Advanced Techniques for Enhancing Hydrogen Availability in Refineries

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2 Advanced Techniques for Enhancing Hydrogen Availability in Refineries Sanjiv RATAN, Group DVP, H2 Product-line & Technologies Technip Stone & Webster Process Technology Nitin PATEL, Sr. Engineering Associate H2-Syngas Technology, Air Products and Chemicals 2

3 Presentation Overview Global Hydrogen (H 2 ) demand projections Ways to enhance H 2 Availability Advanced Hydrogen Management Step capacity Revamping & Feed switching to NG Mega H 2 concept Make v/s Buy Reliability Enhancement Conclusions 3

5 Drivers for Refinery Hydrogen Volume growth Global fuels demand growth + clean fuels catch-up Increasing proportions of Opportunity and/or Unconventional crudes Bottom-of-the barrel strategies Economies of scale Multi-client hydrogen franchise networks Hydrogen considered as an asset in refinery Optimization and not minimization of hydrogen usage Focus on operating margins rather than operating costs Mega H 2 plant typically ranges knm3/h in a single train 5 5

6 Refinery Hy-way Intensification Opportunity Crudes Oil-gas price gap H 2 Demand Clean Fuels BoB upgrading; Min. FO Dieselization More Hydrogen!! Heavy/Sour Crude Time-line 6 6

7 Global Refinery Hydrogen Demand Growth Year Global H2 Demand, (Captive; On-purpose) BCFD North America: Western Europe Asia/Pacific: China India Japan Other Asia/Pacific Other Regions (SA, ME, AFR) % growth ( ) Global ~ 4 % India + China ~ 7 % Global H 2 growth ( ) : Captive + 20% Merchant 10 bcfd Average bcfd/yr ~1 7

8 Refinery Hydrogen: Asian Trends & Needs Technical Larger plant capacities Catch-up against US & Euro norms Lack of NG : Multiple / Liquid feedstocks flexibility Power (un)reliability Increasing HSE requirements and CO 2 focus Need for enhanced RAM (Reliability, Availability and Maintenance) Commercial Higher demand growth v/s domestic crude scarcity Product slate and demand pattern; Diesel v/s Gasoline Lower cost of ownership for H 2 critical for refinery profitability Larger domestic portion in execution of projects (materials and labour) 8

9 Technip Catering for Hydrogen Demand Custom-optimized Solutions State-of-the-art technology Global Market Share Leading Global Hydrogen Technology and Plant Supplier 9

11 Refinery Off Gas (ROG) H 2 Recovery and Utilization Refinery Off Gases (ROG) High Purity Hydrogen Network End users - A HC feedstock High Purity H 2 Recovery Blending Direct Compression / pre-treatment End users - B Purity and Pressue Cascading Low Purity H 2 Recovery Compression Refinery Fuel Gas Network Hydrogen Plant End users - C 11

12 Advanced Hydrogen Management developed by Technip Specific methodologies combined with transversal competences Advanced LP programming using PIMS platform Suite of tools includes H 2 -pinch analysis and purity / pressure cascading Rigorous unit operation modelling simulator, data import and reconciliation Global cost database for realistic economic analysis and case evaluation Tailored to specific objective functions for grassroot refineries as well as revamps, expansions & retrofits of existing refineries No compromise on safety, reliability and operational flexibility 12

13 HyN-DT Analysis Cluster Output 13

14 HyN DT TM Example Analysis : Base Case FG Network 3.1 t/d 67.8%vol. NAPHTHA HDT HP Separator 0.2 t/d 16.1%vol. KEROSENE HDT HP Separator 1.0 t/d 33.9%vol. DIESEL HDT HP Separator 8.0 t/d 81.5%vol. Fractionator HYDROCRACKER HP Separator Cold Sep t/d 90.6%vol. RFG Network Cont.H t/d 24.1 Barg 24.3 Barg 58 Barg 155 Barg 6.4 t/d 2.3 t/d 17.1 t/d t/d H2 High Purity Network, 99.9% vol H2 Network 257,264 Nm3/h t/d t/d 3.9 t/d 13.1 t/d t/d 551 t/d PSA NEW HGU (H2) 73,352 Nm3/h FG Network PSA 11.3 t/d 58.7%vol. CCR (H2) 70,937 Nm3/h AROMATICS COMPLEX ISOMAR TATORAY PSA 33.1 t/d 53.3%vol. Existing HGU (H2) 112,977 Nm3/h 14

