Maximize Conversion and Flexibility

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1 Maximize Conversion and Flexibility The UOP TM Robert Haizmann UOP LLC 6 th Russia & CIS BBTC Conference April 13-14, 2011 Moscow, Russia 2011 UOP LLC. All rights reserved.

2 Maximize Conversion and Flexibility With the UOP Market Factors Technology Summary Capital Savings Through Integration 2

3 Product Demand, Specifications, and Prices are Changing Incremental Fuel Demand Bunker Fuel Oil Sulfur Specifications 5.0 MM BPD Gasoline Diesel Kerosene /Jet Source: Purvin & Gertz, 2010 GPMO Residue Fuel Oil NW European Product Differentials to Brent, Forecast in Constant 2010 $/Bbl Euro Unleaded Diesel EN590 RFO, 1%S RFO, 3.5%S Product Value ($/MT) Sulfur, Wt% max Global Global Delayed ECA Diesel Price Premium over Coke Coke Diesel Source: Purvin & Gertz, 2010 GPMO Common goal: Maximize residue conversion to distillates 0 20 (2000) 40 (2004) 60 (2009) 80 (Future) Crude Price, $/bbl (year) 3

4 UOP s Heavy Oil Upgrading es Naphtha Naphtha Hydrotreating & Reforming Crude Oil Distillation Distillates Vacuum Gas Oil Distillate Hydrotreating FCC or Hydrocracking Transportation Fuels: Gasoline, Jet Fuel, Diesel Vacuum Residue Residue Conversion UOP Solutions UOP Solutions for Residue Conversion UOP UOP RCD RCD UOP/FWUSA FWUSA FWUSA SYDEC SYDEC Unionfining TM TM TM Solvent Solvent UOP/FWUSA TM UOP UNIFLEX Delayed Delayed Deasphalting Visbreaking Residues: Heavy Fuel Oil, Pitch, Coke 4

5 UOP Makeup Hydrogen Vacuum Residue Volume% of Feed Reactor Catalyst Gasoline Diesel VGO Pitch Typical Yields Naphtha Distillate VGO Coke (wt.%) Naphtha Distillate VGO Pitch (wt.%) Slurry hydrocracking technology High conversion to desired products Contains elements of proven processes CANMET Hydrocracking UOP Unionfining TM and UOP Unicracking TM es has >25% yield advantage over Delayed -35 Delayed 5

6 Extensive Commercial Experience 25 years R&D 15 years commercial operation Variety of feedstocks High conversion 97%+ availability Petro-Canada Montreal Unit 100 Commercial Performance 85% 90% 94% Conversion Yield, vol % Naphtha Distillate VGO Pitch -20 Many UOP improvements in the last 5 years 6

7 Proven Flowscheme with Improvements Makeup H 2 Reactor Hot Separator Cold Separator Recycle H 2 Flash Gas C 4 - Vacuum Residue Feed Recycle Gas Heater Feed Heater Catalyst Hot Flash Drum HVGO Recycle Cold Flash Drum Stripper/ Product Fractionator Fractionator Heater Naphtha Diesel Vacuum Fractionator LVGO Pitch Large Unit Capacities Capital Cost Savings Through Integration 7

8 HVGO Recycle Improves Yields and Quality Wt.% of Feed Delayed + HVGO Recycle Increased Naphtha & Distillate Yields Lighter VGO, easier to process Pitch/Coke 524+ Gasoil C Distillate C Naphtha C5-204 C Fuel Gas + LPG Maximum naphtha and diesel yield from vacuum residue VGO conversion without a separate Mild Hydrocracking Unit 8

9 Base Case: Compared to Other VR Conversion es Benefits: High liquid yields on vacuum residue feed, especially distillates Minimum residue by-products Significantly increases margins Vol.% of Feed SDA Delayed Residue Conversion Yields EBED HC SDA Delayed EBED HC 60% SDA Delayed EBED HC Upgrading Margins With Hydrocracking Vol.% of Feed Distillate Yield (After Hydrocracking) 40 Arab Light Vacuum Residue 30 9

