERENCE LIST
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OLEFINS CONVERSION TECHNOLOGY (OCT)
METATHESIS REACTION IS ENERGY NEUTRAL
OCT upgrades lower cost butenes
0.74 ton C4 1 ton propylene
1 mole
Ethylene+1 mole
Butene-2
2 moles
Propylene=
OCT can be reversed to shift between
propylene and ethylene product
preferences
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Propylene
Heavy Naphtha
BLOCK FLOW DIAGRAM (CASE 1)
LCO
Slurry Oil
FCC C4s
Light Naphtha
Ethylene
Propylene
LPG
AR: Atmospheric Residue
RHDS: Residue Hydro Desulfurization
ERU: Ethylene Recovery Unit
PRU: Propylene Recovery Unit
OCT: Olefin Conversion Technology
HDS+AEU: Hydrodesulfurization,
Aromatics Extraction Unit
SHU+CD-DeIB: Selective Hydrogenation
and CD Deisobutylene Unit
Fuel Gas
PRU
BTX Products
C5+
Liquid
ARRHDS
OCT
SHU +
CD-DeIB
ERU
HDS+AEU
Indmax
RFCC
C3s
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Propylene
LCO
Heavy Naphtha
FCC C4s
Light Naphtha
Ethylene
C3s
OCT
Propylene
LPG
ERU Fuel Gas
BTX Products
De-
pentanizer
Light Naphtha Recycle C5s
Imported
Ethylene
AR: Atmospheric Residue
RHDS: Residue Hydrodesulfurization
ERU: Ethylene Recovery Unit
PRU: Propylene Recovery Unit
OCT: Olefin Conversion Technology
HDS+AEU: Hydrodesulfurization,
Aromatics Extraction Unit
SHU+CD-
DeIB+CD Iso:: Selective Hydrogenation and CD
Deisobutylene+Isobutylene
Isomerization Units
C5+
Liquid
ARRHDS
HDS+AEU
Slurry
Oil
Indmax
RFCC
SHU +
CD-DeIB +
CD Iso
PRU
BLOCK FLOW DIAGRAM (CASE 2)
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▪ Estimated payback period:
▪ Case 1: 3 years
▪ Case 2: Less than 3 years
Products Study Case 1 Study Case 2
Total Propylene 33% 40%
Heavy Naphtha
(BTX Feed)24% 24%
LCO 12% 12%
CASE STUDY RESULTS
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▪ Flexible ARDS-Indmax RFCC configurations to produce fuels and petrochemicals to meet demand
▪ ARDS and Indmax catalyst technologies continuing to evolve to meet the challenges of:
▪ Increasingly diverse feed sources and difficult feed properties
▪ Increased processing severity expectation
▪ ARDS-Indmax RFCC provide synergies that significantly reduce capital & operating costs
▪ Case study demonstrates an optimized ARDS and Indmax RFCC producing maximum propylene with less than a three-year payback time
SUMMARY
29A World of Solutions
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