15 HyN DT TM Analysis : Optimized Select Case Hydrogen Network Case Analysis PSA combined with Membranes (Recovery Level = 73.8 %) H2 Network 12,046 Nm3/h 26 t/d FG Network 3.1 t/d 67.8%vol. NAPHTHA HDT HP Separator 24.1 Barg 92.4 t/d 0.2 t/d 16.1%vol. KEROSENE HDT HP Separator 24.3 Barg 1.0 t/d 33.9%vol. DIESEL HDT HP Separator 58 Barg 8.0 t/d 81.5%vol. Fractionato HYDROCRACKER r HP Separator Cold 155 Barg Sep. 6.3 t/d 57.6%vol. 6.4 t/d 2.3 t/d 17.1 t/d t/d 38.9 t/d H2 Low Purity Network, 90 % vol H2 High Purity Network, 99.9% vol t/d 3.9 t/d 13.1 t/d PSA 25.8 t/d t/d RFG Network Cont.H2 37 t/d 7.3 t/d H2 Network 245,212 Nm3/h 525 t/d PSA ~ 40% ~ 40% Smaller reduction FG Network NEW HGU (H2) 43,143 Nm3/h PSA 11.3 t/d 58.7%vol. CCR (H2) 70,937 Nm3/h AROMATICS COMPLEX ISOMAR TATORAY PSA 33.1 t/d 53.3%vol. Existing CO SHIFT HGU HT Reac. (H2) (H2) 112, ,977 Nm3/h Nm3/h 1 15

16 Refinery Off gases (ROG) Integration Make-up fuel Purge gas fuel HC feedstock Reforming + Shift 1 PSA Hydrogen Pretreatment 2 3 Recovery PSA To RFG net Optional Qualifiers Available pressure Contaminants ROG Potential H 2 Contribution (Quantitiy * H 2 fraction) Low Medium High 16

18 Hydrogen Step Capacity Revamp Benefits Lower unit cost of (additional) hydrogen Shorter schedule No or smaller additional plot space Utility interfaces and staff in place Process Options Pre-reformer integration (up to 10%) Reformer upgrade (up to 15%) TPR reformer retrofit (up to 30%) Attractive additional Hydrogen with No compromise on HSE and Reliability 18

19 Technip Parallel Reformer (TPR) Retrofit Uses high grade heat of reformer effluent to reform additional feed More reforming without increasing radiant duty, thus lowering firing and related CO 2 per unit H 2 Off-loads the whole steam system despite higher capacity Allows near Zero export steam Installation within a typical refinery turnaround (4-6 weeks) Reformed gas 19

20 TPR Regenerative Reforming Cycle Export steam NG PR + SMR TPR Shift + 2-st APH PSA H 2 Up to 30% more H 2 Lower Export Steam Lower corrected Specific CO 2 Emission 20 20

21 Recent TPR Revamps Overview Project 1 Project 2 Project 3 Project 4 Project 5 Start-up Pre-revamp capacity (knm3/h) Incremental capacity (knm3/h) Capacity increase (%) Feedstock Naphtha/ NG Naphtha NG NG NG 21

22 Feed Switching (from Naphtha) to NG Expanding NG networks Higher H2 yield due and improved process efficiency NG feed Opex generally lower than for Naphtha, when latter credits higher premium as Petrochemicals feedstock Reduced CO 2 emission (~ 15%) Easier to operate (even more with fuel substitution) No residue on evaporation / fouling Easier desulphurization No liquid pockets or slugs, esp during transient conditions Reduced risk on carbon formation in SMR even with lower S/C More stable composition and quality Easier to recover from upsets On-line feed change-over well referenced (as alternative and/or mixed feed) 22 22

23 Presentation Overview Global Hydrogen (H2) demand projections Ways to enhance H 2 Availability Advanced Hydrogen Management Step capacity Revamping & Feed switching to NG Mega H 2 concept Make v/s Buy Reliability Enhancement Conclusions 23

24 Hydrogen Generation : Economy of Scale 105 Relative UCH, % % Basis: Natural 20/Gcal Capex + Opex H2 Plant Capacity, MMSCFD knm3/h 24

25 Benefits of Single v/s Dual Train H 2 Plant Total Installed Cost lowered by 10-15% Smaller plot space by 30-50% Enhanced energy efficiencies, apart from better justification for incremental investment Shorter implementation schedule and/or labor intensity Lower operating costs (staff, inventories and capital spares) More suitable for CO 2 capture readiness Such merits outweigh the minor benefit on lower turn-down and plant availability of Dual-train units, with negligible impact on overall onstream factor. Dual train configuration at times gets governed by phased investment and execution philosophy or case-specific requirements Large single-train H 2 plants do call for a higher degree of design optimization and competence as well as EPC capabilities and experience. 25