10 Integrated with UOP/FW Solvent Deasphalting & Unicracking Vacuum Gas Oil Vacuum Residue UOP/FWUSA Solvent Deasphalting DAO UOP Unicracking Unicracking Naphtha and Distillate SDA Pitch UOP VGO Unicracking UCO (to FCC) Naphtha and Distillate To New or Existing HDT Pitch Maximum Distillate Production - 95% Vacuum Residue Conversion with and SDA - 99+% VGO conversion with Unicracking Low Capital Cost Upgrading Complex - Low capital cost SDA - Small, moderate reactor pressure Unit 10

11 Integrated Case: Solvent Deasphalting//Unicracking es SDA//Unicracking Benefits: 110 Delayed SDA + SDA + Very high vacuum residue conversion Maximum distillate yields on vacuum residue feed Highest margins Vol.% of Feed Capital cost reduced 10 Increased operating flexibility Delayed SDA + Upgrading Margins With Hydrocracking SDA Delayed Residue, wt% DAO VGO Distillate Naphtha SDA + Distillate Yield (After Hydrocracking) SDA + Arab Light Vacuum Residue 11

12 UOP/FWUSA SDA Commercial Experience UOP/FWUSA Combined Experience Over 70 units licensed (500 to BPD) Proven scale-up between pilot plant and commercial operations Recent Selection in 6 Projects All units won in competitive bidding Utilizing features from both UOP and FW technologies 12

13 UOP Unicracking Commercial Experience Proven Experience >60% of the World s Licensed Hydrocracking Units 195 Licensed Units in 40 Countries >100 Operating Units 54 Licenses Since 2000 Experience with all flow scheme options and DAO processing Experience IS the difference 13

14 Integrated with Existing Delayed Unit Vacuum Residue Feed HCGO Pitch Delayed Products Products Coke Increased Naphtha and Distillate yield Heavy Coker Gas Oil converted in Pitch converted in Coker Debottleneck Coker and Coker Heavy Gas Oil Hydrotreater 14

15 Integration of Hydroprocessing Units Naphtha Naphtha Hydrotreating Crude Oil Distillation Distillates Vacuum Gas Oil Distillate Hydrotreating Hydrocracking Transportation Fuels: Gasoline, Jet Fuel, Diesel Vacuum Residue UOP Integration Drivers - Capital Cost Reduction and Energy Efficiency Residues: Heavy Fuel Oil, Pitch, Coke 15

16 Slurry Hydrocracking and Hydroprocessing Issues that impact optimal degree of integration Economics Capital cost savings Utilities savings Design and operating flexibility Operating pressures and relative flowrates of units Future changes in crudes and product slate Catalyst performance in HC and HDT Timing of catalyst and inspection turn-arounds Start-up, shut-down, emergency procedures 16

17 Full Integration Challenges Straight Run Diesel and VGO Slurry HC Rx Vacuum Residue Hydroprocessing Rx Recycle Gas Features Combines slurry hydrocracking and Hydroprocessing in one hydrogen gas loop Requires both sour and sweet fractionation systems products fractionated twice Slurry HC and Hydroprocessing sections require same high reactor pressure Challenges Moderate effect on overall capital and operating costs H 2 S and NH 3 depress catalytic activity and selectivity Diesel yield loss via cracking 17

18 Selective Integration Benefits UOP offers many integration options to meet refiners varied requirements Examples Common H 2 recovery and compression systems for make-up gas and off-gas Parallel recycle gas systems products integrated directly to UOP Unicracking and UOP Distillate Unionfining Benefits >10% capital savings for, Unicracking, Distillate Unionfining Heavy Oils Complex Performance optimized of each unit Reduced contamination in catalytic process units Unicracking: >99% VGO conversion Distillate Unionfining - Maximum diesel yield, quality and cycle length at minimum reactor pressure 18

19 UOP Will Meet Your Future Transportation Fuel Requirements Ideal for Maximizing Transportation Fuels from Vacuum Residue Unique Solutions for Maximizing Distillate Extensive Commercial Operations Background UOP Development Program Assures Future Units Success Optimization and Integration Solutions will Maximize Benefits for your Refinery 19

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