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Ashis Banerji UOP LLC © 2006 UOP LLC. All rights reserved. UOP 4673-01 Refining Challenges and Opportunities University of Houston November 2006.

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Presentation on theme: "Ashis Banerji UOP LLC © 2006 UOP LLC. All rights reserved. UOP 4673-01 Refining Challenges and Opportunities University of Houston November 2006."— Presentation transcript:

1 Ashis Banerji UOP LLC © 2006 UOP LLC. All rights reserved. UOP 4673-01 Refining Challenges and Opportunities University of Houston November 2006

2 Who We Are Global company with manufacturing sites and offices in 16 countries Global company with manufacturing sites and offices in 16 countries Over 2,800 highly trained employees Over 2,800 highly trained employees Acquired by Honeywell in 2005 Acquired by Honeywell in 2005 More than 90 years of innovative solutions for the hydrocarbon processing industry More than 90 years of innovative solutions for the hydrocarbon processing industry More than $1 billion in revenues annually from over 110 countries More than $1 billion in revenues annually from over 110 countries UOP 4673-02

3 World’s Largest Process Technology Licensing Organization More than 70 licensed processes More than 70 licensed processes 2,500 active patents 2,500 active patents 300+ catalysts 300+ catalysts More than 150 Molecular sieve adsorbents More than 150 Molecular sieve adsorbents 30+ engineered products 30+ engineered products − Packaged process units and systems − Proprietary equipment − Control systems and instrumentation Engineering, technical and training services Engineering, technical and training services UOP 4673-03

4 What is Driving Change in the North American Region? High utilization combined with growth High utilization combined with growth Growth of diesel is greater than gasoline Growth of diesel is greater than gasoline Growth in light product / declining resid Growth in light product / declining resid Processing heavy crudes Processing heavy crudes Regulations Regulations Growth with utilization near sustainable limit  more capacity Refining Utilization and Demand Growth 75.0 80.0 85.0 90.0 95.0 2002200720122017 Utilization % 0 5 10 15 20 25 Demand Growth Mbpd Demand Growth N. America EuropeAsia UOP 4673-04

5 Crude Oil Quality Trends Average crude quality declining Average crude quality declining –Increasing light / heavy price differentials Significant impact on desulfurization requirements Significant impact on desulfurization requirements –Impact on heavy fuel oil markets –Light to heavy differential increasing (Sources: Purvin & Gertz) Increasing residue conversion to transport fuels UOP 4673-05

6 More Conversion Needed to Process Heavy Crudes Heavier crudes yield less gasoline and distillate Heavier crudes yield less gasoline and distillate Add conversion needed Add conversion needed Heavier crudes require hydrogen addition to meet distillate fuel quality Heavier crudes require hydrogen addition to meet distillate fuel quality Yield Tapis WTI ArabMed Maya UOP 4673-06

7 Oil Resources As Function of Economic Price Already Produced OPEC ME Other Conv. Oil Heavy Oil bitumen Oil Shales EOREOREOREOR Deep Water Arctic Super deep Cumulative need to 2030 Source: IEA, Resources to Reserves, 2005 Heavy oil development viable at current prices UOP 4673-07

8 North America Incremental Product Demand 2006-2015 Diesel demand increasing by 1.2 MMBPD (25% increase) Diesel demand increasing by 1.2 MMBPD (25% increase) Gasoline demand increasing by 1 MMBPD (19% increase) Gasoline demand increasing by 1 MMBPD (19% increase) (Source: Purvin & Gertz) More diesel then gasoline with no resid fuel UOP 4673-08

9 Product Specifications Gasoline & Diesel Low / ultra-low sulfur legislation Low / ultra-low sulfur legislation More stringent benzene, RVP specs More stringent benzene, RVP specs Further vehicle emissions standards anticipated Further vehicle emissions standards anticipated –Tighter NOx standards Biofuels Ethanol pursued in many countries Ethanol pursued in many countries US Renewable Fuels Standard US Renewable Fuels Standard Widespread discussion of biodiesel and green diesel legislation Widespread discussion of biodiesel and green diesel legislation Fuel Oil No major changes for inland fuel oil No major changes for inland fuel oil Bunkers remain growing fuel oil outlet Bunkers remain growing fuel oil outlet Clean fuels needs will continue to drive business UOP 4673-09

