KBR Olefins Technology : Responding to the changing market needs of tomorrow Sourabh Mukherjee Indian Petrochem
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1 KBR Olefins Technology : Responding to the changing market needs of tomorrow Sourabh Mukherjee Indian Petrochem KBR, Inc. All Rights Reserved 1
2 Ethylene Complex Utilities Waste Hydrocarbon Feed Steam Cracker Ethylene Co-Products Traditional focus Hydrogen Methane Propylene C4 s PFO Etc.. Potential to drive Technology Selection Operations & Maintenance 2014 KBR, Inc. All Rights Reserved 2
3 Does Ethylene Selectivity Matter? 2014 KBR, Inc. All Rights Reserved 3
4 Ethylene Complex Economics (Ethane) Ethane Feed Utilities Waste Steam Cracker Operations & Maintenance Ethylene Co-Products Hydrogen Methane Propylene C4 s PFO Etc.. Cost Ethane Feed 380 $/MT Utilities 98 $/MT Ethylene Operations & Maintenance 53 $/MT Ethylene Depreciation + ROC 250 $/MT Ethylene Revenue Ethylene 1000 $/MT Co-Products Note 1 $/MT Note 1: Dependent upon co-product recovery 2014 KBR, Inc. All Rights Reserved 4
5 Example 1: US Gulf Coast Cracker Overall Material Balance Grassroots Cracker Location: US Gulf Coast Feedstock: Ethane (US Shale Gas) Products: KTA Ethylene -C3+ Stream (Sell) -Fuel Oil -Fuel Gas Feed / Product 77% Yield (KTA) 80% Yield (KTA) Ethane Ethylene Fuel Gas Mix C Fuel Oil 5 2 Ethane Feed Tail Gas Ethylene C3+ Fuel Oil 2014 KBR, Inc. All Rights Reserved 5
6 Example 1: US Gulf Coast Economics Revenue ($MM USD) Products 77% Yield 80% Yield Ethylene 1,000 1,000 Fuel Gas Mix C Fuel Oil Sub-Total 1,131 1,111.4 Cost ($MM USD) Category 77% Yield 80% Yield Ethane Feed Utilities O&M Depreciation + ROC Sub-Total Margin ($MM USD) Category 77% Yield 80% Yield Revenue 1,131 1,111.4 Cost Total Margin Lower selectivity = ~$5.6 MM USD/yr Advantage 2014 KBR, Inc. All Rights Reserved 6
7 Example 2: CIS Region Cracker Overall Material Balance Grassroots Cracker Location: CIS Region Feedstock: Ethane (Gas Plant) Products: KTA Ethylene -C3+ Stream (Fuel) -Fuel Oil -Fuel Gas Feed / Product 77% Yield (KTA) 80% Yield (KTA) Ethane Ethylene Fuel Gas Mix C Fuel Oil 5 2 Ethane Feed Tail Gas Ethylene C3+ Fuel Oil 2014 KBR, Inc. All Rights Reserved 7
8 Example 2: CIS Region Economics Revenue ($MM USD) Products 77% Yield 80% Yield Ethylene 1,000 1,000 Fuel Gas Mix C Fuel Oil Sub-Total 1,051 1,043.4 Cost ($MM USD) Category 77% Yield 80% Yield Ethane Feed Utilities O&M Depreciation + ROC Sub-Total Margin ($MM USD) Category 77% Yield 80% Yield Revenue 1,051 1,043.3 Cost Total Margin Higher selectivity = ~$6.3 MM USD/yr Advantage 2014 KBR, Inc. All Rights Reserved 8
9 Example 3: CIS Region Cracker (Fixed Feed) Grassroots Cracker Feed / Product Overall Material Balance 77% Yield (KTA) 80% Yield (KTA) Ethane Ethane Feed Location: CIS Region Feedstock: KTA Ethane (Gas Plant) Products: -Ethylene -C3+ Stream (Use for Fuel) -Fuel Oil -Fuel Gas Tail Gas Ethylene Ethylene Fuel Gas Mix C C3+ Fuel Oil Fuel Oil KBR, Inc. All Rights Reserved 9
10 Example 3: CIS Region Economics (Fixed FEED) Revenue ($MM USD) Products 77% Yield 80% Yield Ethylene Fuel Gas Mix C Fuel Oil Sub-Total 979 1,001.3 Cost ($MM USD) Category 77% Yield 80% Yield Ethane Feed Utilities O&M Depreciation + ROC Sub-Total Margin ($MM USD) Category 77% Yield 80% Yield Revenue 979 1,001.3 Cost Total Margin Higher selectivity = ~$22.3 MM USD/yr Advantage 2014 KBR, Inc. All Rights Reserved 10
11 Relative Percent Yield Improvement How Can Technology Impact Selectivity? Residence Time Effect on Ethylene Yields More Ethylene More Co-Products 20 NAPHTHA GAS OIL BUTANE 10 PROPANE ETHANE 2014 KBR, Inc. All Rights Reserved Residence Time (sec))
