A Century of Innovation in the Oil and Gas Industry
© 2016 UOP LLC. All rights reserved. UOP 7197-1
LD ParexTM Aromatics Complex: Lowest Cost of Production for PX Technology John Robertson Honeywell UOP
5th IndianOil Petrochemical Conclave
February 4, 2016Mumbai, India
2009 - 2010
Technology
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Net Feedstock
Capital Costs
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How Can UOP Further Reduce Your Paraxylene Production Costs?
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Aromatics Complex Costs
2009 - 2010
Technology
Energy Efficient
Aromatics Complex
LD Parex Aromatics
Complex
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LD Parex Aromatics
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Heavy Desorbent Has Been the Primary System Used for Selective Xylene Adsorption
• When UOP started licensing the selective pX adsorption, or Parex, process in the 1970s, both heavy and light desorbent (LD) systems were used
• As energy prices continued to increase, our clients have continued to choose the heavy desorbent (HD) system for pX separation
- Based on our knowledge at the time, the HD system adsorbent had a lower
desorbent to feed ratio (D/F)
- A lower D/F enables less circulation and, therefore, lower utilities consumption
• Over the last 40+ years, UOP has gained extensive manufacturing knowledge from the production of a range of commercial adsorbents for xylenes separation
- Adsorbent innovation primarily focused on HD system, since most prevalent
- ADS-47 is well proven as providing a step change in adsorbent performance
What if we take the knowledge we now have of the HD system adsorbent and apply it to an LD system?
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UOP’s Continuous Innovation Drives Down pX Cost of Production
• Combining the extensive adsorbent manufacturing knowledge and experience with engineering advancements have enabled UOP to develop the LD Parex Aromatics Complex technology
• ADS-47 only required slight modification to make it compatible with a light desorbent system
• Removal of heavy desorbent enables separation efficiencies that allow for an optimized fractionation flow scheme
- 20% less equipment and fractionation tray requirements
reduces capital investment by 15-17%
- Less constrained flow scheme enables same energy savings
as the EEAC design, at a lower total investment cost
- Flow scheme also enables flexibility to shift CAPEX savings
to additional OPEX savings, depending on your needs
15-17% reduction in CAPEX combined with reduced OPEX of EEAC design enables lowest cost pX production in the industry
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Back to the
Future
Comparison of UOP Heavy & Light Desorbent Parex Systems
Heavy Desorbent Light Desorbent
First Year Licensed 1971 1972
Units Licensed 100 13
Desorbent para-diethylbenzene toluene
Latest Adsorbent ADS-47 ADS-50; ADS-40
Aromatics Selectively
Adsorbed para-xylene para-xylene; meta-xylene
No. Chambers 2 2
No. Downstream
Fractionation Columns 5 3
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Removal of the Heavy Desorbent Allows Opportunity for Optimized Fractionation Current Energy Efficient Aromatics Complex (EEAC) Design
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Isomar Unit
Raffinate
Benzene
Heavy Aromatics
Column
Reformate Splitter
Heavy Aromatics
Reformate
Deheptanizer
Light Ends
Light Ends
Xylene Column No. 2
Paraxylene
Finishing Column
Raffinate Column 1
Desorbent Rerun Column
Extract Column
Desorbent Makeup
Tatoray
Unit
ED Sulfolane Unit
Parex
Unit Raffinate Column 2
Benzene-Toluene Column
Xylene Column No. 1
Heavy Aromatics
Heavy Aromatics Rectifier
A8 Rerun Column
A8 Stripper
Note: Columns are to scale
As Needed Make-up Desorbent
Raffinate Column
Paraxylene
Paraxylene Column
• Uses Heavy Desorbent (p-DEB)
• Desorbent taken as Raffinate & Extract Column Bottoms
• Xylene Fractionation requirements set by A9 limit in Xylene Column overhead
• Energy reduced 20-40% by evaluating overall complex as a “system” and rearranging heat integration
Compared to a heavy desorbent system, using light desorbent enables separation efficiencies that allow for an optimized fractionation flow scheme, enabling high energy efficiency at a
significantly reduced cost.