10 New flow schemes New flow schemes –Maximize yield of high value products –Flexible product slate –Distressed stream processing –Process integration New catalysts New catalysts –Efficient hydrogen utilization –Higher activity and yields –Rapid catalyst commercialization Technology Innovations are Key to Success UOP 4673-10

11 R-34 catalyst – low Pt version Examples of UOP Reforming Catalyst Innovations First SR Platforming unit First CCR Platforming unit R-132™ catalyst - high activity, surface area stable R-72™ catalyst – high yields R-56™ catalyst - maximum stability R-62™ catalyst – high stability R-32™ catalyst - lower Pt R-86™ catalyst - high yields, low costs R-274™ catalyst - high yield 1949 1971 1975 1983 1988 1992 1993 1994 2000 2001 2002 R-234™ catalyst - low coke, increased flexibility R-264™ catalyst - high density, high activity 2003 2005 R-98™ catalyst – high yields Fixed-bed Platforming catalysts CCR Platforming catalysts UOP 4673-11

12 Continuous Innovation and Improvement: Fluid Catalytic Cracking Octane Barrel Capacity of FCC New Reactor Concepts Improved Reaction Systems Octane Catalysts Extended Riser Zeolite Catalysts Amorphous Catalysts 6,200 6,000 5,800 5,600 5,400 5,200 5,000 4,800 195019601970198019902000 Theoretical Octane Barrels Octane Barrels / 100 Barrels Feed UOP 4673-12

13 Clean Fuels Yields Flexibility Low Cost Levers Feed Char Product Char Reaction Engr Metal Function Acidity Pore Geometry DriversFeaturesTechnologyTools Yield Hydrogenation Activity Stability UOP Has Developed Rapid Delivery of High-Performance Catalysts UOP Catalyst Design Engine (CDE) converted fundamental knowledge and experimental database into a computer model for catalyst design UOP Catalyst Design Engine (CDE) converted fundamental knowledge and experimental database into a computer model for catalyst design Process Models Catalysts Process Catalyst Design Engine UOP 4673-13

14 An Evolution in Perspective Traditionally: Traditionally: Viewed catalysts from activity versus selectivity standpoint Viewed catalysts from activity versus selectivity standpoint UOP 4673-14

15 An Evolution in Perspective Now: View catalysts from more dimensions View catalysts from more dimensions UOP 4673-15

16 An Evolution in Perspective UOP 4673-16

17 An Evolution in Perspective Now: View catalysts from more dimensions View catalysts from more dimensions Hydrogenation is a key variable UOP 4673-17

18 Synthetic Crudes and Heavy Crudes Available in Market Heavy Crude/Bitumen Production Upgrading HeavyCrudeRefineries MediumCrudeRefineries LightCrudeRefineries LightSCO SynDilBit HeavySCO LightSynthetic Crude Oil (SCO) Condensate Refining DilBit SynBit Source: Purvin & Gertz, 2004 UOP 4673-18

19 Processing Heavy Crudes Affect All Areas of the Refinery High Resid Contnt Coking or SDA required Coking or SDA required High contaminant level High contaminant level –High-severity hydrotreating High VGO content after resid conversion High VGO content after resid conversion Synthetic Crudes No resid content No resid content –Blending with other heavy crudes Low-quality distillate Low-quality distillate –High-severity hydrotreating Large volume of low- quality VGO Large volume of low- quality VGO –FCC feed pretreatment UOP 4673-19