12 Relative Percent Yield Improvement How does KBR Address Residence Time? Furnace Coil Portfolio SC-1 SC-2 SC-4 20 NAPHTHA GAS OIL BUTANE 10 PROPANE ETHANE 2014 KBR, Inc. All Rights Reserved Residence Time (sec))
13 KBR Furnace Portfolio & Experience SC-1 SC-2 SC-4 Single Pass Straight Tube (~ sec) Two-Pass U-Coil (~ sec) Serpentine-Type E.g., W-Coil (~ sec) # of Furnaces KBR, Inc. All Rights Reserved 13
14 KBR & competitors Coil Type Residence Time (sec) KBR Competitors W type 0.4 SC-4 Yes U Type 0.2 SC-2 Yes One pass 0.1 SC-1 No KBR has BROADEST Technology Portfolio 2014 KBR, Inc. All Rights Reserved 14
15 Conclusions Selectivity is important and should be a key decision criteria Duplicate grassroots designs might miss economic opportunity Critical Factors for Coil Technology Selection: Availability and Constraints on Feeds Demands and Constraints on Products 2014 KBR, Inc. All Rights Reserved 15
16 Steam Cracking Around the World North America: Shale Gas The Heavier the Hydrocarbon Feed the more complicated the economics Russia/CIS: LPG Refinery Integration Naphtha Middle East: Ethane Refinery Integration Liquids Asia: Naphtha Heavy Liquids KBR Collaborates with Client to determine best configuration 2014 KBR, Inc. All Rights Reserved 16
17 KBR Olefins Technology Offerings What Feeds Features SCORE (Steam Cracking) K-COT TM (Catalytic Olefins) Ethane thru Gas Oil Residence time ~ sec Low CAPEX Superior Performance Offered via Agreement with ExxonMobil Olefinic C4-C10 P/E ratio ~ 2/1 Gasoline by-product >50% aromatics Recycle C4-C6 NA to extinction without additional treating Paraffinic naphtha, light distillates P/E ratio ~ 1/1 Recycle C4s/C5s without additional treating Non-traditional High olefin yields from methanol, ethanol and other oxygenates and MTO/MTP and FT by-products 2014 KBR, Inc. All Rights Reserved 17
18 K-COT TM Overview Catalytic cracking of light olefinic and/or paraffinic feeds High propylene yields, with ethylene and aromaticrich gasoline byproducts Typical P/E ratio = 2:1 for olefin-rich feed Typical P/E ratio = 1:1 for straight run naphtha Use of custom formulation of ZSM-5 catalysts Utilizes fluidized reactors (FCC) Over 60 years of KBR experience in FCC Product separation similar to ethylene plants with trace impurity removal to produce polymer grade products Over 60 years of KBR experience in Ethylene 2014 KBR, Inc. All Rights Reserved KBR, Inc. All Rights Reserved 18
19 Typical Refinery and Steam Cracker Crude Oil CDU FCC Isom Hydrotreaters De- Coker asphalting Others Gasoline Distillate Jet / Kero Fuel Oil Naphtha Hot Section Cold Section Ethylene Propylene Butadiene PyGas KBR, KBR, Inc. Inc. All Rights All Rights Reserved Reserved 19 19
20 Typical Refinery and Steam Cracker FCC Isom Crude Oil CDU Hydrotreaters De- Coker asphalting Others Gasoline Distillate Jet / Kero Fuel Oil Naphtha Catalytic Olefins Recovery Hot Section Cold Section Ethylene Propylene Butadiene PyGas 2014 KBR, Inc. All Rights Reserved 20 Flexibility is the KEY
21 Flexible and Scalable More Profit Liquid Recycle Streams: C4 streams -C4 Raf 1 -C4 Raf 2 -C4 Raf 3 -Butane C5+ streams -Raw C5+ -1x Hydro -2x Hydro ->Buy More from Outside! Consider Refinery Streams: Refinery C4 s FCC Naphtha Coker Naphtha Visbreaker Naphtha ->Excellent Yields! Add Conventional Liquid Steam Cracker Feeds (eg Naphtha) ->Higher P/E -> More BTX Consider Other Streams: Alcohols -MeOH -EtOH -Etc Other Oxygenates FT, MTO/MTP By-Products ->Excellent Yields! KBR, KBR, Inc. Inc. All Rights All Rights Reserved Reserved Can be run in Single Converter
