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Solutions for Refinery Optimization. Agenda. Global trends in energy and fuel markets Fuel production challenges Innovative solutions for refining and petrochemicals Resid conversion strategy Flexible petchem and fuel production Energy efficiency improvement Alternative fuel solutions.

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Agenda
Agenda

  • Global trends in energy and fuel markets

  • Fuel production challenges

  • Innovative solutions for refining and petrochemicals

    • Resid conversion strategy

    • Flexible petchem and fuel production

    • Energy efficiency improvement

  • Alternative fuel solutions

PETROTECH 2009 - January 11-15, 2009 - New Delhi, India


Global trends energy and fuel markets
Global Trends Energy and Fuel Markets

GDP

Energy demand

Energy sources

000 billion $

Million bbloe

Million bbloe

+1.2%?

1.2%?

3.6%

2.2%

1.8%

6.0%

74%

1.5%

0.3%

Emerging & developing countries

Advanced economies

  • A growing population

    • Richer

    • Increasing energy needs

    • Aspiring to a higher mobility

PETROTECH 2009 - January 11-15, 2009 - New Delhi, India

Source: Axens & other sources


Global liquids supply demand
Global Liquids Supply & Demand

 Oil demand driven by transportation fuels (+2.1%/yr?)

A Continuous change in product mix

2007

2010

2020

Global demand forecast

96 to 103

Mbpdoe

Crude Oil 77.6 78.1

NGL/condensate 5.1 5.3

Processing Gain 2.0 2.2

Alternative Fuels * 0.9 1.4

Global demand 85.6 87.0

*Biofuels + GTL, CTL

DCL, DME, HDT veg. oils

BTL

EtOHex-LC

CTL

EtOH

FAME

GTL

40’s

70’s

90’s

00’s

2010

2015

PETROTECH 2009 - January 11-15, 2009 - New Delhi, India

Source: Axens & other sources


Agenda1
Agenda

  • Global trends in energy and fuel markets

  • Fuel production challenges

  • Innovative solutions for refining and petrochemicals

    • Resid conversion strategy

    • Flexible petchem and fuel production

    • Energy efficiency improvement

  • Alternative fuel solutions

PETROTECH 2009 - January 11-15, 2009 - New Delhi, India


Crude oil supply quality trends
Crude Oil Supply Quality Trends

API Degrees

Sulfur, wt%

PETROTECH 2009 - January 11-15, 2009 - New Delhi, India

Source: Axens & Hart WRFS, 2007 Edition


Regional gasoline diesel quality forecasts 2006 2015
Regional Gasoline & Diesel Quality Forecasts 2006-2015

Gasoline Pool Sulfur Content

Diesel Pool Sulfur Content

ppm

ppm

2007 (in use)

2010 (forecast)

2015 (forecast)

CIS

Africa

Europe

CIS

Africa

Middle East

Asia Pacific

Europe

Latin America

North America

India (National)

Latin America

Middle East

Asia Pacific

North America

India (National)

Same trends for non-road fuels

Source: Hart WRFS 09

PETROTECH 2009 - January 11-15, 2009 - New Delhi, India


Fuel oil demand world

AAGR07-20

Market Structure, %

-4.6%

-3.5%

0.5%

1.0%

2.8%

9.1 Mboepd

9.7 Mboepd

-0.6%

2006

2012

2015

2020

4.5%

3.5 %

3.5%

0.5%?

2006

2010

2015

2020

?

1.5%

1.0%

0.10%

Fuel Oil DemandWorld

Market Demand, Mboepd

Power Generation

Industry

Marine fuels

Future specifications

Other uses

Refinery Fuel

Bunkers

Other Uses* = Petrochemical Feedstock, Transport, Residential,

Commercial/Agriculture, …

Global

SECA

PETROTECH 2009 - January 11-15, 2009 - New Delhi, India

Source: Axens & other sources (2007)


Fuel production challenges
Fuel Production Challenges

Market Trends

Technological Solutions

  • Heavier Crudes & Heavy fuel oil decline

  • Uncertainty on demand

  • Clean fuels program will continue to expand

  • CO2 emissions

  • Supply diversification

  • Conversion technologies

  • Fuels to petrochemicals flexibility

  • Hydrotreating

  • Energy efficiency

  • Alternative fuels

PETROTECH 2009 - January 11-15, 2009 - New Delhi, India


Integrated h oil rc hyk innovative project
Integrated H-OilRC + HyK Innovative Project

Project Context

  • Location: Eastern Europe Inland

  • Feedstock: Ural

  • VR capacity: 47 000 bpsd

  • VGO capacity: 37 000 bpsd

  • Objectives:

    • 70% VR conversion

    • Maximize diesel Euro V production

    • LSFO @1 wt% S demand

    • No market for high sulfur coke

    • Existing refinery

PETROTECH 2009 - January 11-15, 2009 - New Delhi, India


Selected configuration
Selected Configuration

FG

SRGO

HDT

LPG

AT

Integrated

C3=

VGO

FCC

Naphtha

AR

HyK

Gasoline

VT

MD

VGO

VR

Fuel Oil

(1%S)

