PROCESS ECONOMICS PROGRAM

Transcription

1 PROCESS ECONOMICS PROGRAM SRI INTERNATIONAL Menlo Park, California Abstract Process Economics Program Report No. 132 GAS OIL CONVERSION TO FUELS AND PETROCHEMICALS (February 1981) This study examines some of the process and economic interactions in the conversion of gas oil in refineries and chemical complexes in the United States, Western Europe, and Japan. For each of the three major industrial areas, two basic cases are studied for the use of Arabian Light crude oil: an existing average fuels refinery operating in 1979, and a future petroleum refinery operating in 1990 that integrates fuels with worldscale olefins and aromatics production. Three additional cases are examined for the United States. These are: an existing fuels refinery using Alaskan North Slope crude oil in 1979; a future chemical refinery using Alaskan North Slope crude oil; and a future chemical refinery designed to manufacture an even greater share of petrochemicals from Arabian Light crude oil. These cases illustrate the use of fluid catalytic cracking, hydrocracking, and steam cracking to convert gas oil in an integrated system that produces fuels and basic petrochemicals.

2 Report No. 132 GAS OIL CONVERSION TO FUELS AND PETROCHEMICALS by STANFORD FIELD I f-2 0 I CB I I February 1981 A private report by the PROCESS ECONOMICS PROGRAM Menlo Park, California 94025

3 For detailed marketing data and information, the reader is referred to one of the SRI programs specializing in marketing research. The CHEMICAL ECONOMICS HANDBOOK Program covers most major chemicals and chemical products produced in the United States and the WORLD PETROCHEMICALS Program covers major hydrocarbons and their derivatives on a worldwide basis. In addition, the SRI DIRECTORY OF CHEMICAL PRODUCERS services provide detailed lists of chemical producers by company, product, and plant for-the United States and Western Europe. ii

4 CONTENTS INTRODUCTION... SUMMARY... GAS OIL CONVERSION PERSPECTIVES... Thermal Cracking.... Catalytic Cracking.... Hydrocracking... Steam Cracking.... Petroleum Refinery Product Spectra.... METHODOLOGY AND BASES... Methodology... Prices... Construction Cost Indices... Profitability Calculations.... GAS OIL CONVERSION IN THE UNITED STATES... GAS OIL CONVERSION IN WESTERN EUROPE.... GAS OIL CONVERSION IN JAPAN... Summary of Cases Studied.... PROCESS INFORMATION FROM LICENSORS FLUID CATALYTIC CRACKING (Contributed by Gulf Research and Development Company).... ULTRA-ORTHOFLOW FLUID CATALYTIC CRACKING (Contributed by Pullman Kellog)... ISOCBACKING (Contributed by Chevron Research Company) CITED REFERENCES iii

5 ILLUSTRATIONS Cracking Capacity as a Function of Naphtha + Gasoline Output in 1976/ Relationship Between Catalytic Cracking and Hydrocracking in Large U.S. Petroleum Refineries in Plant Location Factors for West Germany and Japan Relative to the United States Profitability as a Function of Payback Period Contemporary United States Fuels Refinery - Case 1 Flowsheet... Contemporary United States Fuels Refinery - Case 2 Flowsheet Future United States Chemical Refinery - Case 3 Flowsheet Future United States Chemical Refinery - Case 4 Flowsheet... Future United States Chemical Refinery - Case 5 FlowSheet Contemporary Western European Fuels Refinery - Case 6 FlowSheet Future Western European Chemical Refinery - Case 7 FlowSheet Contemporary Japanese Fuels Refinery - Case 8 FlowSheet Future Japanese Chemical Refinery - Case 9 Flow Sheet V

6 SummaryofCases Relative Total Fixed Capital Investment for Steam Crackers Comparison of Thermal and Catalytic Cracking of a API Mid-Continent U.S. Gas Oil Comparison of Typical Yields by Different Gas Oil Conversion Methods Effect of Feedstock Characteristics on Product Distribution in the Steam Cracking of Light Gas Oil... Comparison of Petroleum Refinery Output in Major Industrial Areas (1976/77) Comparison of Petroleum Products Usage in the United States, Western Europe, and Japan (1976 and 1977) Distribution of Catalytic Cracking, Hydrocracking, and Catalytic Reforming Capacities in Free World Petroleum Refineries ( ) Geographic Distribution of Gas Oil Conversion Capacities (MM BPCD) Distribution of Cracking Capacity in Large U.S. Petroleum Refineries in Estimated Refinery Gate Prices for Crude Oil, Petroleum Products, and Basic Petrochemicals in the United States, Western Europe, and Japan Estimated Refinery and Chemical Plant Utility Prices (1979$)... PEP Construction Cost Indices Bases for Capital Charges Estimates Product Specifications Casel vii

