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Solutions for Refinery Optimization

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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Solutions for Refinery Optimization

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  1. Solutions for Refinery Optimization

  2. 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

  3. 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

  4. 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

  5. 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

  6. Crude Oil Supply Quality Trends API Degrees Sulfur, wt% PETROTECH 2009 - January 11-15, 2009 - New Delhi, India Source: Axens & Hart WRFS, 2007 Edition

  7. 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

  8. 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)

  9. 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

  10. 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

  11. 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

  12. 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

  13. 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

  14. 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

  15. 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

  16. 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

  17. 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

  18. 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

  19. 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

  20. 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

  21. 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

  22. 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

  23. 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

  24. 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

  25. 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

  26. 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

  27. 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

  28. Coal Liquefaction Reactors PETROTECH 2009 - January 11-15, 2009 - New Delhi, India

  29. 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

  30. Solutions for Refinery Optimization

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