Note: Columns are to scale
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Isomar Unit
Raffinate
Benzene
A8 Rerun Column
Reformate Splitter
Heavy Aromatics
Reformate Light Ends
Paraxylene
Paraxylene Column
Raffinate Column
Extract Column
Tatoray
Unit
ED Sulfolane Unit
Parex
Unit A8 Stripper
LD Parex Aromatics Complex Design
Heavy Aromatics Rectifier
Benzene-Toluene Column
As Needed Make-up Desorbent
The 3 main components of the LD Parex Aromatics Complex system are all
commercially proven & reliable:
1. Desorbent
2. Adsorbent
3. Heat Integration • Uses Light Desorbent
(Toluene)
• Desorbent taken as Raffinate Column overhead & Extract Column sidedraw
• A9 limit in XC overhead no longer a design constraint
• Overall complex still evaluated as a “system” to increase heat integration and reduce energy input
UOP’s 45 Years of Sorbex Technology Spans the Globe
US:
• 7 HD
• 3 LD
LA:
• 1 HD
ME:
• 8 HD
• 1 LD
EU:
• 14 HD
• 2 LD
OAP:
• 11 HD
• 1 LD
China:
• 21 HD
• 2 3 LD
Russia / CIS:
• 3 HD
Mexico:
• 1 HD
Korea:
• 12 HD
• 2 LD
India:
• 7 HD
Taiwan:
• 5 HD
• 1 LD
Japan:
• 10 HD
• 1 LD
UOP’s Sorbex technology includes 100 HD & 13 14 LD Units with more than 1,600 operating years of experience
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HD - Heavy Desorbent
LD - Light Desorbent
New LD Parex Unit Announced:
600 KMTA PX Project in China Using
UOP’s New LD Parex Design for
2016 Construction
LD Parex Aromatics Complex design builds upon decades of reliable operating experience that only UOP holds
Light Desorbent Systems are Well Proven Technology
Location
Startup
Year
Operating
Years
Light Desorbent Parex
France 1972 43
Texas 1974 41*
Meta-Xylene Sorbex
Texas 1998 17*
Korea 1998 17*
Texas 1998 17*
Singapore 1998 17*
China 1999 16*
Spain 2007 8*
Korea 2008 7*
Japan 2010 5*
Taiwan 2011 4*
China 2017
Middle East 2017
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* Operating with initial adsorbent load
Technology Evolution Transforms Prior Inventions into Economical Solutions
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Ford Model T
1908
Tesla Model S
2009
Thomas Parker Electric Car
1884
ADS-4 (Parex - Light Desorbent)
1972
ADS-7 (Parex - Heavy Desorbent)
1980 ADS-50 (Parex - Light Desorbent)
2015
Continuous Innovation Translates across Both Heavy & Light Desorbent Systems
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1971 – ADS-3
1980 – ADS-7
1990 – ADS-27
2004 – ADS-37
2011 – ADS-47
Heavy Desorbent
Adsorbent
Portfolio
Light Desorbent
Adsorbent
Portfolio
2015 – ADS-50
1996 – ADS-40
ADS-23
1972 – ADS-4
ADS-47
Series
ADS-27
Series
ADS-3
Series
In 44 years of licensing the Parex process, all production capacity & product quality guarantees have been achieved
0.5
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1
ADS-7 ADS-27 ADS-37 ADS-47
Relative Requirement to Process Same Amount of Feed
Adsorbent
Desorbent
ADS-47 Series Adsorbent Provides Dramatic Performance Improvements
Significant breakthrough in paraxylene separation adsorbent technology provides ability to improve light desorbent economics
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Parex Design Benefits
from ADS-47
• Adsorbent chamber reduced by 35%
• Desorbent circulation reduced by 32%
• Highest commercially proven reliability
• Successful operation in 10 units starting in 2011
Heavy Desorbent Adsorbent Portfolio
Latest Generation
Light Desorbent Adsorbent
Heat Integration Technology Based on Energy Efficient Aromatics Complex Design
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• As with EEAC design, overall complex evaluated as a “system” to increase heat integration and reduce energy input
• LD Parex simplified fractionation scheme enables:
- Capital savings in addition to energy savings
- Flexibility to shift capital savings to additional energy savings
Location
Startup
Year
Capacity,
KMTA
Korea 2014 1,000
Korea 2014 1,000
Korea 2014 1,400
Middle East 2017 1,440
China 2018 800
Middle East 2020 1,440
All components of the LD Parex Aromatics Complex design are well proven & reliable
LD Parex Aromatics Complex Offers Lowest Cost PX Production
Conventional EEAC
LD Parex Aromatics Complex
1971 2011
2015
20 – 40% OPEX Reduction
15-17% CAPEX Reduction
OPEX Reduction and
CAPEX Reduction
LD Parex Aromatics Complex Combines Step-Change Improvements in Capital AND Energy Efficiency
Energy Consumption
CA
PE
X
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LD Parex Aromatics Complex Drives Step-Change Improvement in Capital Efficiency
• 20% less equipment results in:
-15 – 17% lower estimated erected cost
-20% lower steel weight
-25% less plot space
-Reduced EPC schedule risks
-Decreased maintenance costs
• 7% less adsorbent
• Expensive external desorbent supply eliminated
• Total plant inventory reduced by 24%
-$8 MM NPV contribution from lower working capital
-$1/MT PX reduction in operating cost
• Maintains industry leading energy efficiency
• Net result 3-7% improvement in IRR