7 5.2 Gasoline Blending Casel Sources of Light Hydrocarbons (BPSD) Case Refinery Primary Energy Use Casey Estimated Utility Requirements Casel Estimated Operating Costs for Utilities, Casey Estimated Total Facilities Investment Case Product Slate and Annual Gross Revenue Case Estimated Profitability at 1979 Prices Casey Product Specifications Case Gasoline Blending Case Sources of Light Hydrocarbons (BPSD) Case Refinery Primary Energy Use Case Estimated Utility Requirements Case Estimated Operating Costs for Utilities, Catalysts, and Chemicals Case viii

8 5.16 Estimated Total Facilities Investment Case Product Slate and Annual Gross Revenue Case Estimated Profitability at 1979 Prices Case Fuel Product Specifications Case Gasoline Blending Case Sources of Light Hydrocarbons (BPSD) Case Hydrogen Balance Case Chemical Refinery Primary Energy Use Case Estimated Utility Requirements Case Estimated Operating Costs for Utilities, Case Estimated Total Facilities Lnvestment Case Product Slate and Annual Gross Revenue Case Estimated Profitability at 1990 Prices CaseS Fuel Product Specifications Case ix

9 5.30 Gasoline Blending Case Sources of Light Hydrocarbons (BPSD) Case Hydrogen Balance Case Chemical Refinery Primary Energy Use Case Estimated Utility Requirements Case Estimated Operating Costs for Utilities, Case Estimated Total Facilities Investment Case Product Slate and Annual Gross Revenue Case Estimated Profitability at 1990 Prices Case Fuel Product Specifications Cases Gasoline Blending 5.41 Sources of Light Hydrocarbons (BPSD) Cases Hydrogen Balance 5.43 Chemical Refinery Primary Energy Use CaseS X

10 5.44 Estimated Utility Requirements 5.45 Estimated Operating Costs for Utilities, 5.46 Estimated Total Facilities Investment 5.47 Product Slate and Annual Gross Revenue 5.48 Estimated Profitability at 1990 Prices 6.1 Product Specifications Case Gasoline Blending Case Sources of Light Hydrocarbons (BPSD) Case Refinery Primary Energy Use Case Estimated Utility Requirements Case Estimated Operating Costs for Utilities, Catalyst, and Chemicals Case Estimated Total Facilities Investment Case Product Slate and Annual Gross Revenue Case Estimated Profitability at 1979 Prices Case xi

11 6.10 Fuel Product Specifications 6.11 Gasoline Blending Case Sources of Light Hydrocarbons (BPSD) Case7...;m 6.13 Hydrogen Balance 6.14 Chemical Refinery Primary Energy Use 6.15 Estimated Utility Requirements 6.16 Estimated Operating Costs for Utilities, 6.17 Estimated Total Facilities Investment Case7..., Product Slate and Annual Gross Revenue 6.19 Estimated Profitability at 1990 Prices 7.1 Product Specifications Case Gasoline Blending Casea Sources of Light Hydrocarbons (BPSD) Case Refinery Primary Energy Use Case Xii

12 7.5 Estimated Utility Requirements Casea Estimated Operating Costs for Utilities, Case Estimated Total Facilities Investment Casea Product Slate and Annual Gross Revenue Casea Estimated Profitability at 1979 Prices Case Fuel Product Specifications Case Gasoline Blending Case Sources of Light Hydrocarbons (BPSD) Caseg Hydrogen Balance Caseg Chemical Refinery Primary Energy Use Caseg Estimated Utility Requirements Case Estimated Operating Costs for Utilities, Case Estimated Total Facilities Investment Case Product Slate and Annual Gross Revenue Case Estimated Profitability at 1990 Prices Case xiii