26 Mega Hydrogen Plants with Feed Flexibility 26

28 Hydrogen supply : Make v/s Buy Make Case Buy Case Key design objective Low capital cost Optimized UCH Financing & insurance Customer Supplier Project / construction risk Customer / Contractor Supplier Permitting & commissioning Customer Supplier Warranty Typically 1 yr after start up 20 years Performance guarantee GTR within 2-12 months 20 years On-stream guarantee None 20 years Opex liabilities None 20 years Major failure after warranty None 20 years 28

29 Air Products- Technip Global H 2 Alliance Incepted in 1992 Befitting Synergy Technip s leadership in H 2 plant supply Air Products leadership in OTF H 2 supply 34 plants to date > 2.5 bcfd H 2 capacity > 1 bcfd H 2 in past 5 years Longest and most successful Sale-of-Gas H 2 alliance 29

30 GTE - SMR Cogen Integration / Combined Cycle Gas Turbo Generator NG GTE split (Optional) Process Steam Export Steam Steam Turbo Generator HRSG Aux. firing (Optional) Cond. 110 barg Air Comb, Air Steam Drum Fuel Feed Steam S/Heater Boiler Boiler To PG Boiler Economizer To Stack 30

31 Benefits of SMR / Cogen Integration Better Economics compared to standalone units Lower TIC by ~ 10% O & M staffing synergies benefit ~ 5% Improved thermal efficiency benefit ~ 3 % Reduced specific CO 2 and NOx by ~ 15% Island mode capabilities during special operational modes Enhanced reliability for H 2 (>99.9%) as well as power supply for the refinery complex under various H2 / power load ratios 100 mmscfd H2 20 MW export Without HRSG 105 mmscfd H2 100 MW power 400 t/h HPS With HRSG Upto 100 MW generation from 100 mmscfd H 2 plant Reliable and cost-effective (captive) power self-sufficiency 31

32 Presentation Overview Global H2 demand projections Ways to enhance H 2 Availability Advanced Hydrogen Management Step capacity Revamping & Feed switching to NG Mega H2 concept Make v/s Buy Reliability Enhancement Conclusions 32

33 Air Products-Technip Reliability Program Reliability Focused Operations and Work Processes Global Downtime and Cost of Non-conformance (CoNC) metrics Advanced Model Predictive Control (MPC) control strategies State of the art Condition Monitoring (CM) Standardized outage planning and execution Critical Spares management Robust Electronic Management of Change (MOC) system Best Practices sharing amongst sites worldwide Extensive use of Continuous Improvement Tools Site Reliability, Training, and Procedure Assessment Programs in place 33

34 On-Stream Reliability of AP-TP Large H 2 plants Refinery H 2 underlines strong need for high reliability and availability Start-up Year Capacity MMSCFD % On-stream * to date * Based on documented reliability data of AP-TP SOG H 2 plants, excluding scheduled outage 34 34

35 Progression of Cost-Effective Reliability Early 90s Mid 90s Single (SMR) train max. H 2 capacity, mmscfd Relative Reformer box size (m x m x m), % Relative Specific energy (GJ/kNm3), % Relative Burner-NOx target (ppmv), % Continuous operation / turnaround cycle, years ~ 2 ~ 3 ~ 4 Reliability (stand-alone on-stream) % > 95 % > 97 % > 99 % Relative Plot area ISBL (m x m), % Relative EPC execution schedule (months), % Relative TIC (ISBL; adjusted NPV; MM $), % Relative Unit Cost of Hydrogen ($/knm 3 ), % 100 % 94 % 88 % 35

37 Conclusions The growing refining landscape and its emerging needs, especially in Asia, call for concerted strategies for ensuring H 2 availability efficiently and cost-effectively. In modern high-conversion integrated refineries, H 2 need can be satisfied starting with judicious hydrogen management, followed by potential capacity revamp of existing H 2 plants, and eventually efficient & reliable H 2 generation, furthered by buy mode via overthe-fence supply. Asian refining and hydrogen markets carry few specific trends and needs to be addressed for meeting the ongoing and future goals. Technip as a global leader for supply of H 2 technology and plants, together with its trend-setting global alliance with Air Products, carries a comprehensive portfolio of proven technological options and advanced solutions for satisfying current and upcoming H 2 needs. 37

38 Thank You! 38