22 K-COT TM - Separation Reactor Effluent R E C O V E R Y Ethylene Propylene Tail gas BTX gasoline Product treatment and separation follow ethylene plant technology Compression Acid gas removal and drying Separation and fractionation to chemical or polymer grade products Proprietary expertise for trace impurities removal C4s and C5s can be recycled to reactor with no further treatment All proven technology 2014 KBR, Inc. All Rights Reserved KBR, Inc. All Rights Reserved 22
23 Potential Applications for K-COT TM Liquid crackers, looking to upgrade C4, C5, non-aromatic gasoline recycle to K-COT TM Refiners with excess naphtha (straight run or cracked) upgrade to olefins, especially C3 Integrated refinery / petrochemical complexes looking to improve overall flexibility and value upgrade Upgrade by-products from FT/CTL/MTO/MTP facilities KBR, KBR, Inc. Inc. All Rights All Rights Reserved 23 23
24 Vacuum FCC Crude Distillation Refinery Configuration Naphtha HDS Reformer GASOLINE Ultra Low Sulfur Diesel Hydro De-sulfurizer DIESEL CRUDE PROPYLENE MIXED BUTENES LIGHT NAPHTHA HEAVY NAPHTHA KEROSENE LCO Coker FUEL OIL COKER LN COKE 2014 KBR, Inc. All Rights Reserved KBR, Inc. All Rights Reserved 24
25 Vacuum FCC Crude Distillation Refinery Configuration Naphtha HDS Reformer GASOLINE Ultra Low Sulfur Diesel Hydro De-sulfurizer DIESEL CRUDE PROPYLENE MIXED BUTENES LIGHT NAPHTHA HEAVY NAPHTHA KEROSENE LCO Coker FUEL OIL COKER LN COKE 2014 KBR, Inc. All Rights Reserved KBR, Inc. All Rights Reserved 25
26 Liquid Crackers - Marginal Producers Liquid Feed Liquid Crackers have become the Marginal Ethylene Producers but comprise 50% of the world s capacity Liquid Crackers Forecasted to Run at Lower Ethylene Operating Rates How Can Liquid Crackers Improve Cost of Ethylene (COE) and Profits in this Environment? KBR, KBR, Inc. Inc. All Rights All Rights Reserved Reserved 26 26
27 Recycle Converter Feed Pyrolysis Furnaces Typical Ethylene Plant HP Steam Exch Oil Quench Water Wash P PG G Caustic/ Drying R E C O V E R Y Tail gas Ethylene Propylene Butadiene C4 s C5+ Pygas Ethane/Propane Recycle Fuel oil 2014 KBR, Inc. All Rights Reserved KBR, Inc. All Rights Reserved 27
28 Recycle Converter Fuel Oil Converter O2 Reactor Deprop / Dehex C4/C5/C6NA from Ethylene Plant BTX-Gasoline Naphtha Feed Pyrolysis Furnaces HP Steam Exch Oil Quench Water Wash P G C3 & Lighter Caustic/ Drying R E C O V E R Y Tail gas Ethylene Propylene Butadiene C6+ Pygas Fuel oil Ethane/Propane Recycle 2014 KBR, Inc. All Rights Reserved KBR, Inc. All Rights Reserved 28
29 $ / Ethylene Ton Naphtha Cracker: Recycle vs. Sell Based on historical price data C4 Raff 1 C5's C6NA All C4 Raff 1 C5's C6NA All Steam Cracking Catalytic Olefins Since Jan Since Jan Since Jan KBR, KBR, Inc. Inc. All Rights All Rights Reserved 29
30 Combined Olefins Process K-COT TM Recycles Fresh Feeds Pyrolysis R E C O V E R Y Tail gas Ethylene Propylene Raw C4s BTX-gasoline Fuel oil Recycles KBR, KBR, Inc. Inc. All Rights All Rights Reserved Reserved 30 30
31 K-COT TM Advantages Catalytic Olefins Commercial Demonstration Unit, Ulsan, South Korea Oct Startup KBR, KBR, Inc. Inc. All Rights All Rights Reserved Naphtha feeds converted to higher yields of olefins, especially propylene P/E ratio of ~1/1 Olefin-rich feeds converted to very high yields of propylene, with significant ethylene and aromatics byproducts P/E ratio of ~2/1 Unmatched feed flexibility Very attractive economics Grassroots and Revamp opportunities THANK YOU for your Kind Attention! Questions?
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