Diesel

H-OilRC

HCO

Existing/Revamped

LSFO

7%

LPG, C3= and C5+ throughput

33% Naphtha

& Gasoline

New

MD

52%

►Design Stage

Yields vs crude

PETROTECH 2009 - January 11-15, 2009 - New Delhi, India


Integrated h oil rc hyk benefits
Integrated H-OilRC + HyKBenefits

  • Optimized Capex for H-OilRC and HyK units:

    • Single optimized H2 management system for HyK & H-OilRC

  • High flexibility:

    • HyK and H-OilRC can operate independently

  • Maximized diesel production:

    • No secondary cracking of gasoil (recovered and upgraded in hydrotreating unit)

    • Hydrogen addition to the right products

PETROTECH 2009 - January 11-15, 2009 - New Delhi, India


Fuel production challenges1
Fuel Production Challenges

Market Trends

Technological Solutions

  • Heavier Crudes & Heavy fuel oil decline

  • Uncertainty on demand

  • Clean fuels program will continue to expand

  • CO2 emissions

  • Supply diversification

  • Conversion technologies

  • Fuels to petrochemicals flexibility

  • Hydrotreating

  • Energy efficiency

  • Alternative fuels

PETROTECH 2009 - January 11-15, 2009 - New Delhi, India


Flexible petchem and fuel production
Flexible Petchem and Fuel Production

Flexible conversion for propylene and fuel production, depending on demand and prices

Based on the R2RTM RFCC Process

Different process options can be combined to adapt propylene and fuelproduction according to market demand

  • Conventional gasoline mode

  • Maxi propylene mode

  • Maxi propylene - Maxi LCO mode

PETROTECH 2009 - January 11-15, 2009 - New Delhi, India


Propylene production forecast by source
Propylene Production Forecastby Source

2007 Production~ 74 Million tons (Mt)

Additional Propylene Demand by Process Technology

Mt/y

From Refineries (FCC)

From Steam crackers

Basis

On purpose production

  • Global Additional Demand 2008-2015: 34 Mt Average annual growth rate (AAGR): ~ 4.5%

    • Additional demand from FCC = 13 Mt

Source: Nexant + CEH SRI

PETROTECH 2009 - January 11-15, 2009 - New Delhi, India


Resid to propylene process scheme technology
Resid to Propylene Process Scheme & Technology

Fuel Gas

Propylene

(Polymer grade)

C3 C4 LPG

Treatment

& Separation

Fractionator &

Gas Recovery

C3

Splitter

720-740°C

Propane

590°C

C/O 12

Naphtha

Splitter

Raw C4

HCN

LCO

660°C

Slurry/CLO

FEED

R2R

Risers &

Regenerators

R2R

Risers &

Regenerators

Main Riser

Resid

PetroRiser

LCN

LCN Recycle

R2R Unit

PETROTECH 2009 - January 11-15, 2009 - New Delhi, India


Npv sensitivity study to propylene gasoline price differential
NPV Sensitivity Study to(Propylene - Gasoline) Price Differential

NPV, Million US $ (M US $)

ZSM-5 + Petroriser (12 wt % C3=)

Conventional R2R (5 wt % C3=)

NPV Diff. ~ 400 M US $

NPV Diff. ~ 200 M US $

Base Scenario: 456 US $/t

(Propylene - Gasoline) Price Differential, US $/t

Crude Price used in the study: 75 $/bbl

PETROTECH 2009 - January 11-15, 2009 - New Delhi, India


Petroriser synthetic feed recycle polynaphtha tm

Fuel Gas

C3 C4 LPG

Treatment

& Separation

C3

Splitter

Fractionator &

Gas Recovery

Propane

Naphtha

Splitter

C4 SHU

C4 Paraffin-rich cut

HCN

LCO

FEED

PetroRiser + Synthetic Feed RecyclePolynaphthaTM

  • C4 conversion to propylene by recycle of "synthetic" naphtha to the 2nd riser

    • oligomerization of C4 to C8-C12 olefins

    • recycle oligomers to the second riser

    • higher propylene yield at second riser operating conditions

Propylene

(Polymer grade)

C4 s

Slurry/CLO

FEED

Polynaphtha

Unit

Polynaphtha

Unit

R2R Risers &

Regenerators

Risers &

Regenerators

LCN

Recycle

C8-C12 Olefins

Oligomers

Kero + gasoline if no recycling to the riser

PETROTECH 2009 - January 11-15, 2009 - New Delhi, India


Resid to propylene cumulative effects
Resid to Propylene Cumulative Effects

Conventional Gasoline Designpropylene yield 5 wt %

Different process options can be combined to maximize propylene yield

Propylene yield

  • Single riser Maxi propylene (ZSM-5) about 10-12 wt%

  • Dual risers with LCN recycle add. 1-2 wt%

  • Dual risers with LCN + Oligomer recycle add. 2-3 wt%

R2R - a highly adaptable conversion process enablingto adjust propylene & fuel production according to market demand