Combination of reduced capital investment and energy costs enables lowest cost pX production
Equipment Type Delta
Major Columns* - 4
Other Vessels -2
Heat Exchangers -6
Tanks -2
Pumps -2
Total -16
*Fractionation Trays -185
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120.0
Next Best Alternative LD Parex Aromatics Complex
Refe
ren
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Total Steel Weight by Process Unit
Xylene Fractionation
Isomerization
PX Purification
Transalkylation
B-T Fractionation
Extractive Distillation
20% Weight Reduction
LD Parex Technology Saves 20% in Steel Weight
LD Parex Complex reduces the total steel weight of vessels by 20%
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Results Confirmed in 2014 by Major Western EPC
Basis: 1200 KMTA PX Complex
Extractive Distillation
B-T Fractionation
Transalkylation
PX Purification
Isomerization
Xylene Fractionation
Dec
reas
ed
Inve
stm
ent
Co
sts
Independent Cost Savings Analysis by Major Western EPC
Process Unit Comparison (1200 KMTA PX)
Next Best
Alternative LDPX Delta (%)
Extractive Distillation
Base
+12%
B-T Fractionation -0%
Transalkylation -6%
PX Purification -2%
Isomerization -39%
Xylene Fractionation -46%
Total -17%
1,200 kMTA pX complex; USGC basis:
• Equipment Cost Savings = 17%
• Total Installed Cost Savings = 15%
Sulfolane
B-T Fractionation
Tatoray
Parex
Isomar
Xylene Fractionation
17% equipment cost
savings
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20% reduction in equipment results in 15-17% capital savings, as confirmed
by a major western EPC
Next Best Alternative LD Parex Aromatics Complex
Equipment Cost Comparison, Breakdown by Unit
Extractive Distillation
B-T Fractionation
Transalkylation
PX Purification
Isomerization
Xylene Fractionation
Simplified, Less Constrained Design Provides Significant Advantages
• Less equipment and elimination of external desorbent supply
results in less liquid inventory
-Enables easier, faster startup and shutdown
No desorbent treatment requirements
Flexibility to divert liquid inventory without losing expensive desorbent
-Minimizes potential environmental exposure
• 15-20% reduction in flare loads
• Ability to use HP Steam in place of fuel
-Elimination of major fired heaters further improves safety
-Enables even larger flare load reduction
-Provides further plot space reduction
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Technology advancements enable
safer, more reliable and
environmentally friendly design
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V (
$M
M)
Discount Rate (%)
LD Parex Aromatics Complex
Next Best Alternative
2009-2010 Technology
Typical Hurdle Rate
+$530 MM Higher NPV Compared to 2009-2010 Design
+$115 MM Higher NPV Compared to Next Best Alternative
+8% IRR Compared to 2009-2010 Design
+3% IRR Compared to Next Best Alternative
Lower CAPEX & OPEX Drives Greater Return on Investment
Recent technology enables most economical pX production 19 UOP 7197O-19
Basis: 2000 KMTA PX Complex
LD Parex Process Enables Profitable pX Investments, Even in Down Cycles
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IRR
(%
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Pro
ba
bil
ity
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PX - Feed Spread ($/MT)
Probability
2009-2010 Technology
Typical Hurdle Rate
Expected Value =
$401/MT
PX (contract) – Naphtha (spot) Spread Probability: Normalized distribution of annual IHS data from last 15 years
Basis: 2000 KMTA PX Complex
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PX - Feed Spread ($/MT)
Probability
LD Parex Aromatics Complex
Next Best Alternative
2009-2010 Technology
Typical Hurdle Rate
Expected Value =
$401/MT
PX (contract) –Naphtha (spot) Spread Probability: Normalized distribution of annual IHS data from last 15 years
LD Parex Process Enables Profitable pX Investments, Even in Down Cycles
Provides Capability of Maintaining Profitability at pX-Feed
Spreads Lower Than $200/MT! 21 UOP 7197O-21
Basis: 2000 KMTA PX Complex
Leveraging Historically Proven UOP Technology for Your Future Success
• UOP’s 45 years of experience with adsorption-
based separation technology in >100 operating
units enables us to lead the market in innovation
• ADS-47 is a significant breakthrough in pX
separation technology, making the light
desorbent technology economically viable
• The 3 major components of the LD Parex
Aromatics Complex design—desorbent,
adsorbent and heat integration—are all
commercially proven & reliable
• First LD Parex Complex in Schedule A for 2016
construction
• Solution enables a step-change improvement
in capital efficiency while still maintaining the
industry-leading energy efficiency
Gain the greatest return on your investment for your by choosing the lowest cost of pX production technology available UOP 7197O-22 22
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Q&A
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