20 Processing Heavy Crudes Affect All Areas of the Refinery Bitumen Blends High resid content High resid content –Coking or SDA required High contaminant level High contaminant level –High-severity hydrotreating High VGO content after resid conversion High VGO content after resid conversion Synthetic Crudes No resid content No resid content –Blending with other heavy crudes Low-quality distillate Low-quality distillate –High-severity hydrotreating Large volume of low- quality VGO Large volume of low- quality VGO –FCC feed pretreatment Additional VGO Conversion Required! UOP 4673-20

21 Heavy Crude-derived VGOs are Hydrogen Lean and Contaminant Rich Lt. Arabian Cold Lake Athabasca Coker PropertyVGO VGO VGO HGO Gravity, °API22.716.314.211.4 Sulfur, wt-%2.103.103.774.99 Nitrogen, wppm820138018544032 Hydrogen, wt-%12.4711.3810.8010.43 Total Aromatics, vol-%58606976 UOP 4673-21

22 Integration of Hydroprocessing and FCC Operation is the Key to Processing Bitumen-derived Crudes Diesel Diesel Gasoline FCC Feed Hydrogen Content Must be Optimized HDS HDS FCC UOP 4673-22

23 FCC Feed Pretreating is Not Always the Right Solution FCC capacity still limited by high VGO content of heavy and synthetic crudes FCC capacity still limited by high VGO content of heavy and synthetic crudes High-quality distillate fuels cannot be produced in an FCC unit High-quality distillate fuels cannot be produced in an FCC unit UOP 4673-23

24 Hydrocracking Required to Convert Incremental VGO and Produce Right Product Mix Diesel Diesel Gasoline Unionfining™ FCC Diesel Diesel Gasoline Unicracking™ FCC Gasoline UOP 4673-24

25 Is the Once-through Unicracking Process the Right Choice? Higher yields of naphtha and distillate Higher yields of naphtha and distillate Higher quality FCC feedstock Higher quality FCC feedstock Flexibility to adjust conversion for seasonal demand Flexibility to adjust conversion for seasonal demand UOP 4673-25

26 Once-through Unicracking Process Produces FCC Feed with High Hydrogen Content R-1 R-2 Naphtha Kerosene Heavy Diesel FCC Feed 60 64 5 12 17 30 61.5 16 mm Smoke Point 45 Cetane No. H2H2H2H2 Feed UOP 4673-26

27 0 30 Conversion, wt-% Cetane Index Smoke Point 25 20 15 10 5 0 2040100 80 70 60 50 40 30 Conventional VGO Feed Kerosene Smoke Point, mm 6080 Diesel Cetane Index Increased Conversion Produces Higher-quality Fuels UOP 4673-27

28 Is Recycle or Co-Processing Unicracking Process the Right Choice? Once-Through hydrocracking mode has poor hydrogen utilization Once-Through hydrocracking mode has poor hydrogen utilization - Lower light product quality - Sub-optimal hydrogen content of FCC feed Alternative flow schemes needed for independent control of product quality Alternative flow schemes needed for independent control of product quality UOP 4673-28

29 Separate-hydrotreat Configuration Provides Flexibility R-1 R-2 Naphtha Kerosene Heavy Diesel FCC Feed 60 95 11 16 8 30 30 23 mm Smoke Point 57 Cetane No. 30 Independent Control of Distillate and FCC Feed Qualities H2H2H2H2 Feed UOP 4673-29

30 ULSD Co-feed H2H2H2H2 VGO Feed HT Rx HC Rx EHSEHS Fractionation AMINE SEP PT Rx FCC Feed Enhanced Hot Separator Advanced Partial-conversion Unicracking (APCU) Integrates FCC Feed Pretreatment with ULSD Production UOP 4673-30

31 Catalysis and Catalytic Processes will Enable increased Utilization of Heavy Oil in the USGC Hydrogenation optimizes FCC feed hydrogen content Hydrogenation optimizes FCC feed hydrogen content Produces high-quality distillate fuels to meet growing demand Produces high-quality distillate fuels to meet growing demand Diesel produced can meet all ULSD specs Diesel produced can meet all ULSD specs Product slate can be seasonally adjusted Product slate can be seasonally adjusted UOP 4673-31

32 UOP 4673-32


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