PETROTECH 2009 - January 11-15, 2009 - New Delhi, India


Fuel production challenges2
Fuel Production Challenges

Market Trends

Technological Solutions

  • Heavier Crudes & Heavy fuel oil decline

  • Uncertainty on demand

  • Clean fuels program will continue to expand

  • CO2 emissions

  • Supply diversification

  • Conversion technologies

  • Fuels to petrochemicals flexibility

  • Hydrotreating

  • Energy efficiency

  • Alternative fuels

PETROTECH 2009 - January 11-15, 2009 - New Delhi, India


Energy efficiency improvement example refinery case study
Energy Efficiency ImprovementExample: Refinery Case Study

  • Study carried out by Performance Programs to optimize the energy efficiency of a 65,000 bbl/d refinery

  • About 80 improvement items

    • Utilities and process furnaces operation optimization

  • Energy improvement: 35 EII (Solomon Energy Intensity Index) or ~92 MW

    • About 10 of these improvement items could lead to a CO2 reduction of ~116 000 T/y

PETROTECH 2009 - January 11-15, 2009 - New Delhi, India


Fuel production challenges3
Fuel Production Challenges

Market Trends

Technological Solutions

  • Heavier Crudes & Heavy fuel oil decline

  • Uncertainty on demand

  • Clean fuels program will continue to expand

  • CO2 emissions

  • Supply diversification

  • Conversion technologies

  • Fuels to petrochemicals flexibility

  • Hydrotreating

  • Energy efficiency

  • Alternative fuels

PETROTECH 2009 - January 11-15, 2009 - New Delhi, India


Axens estimates alternative fuels 2007 2020
Axens EstimatesAlternative Fuels 2007 - 2020

Mbpdoe

CTL0.38 Mbpdoe

  • Crude oil reserves limited

    • Production Plateau estimated to be about 100 Mbpd

  • Energy security (locally and globally)

  • Political mandates

  • Global warming (GHG emissions reduction)

  • Rural development

GTL0.28 Mbpdoe

Ethanol-2G0.19 Mbpdoe

Biodiesel-2G0.06 Mbpdoe

Ethanol-1G1.34 Mbpdoe

Biodiesel-1G0.62 Mbpdoe

PETROTECH 2009 - January 11-15, 2009 - New Delhi, India

Source: Axens estimates


Alternative fuels contribution to on road fuels supply
Alternative Fuels Contribution to On-Road Fuels Supply

6.3%

2.5%

Alternative Fuels* incorporation level (energy basis)

Demand (Mbpdoe)

35.4

10.3

45.7

  • 2007-2020

  • On-road fuels: 2.1%/yr

  • Alternative Fuels:

  • ~19% of total growth

* Alternative Fuels = Biodiesel-1G + Biodiesel-2G (BTL) + GTL + CTL +

Ethanol-1G and -2G

PETROTECH 2009 - January 11-15, 2009 - New Delhi, India

Source: Axens estimates


Gas biomass coal to liquids pathways
Gas, Biomass & Coal To Liquids Pathways

X to Liquid Technologies – GTL, CTL, BTL

NaturalGas

Syngas

Generation

FT

+ Upgrading

Syngas

GTL Diesel

Biomass

Syngas

Generation

FT

+ Upgrading

Syngas

BTL Diesel

Coal

Gasification

FT

+ Upgrading

Syngas

CTL Diesel

DCL – Direct Coal Liquefaction

DirectLiquefaction

Coal

CoalLiquids

Upgrading

CTL Diesel

PETROTECH 2009 - January 11-15, 2009 - New Delhi, India


Axens’ Syngas to Liquids Technologies

  • GaselTM Technology Suite

  • Axens catalysts manufacturing

  • Axens process design, process integration and licensing know-how

  • Validated with representative feedstock from FT pilot plan

Natural GasBiomassCoal

Fischer-Tropsch Pilot Plant

Fischer- Tropsch

SyngasH2/CO ~2

Hydrocracking

naphtha +high cetane diesel

PETROTECH 2009 - January 11-15, 2009 - New Delhi, India


Axens Direct Coal Liquefaction ProcessH-Coal (Two-Stage)

Recycle Hydrogen

Gas To Clean Up

Hydrogen

IBP-180°C

First-stage

Catalytic Reactor

180-375°C

APS

Hydrogen

Heater

375- 500°C

Pulverized

Coal

VPS

Second-stage

Catalytic Reactor

Slurry

Mix Tank

Vacuum

Bottoms

Slurry

Heater

Recycle Slurry Oil

PETROTECH 2009 - January 11-15, 2009 - New Delhi, India


Coal liquefaction reactors
Coal Liquefaction Reactors

PETROTECH 2009 - January 11-15, 2009 - New Delhi, India


Conclusion
Conclusion

  • Long term market fundamentals should remain favorable

    • Global demand positive for the next 15-20 years

    • Demand driven by developing countries & clean fuels

  • But there are challenges

    • Crude oil becoming heavier, sourer and more difficult to find

    • Increasing demand for clean fuels ... then for low sulfur marine bunker

    • GHG emissions reduction programs

  • Energy efficiency and operation optimization essential for refinery margin improvement

  • Alternative fuels will continue to be developed, where financing is available

PETROTECH 2009 - January 11-15, 2009 - New Delhi, India



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